Jeep KJ Service Manual - 2002

ABS - DESCRIPTION, BRAKES . . . . . . . . . . .
5-32
ABS - OPERATION, BRAKES . . . . . . . . . . . . . 5-32
ABS - SPECIFICATIONS, BRAKES . . . . . . . . . 5-33
ABS BRAKE BLEEDING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
ABS INDICATOR - DESCRIPTION . . . . . . . . . 8J -11
ABS INDICATOR - OPERATION . . . . . . . . . . 8J -11
A/C APPLICATION TABLE,
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 24-9
A/C COMPRESSOR CLUTCH -
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 24-14
A/C COMPRESSOR CLUTCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-14
A/C COMPRESSOR CLUTCH - REMOVAL . . 24-13
A/C COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE. . . . . . . . . . . . . . . 24-12
A/C COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 24-12
A/C COMPRESSOR CLUTCH RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
A/C COMPRESSOR NOISE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 24-42
A/C CONDENSER - DESCRIPTION . . . . . . . . 24-45
A/C CONDENSER - INSTALLATION . . . . . . . 24-46
A/C CONDENSER - OPERATION . . . . . . . . . . . 24-45
A/C CONDENSER - REMOVAL . . . . . . . . . . . 24-45
A/C DISCHARGE LINE - INSTALLATION . . . 24-47
A/C DISCHARGE LINE - REMOVAL . . . . . . . 24-46
A/C EVAPORATOR - DESCRIPTION . . . . . . . 24-49
A/C EVAPORATOR - INSTALLATION . . . . . . 24-49
A/C EVAPORATOR - OPERATION . . . . . . . . . 24-49
A/C EVAPORATOR - REMOVAL . . . . . . . . . . 24-49
A/C HEATER CONTROL - DESCRIPTION . . . 24-16
A/C HEATER CONTROL - INSTALLATION . . . 24-17
A/C HEATER CONTROL - REMOVAL . . . . . . 24-17
A/C HIGH PRESSURE SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-17
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
A/C LIQUID LINE - INSTALLATION . . . . . . . 24-47
A/C LIQUID LINE - REMOVAL . . . . . . . . . . . 24-47
A/C LOW PRESSURE SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-18
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
A/C ORIFICE TUBE - DESCRIPTION . . . . . . . 24-50
A/C ORIFICE TUBE - INSTALLATION . . . . . . 24-50
A/C ORIFICE TUBE - OPERATION . . . . . . . . 24-50
A/C ORIFICE TUBE - REMOVAL . . . . . . . . . . 24-50
A/C PERFORMANCE - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
A/C SUCTION LINE - INSTALLATION . . . . . . 24-49
A/C SUCTION LINE - REMOVAL . . . . . . . . . 24-48
ACCELERATOR PEDAL - INSTALLATION . . . 14-30
ACCELERATOR PEDAL - REMOVAL . . . . . . . 14-29
ACCESS PANEL - DESCRIPTION, LATCH . . 23-139
ACCESS PANEL - INSTALLATION, LATCH . 23-139
ACCESS PANEL - REMOVAL, LATCH . . . . . 23-139
ACCUMULATOR - DESCRIPTION . . . . . . . . . 24-51
ACCUMULATOR - INSTALLATION . . . . . . . . 24-51
ACCUMULATOR - OPERATION . . . . . . . . . . 24-51
ACCUMULATOR - REMOVAL . . . . . . . . . . . . 24-51
ACTUATION TEST MODE - DESCRIPTION,
CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
ACTUATOR - INSTALLATION, BLEND
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
ACTUATOR - INSTALLATION, FLOOR -
DEFROST DOOR . . . . . . . . . . . . . . . . . . . . . 24-25
ACTUATOR - INSTALLATION, PANEL
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
ACTUATOR - INSTALLATION,
RECIRCULATION DOOR . . . . . . . . . . . . . . . . 24-26
ACTUATOR - REMOVAL, BLEND DOOR . . . . 24-20
ACTUATOR - REMOVAL, FLOOR -
DEFROST DOOR . . . . . . . . . . . . . . . . . . . . . 24-24
ACTUATOR - REMOVAL, PANEL DOOR . . . . 24-24
ACTUATOR - REMOVAL, RECIRCULATION
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-26
ADAPTER - INSTALLATION, DISC BRAKE
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
ADAPTER - REMOVAL, DISC BRAKE
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
ADAPTER HOUSING SEAL -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-124
ADAPTER HOUSING SEAL - REMOVAL . . . 21-124
ADAPTOR - REMOVAL, DEFROST
DUCT/DEMISTER . . . . . . . . . . . . . . . . . . . . . 24-32
ADHESIVE LOCATIONS -
SPECIFICATIONS, WELD AND
STRUCTURAL . . . . . . . . . . . . . . . . . . . . . . . . 23-9
ADJ USTER - DIAGNOSIS AND TESTING,
HYDRAULIC LASH. . . . . . . . . . . . . . . . . 9-19,9-30
ADJ USTER - INSTALLATION, SEAT BELT
TURNING LOOP . . . . . . . . . . . . . . . . . . . . . 8O-38
ADJ USTER - REMOVAL, SEAT BELT
TURNING LOOP . . . . . . . . . . . . . . . . . . . . . 8O-37
ADJ USTMENT - STANDARD
PROCEDURE, CAMBER AND CASTER . . . . . . . 2-5
PROCEDURE, CAMBER, CASTER AND
TOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
PROCEDURE, COMPASS VARIATION . . . . . . 8M-3
PROCEDURE, TOE . . . . . . . . . . . . . . . . . . . . . . 2-5
ADJ USTMENT, ADJ USTMENTS . . . 23-119,23-124,
23-131
ADJ USTMENT, ADJ USTMENTS . . . . . . . . . . . 3-55
ADJ USTMENT, ADJ USTMENTS -
SUNROOF GLASS PANEL . . . . . . . . . . . . . 23-178
ADJ USTMENT, FRONT FOG LAMP UNIT . . . 8L-25
ADJ USTMENT, HEADLAMP UNIT . . . . . . . . . 8L-42
ADJ USTMENT, LOCK OUT . . . . . . . . . . . . . . . 5-30
ADJ USTMENT, REAR DRUM BRAKE . . . . . . . 5-12
ADJ USTMENTS - ADJ USTMENT . . 23-119,23-124,
23-131
ADJ USTMENTS - ADJ USTMENT . . . . . . . . . . 3-55
ADJ USTMENTS - SUNROOF GLASS
PANEL ADJ USTMENT . . . . . . . . . . . . . . . . 23-178
ADJ USTMENTS, FRONT AXLE - 186FIA . . . . 3-25
ADJ USTMENTS, GEARSHIFT CABLE . . . . . 21-130
ADJ USTMENTS, PARK-INTERLOCK
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-154
ADJ USTMENTS, REAR AXLE - 8 1/4 . . . . . . . 3-92
AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT - STANDARD
PROCEDURE, SERVICE . . . . . . . . . . . . . . . . . 8O-6
AIR CHECKING TRANSMISSION CLUTCH
OPERATION - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-80
AIR CONDITIONER - DESCRIPTION,
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1
AIR CONDITIONER - OPERATION,
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
AIR CONTROL MOTOR - DESCRIPTION,
IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
AIR CONTROL MOTOR - INSTALLATION,
IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
AIR CONTROL MOTOR - OPERATION,
IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
AIR CONTROL MOTOR - REMOVAL, IDLE . . 14-36
AIR TEMPERATURE SENSOR -
DESCRIPTION, INTAKE . . . . . . . . . . . . . . . . 14-36
INSTALLATION, INTAKE . . . . . . . . . . . . . . . . 14-38
OPERATION, INTAKE . . . . . . . . . . . . . . . . . . 14-36
REMOVAL, INTAKE . . . . . . . . . . . . . . . . . . . 14-37
AIRBAG - DESCRIPTION, DRIVER . . . . . . . . 8O-17
AIRBAG - DESCRIPTION, PASSENGER . . . . 8O-27
AIRBAG - DESCRIPTION, SIDE CURTAIN . . 8O-38
AIRBAG - INSTALLATION, DRIVER . . . . . . . 8O-20
AIRBAG - INSTALLATION, PASSENGER . . . 8O-29
AIRBAG - INSTALLATION, SIDE CURTAIN . . 8O-41
AIRBAG - OPERATION, DRIVER . . . . . . . . . 8O-18
AIRBAG - OPERATION, PASSENGER . . . . . . 8O-27
AIRBAG - OPERATION, SIDE CURTAIN . . . . 8O-39
AIRBAG - REMOVAL, DRIVER . . . . . . . . . . . 8O-19
AIRBAG - REMOVAL, PASSENGER . . . . . . . 8O-28
AIRBAG - REMOVAL, SIDE CURTAIN . . . . . 8O-40
AIRBAG CONTROL MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8O-9
DESCRIPTION, SIDE IMPACT . . . . . . . . . . . 8O-43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-12
INSTALLATION, SIDE IMPACT. . . . . . . . . . . 8O-45
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8O-10
OPERATION, SIDE IMPACT . . . . . . . . . . . . . 8O-43
AIRBAG CONTROL MODULE - REMOVAL . . 8O-11
AIRBAG CONTROL MODULE - REMOVAL,
SIDE IMPACT . . . . . . . . . . . . . . . . . . . . . . . 8O-44
AIRBAG DOOR - INSTALLATION,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8O-30
AIRBAG DOOR - REMOVAL, PASSENGER . . 8O-29
AIRBAG INDICATOR - DESCRIPTION . . . . . . 8J -12
AIRBAG INDICATOR - OPERATION . . . . . . . 8J -12
AIRBAG MOUNTING BRACKET -
INSTALLATION, PASSENGER . . . . . . . . . . . 8O-31
AIRBAG MOUNTING BRACKET -
REMOVAL, PASSENGER . . . . . . . . . . . . . . . 8O-31
AJ AR INDICATOR - DESCRIPTION, DOOR . . 8J -17
AJ AR INDICATOR - DESCRIPTION, GATE . . 8J -20
AJ AR INDICATOR - DESCRIPTION,
GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -21
AJ AR INDICATOR - OPERATION, DOOR . . . 8J -17
AJ AR INDICATOR - OPERATION, GATE . . . . 8J -20
AJ AR INDICATOR - OPERATION, GLASS . . . 8J -21
AJ AR SWITCH - DESCRIPTION, DOOR . . . . 8L-77
AJ AR SWITCH - DESCRIPTION, FLIP-UP
GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
AJ AR SWITCH - DESCRIPTION, HOOD . . . . 8Q-11
AJ AR SWITCH - DESCRIPTION,
TAILGATE. . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-82
AJ AR SWITCH - DIAGNOSIS AND
TESTING, HOOD . . . . . . . . . . . . . . . . . . . . . 8Q-12
AJ AR SWITCH - INSTALLATION, HOOD . . . 8Q-12
AJ AR SWITCH - OPERATION, DOOR . . . . . . 8L-77
AJ AR SWITCH - OPERATION, FLIP-UP
GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
AJ AR SWITCH - OPERATION, HOOD . . . . . 8Q-12
AJ AR SWITCH - OPERATION, TAILGATE . . . 8L-82
AJ AR SWITCH - REMOVAL, HOOD . . . . . . . 8Q-12
AJ AR SWITCH BRACKET -
INSTALLATION, HOOD. . . . . . . . . . . . . . . . . 8Q-13
AJ AR SWITCH BRACKET - REMOVAL,
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
AJ AR SWITCH STRIKER -
INSTALLATION, HOOD. . . . . . . . . . . . . . . . . 8Q-14
AJ AR SWITCH STRIKER - REMOVAL,
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
ALIGNMENT - DESCRIPTION, WHEEL . . . . . . . 2-3
ALIGNMENT - OPERATION, WHEEL . . . . . . . . 2-3
ALIGNMENT, SPECIFICATIONS . . . . . . . . . . . . 2-6
ALUMINUM THREAD REPAIR -
AMBIENT TEMP SENSOR - DESCRIPTION . . 8M-9
AMBIENT TEMP SENSOR - OPERATION . . . 8M-9
AMBIENT TEMPERATURE SENSOR -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8M-9
AMBIENT TEMPERATURE SENSOR
CIRCUIT - DIAGNOSIS AND TESTING . . . . . 8M-9
AMPERAGE TEST - DIAGNOSIS AND
TESTING, FUEL PUMP . . . . . . . . . . . . . . . . . 14-16
AMPLIFIER CHOKE AND RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8A-4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8A-4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
ANCHOR - DESCRIPTION, CHILD TETHER . 8O-13
ANCHOR - OPERATION, CHILD TETHER . . . 8O-13
ANGLE - STANDARD PROCEDURES,
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 3-3
ANTENNA BODY & CABLE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
ANTENNA BODY & CABLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8A-6
KJ INDEX 1
Description Group-Page Description Group-Page Description Group-Page
ANTENNA BODY & CABLE - OPERATION . . . 8A-5
ANTENNA BODY & CABLE - REMOVAL . . . . . 8A-6
ANTENNA BODY AND CABLE -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8A-5
ANTENNA CABLE - INSTALLATION,
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8A-8
ANTENNA CABLE - REMOVAL,
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8A-7
ANTILOCK BRAKE - INSTALLATION,
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . 8E-10
ANTILOCK BRAKE - REMOVAL,
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . 8E-10
ANTILOCK BRAKING SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 5-33
A-PILLAR SEAL - INSTALLATION . . . . . . . 23-185
A-PILLAR SEAL - REMOVAL . . . . . . . . . . . 23-185
A-PILLAR TRIM AND GRAB HANDLE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-156
A-PILLAR TRIM AND GRAB HANDLE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
A-PILLAR WEATHERSTRIP/RETAINER -
INSTALLATION, WINDSHIELD . . . . . . . . . . 23-187
A-PILLAR WEATHERSTRIP/RETAINER -
REMOVAL, WINDSHIELD. . . . . . . . . . . . . . 23-186
APPLICATION TABLE, SPECIFICATIONS -
A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-9
AREA LEAKS - DIAGNOSIS AND
TESTING, REAR SEAL . . . . . . . . . . . . . . . . . . 9-61
ARM - DESCRIPTION, FRONT WIPER . . . . . 8R-12
ARM - DESCRIPTION, LOWER CONTROL . . . 2-21
ARM - DESCRIPTION, REAR WIPER . . . . . . 8R-37
ARM - DESCRIPTION, ROCKER . . . . . . 9-29,9-37
ARM - INSTALLATION, FRONT WIPER . . . . 8R-13
ARM - INSTALLATION, LOWER CONTROL . . 2-10,
2-21
ARM - INSTALLATION, REAR WIPER . . . . . 8R-38
ARM - INSTALLATION, ROCKER . . . . . . . . . . 9-37
ARM - INSTALLATION, UPPER CONTROL . . . 2-21
ARM - OPERATION, FRONT WIPER . . . . . . 8R-12
ARM - OPERATION, LOWER CONTROL . . . . . 2-21
ARM - OPERATION, REAR WIPER . . . . . . . 8R-38
ARM - REMOVAL, FRONT WIPER . . . . . . . . 8R-12
ARM - REMOVAL, LOWER CONTROL . . 2-10,2-21
ARM - REMOVAL, REAR WIPER . . . . . . . . . 8R-38
ARM - REMOVAL, ROCKER . . . . . . . . . . . . . . 9-37
ARM - REMOVAL, UPPER CONTROL . . . . . . 2-20
ARM, BUSHINGS, AND BALL J OINT -
DESCRIPTION, UPPER SUSPENSION . . . . . . 2-20
ARM, BUSHINGS, AND BALL J OINT -
OPERATION, UPPER SUSPENSION . . . . . . . . 2-20
ARM PARK RAMP - INSTALLATION,
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
ARM PARK RAMP - REMOVAL, WIPER . . . 8R-43
ASD AND FUEL PUMP RELAYS -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 8I-4
ASD SENSE - PCM INPUT - OPERATION . . . . 8I-4
ASH RECEIVER LAMP BULB -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-71
ASH RECEIVER LAMP BULB - REMOVAL . . 8L-71
ASH RECEIVER LAMP UNIT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-72
ASH RECEIVER LAMP UNIT - REMOVAL . . 8L-72
ASSEMBLY - ASSEMBLY, INPUT CLUTCH . 21-138
ASSEMBLY - DESCRIPTION, INPUT
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-133
ASSEMBLY - DESCRIPTION,
TRANSMISSION SOLENOID/TRS . . . . . . . . 21-169
ASSEMBLY - DISASSEMBLY, INPUT
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135
ASSEMBLY - INSTALLATION . . . . . . . . . 8W-97-11
ASSEMBLY - INSTALLATION, GUIDE . . . . . 23-179
ASSEMBLY - INSTALLATION,
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . 23-151
ASSEMBLY - INSTALLATION, MODULE . . . 23-181
ASSEMBLY - INSTALLATION,
ASSEMBLY - OPERATION, INPUT
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135
ASSEMBLY - OPERATION,
ASSEMBLY - POWER DISTRIBUTION
CENTER ASSEMBLY . . . . . . . . . . . . . . . 8W-97-10
ASSEMBLY - REMOVAL, GUIDE . . . . . . . . 23-179
ASSEMBLY - REMOVAL, INSTRUMENT
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-149
ASSEMBLY - REMOVAL, MODULE . . . . . . 23-181
ASSEMBLY - REMOVAL, TRANSMISSION
SOLENOID/TRS . . . . . . . . . . . . . . . . . . . . . 21-170
ASSEMBLY, 4C RETAINER/BULKHEAD . . . . 21-123
ASSEMBLY, ASSEMBLY - POWER
DISTRIBUTION CENTER . . . . . . . . . . . . 8W-97-10
ASSEMBLY, DIAGNOSIS AND TESTING . . . . 21-90
ASSEMBLY, DIFFERENTIAL . . . . . . . . . 3-105,3-41
ASSEMBLY, DIFFERENTIAL - TRAC-LOK . . . 3-109,
3-77
ASSEMBLY, DISC BRAKE CALIPERS . . . . . . . 5-16
ASSEMBLY, HVAC HOUSING . . . . . . . . . . . . 24-34
ASSEMBLY, INPUT CLUTCH ASSEMBLY . . 21-138
ASSEMBLY, INSTRUMENT CLUSTER . . . . . . 8J -10
ASSEMBLY, LOW/REVERSE CLUTCH . . . . . 21-146
ASSEMBLY, MANUAL - NV1500 . . . . . . . . . 21-13
ASSEMBLY, MANUAL - NV3550 . . . . . . . . . 21-48
ASSEMBLY, OIL PUMP . . . . . . . . . . . . . . . . . 9-67
ASSEMBLY, OIL PUMP . . . . . . . . . . . . . . . 21-151
ASSEMBLY, PLANETARY GEARTRAIN . . . . 21-160
ASSEMBLY, SINGLE CARDAN
UNIVERSAL J OINTS . . . . . . . . . . . . . . . . . . . . 3-9
ASSEMBLY, TRANSFER CASE - NV231 . . . 21-194
ASSEMBLY, TRANSFER CASE - NV242 . . . 21-230
ASSEMBLY, VALVE BODY . . . . . . . . . . . . . 21-176
ASSEMBLY, WHEEL CYLINDERS . . . . . . . . . . 5-29
ASSEMBLY WINDOW DEFOGGER
FUNCTION - DIAGNOSIS AND TESTING,
REAR HVAC CONTROL . . . . . . . . . . . . . . . . . 8G-9
ASSIST HANDLE - INSTALLATION . . . . . . . 23-157
ASSIST HANDLE - REMOVAL . . . . . . . . . . . . 23-157
AUDIO - DESCRIPTION . . . . . . . . . . . . . . . . . 8A-1
AUDIO - DIAGNOSIS AND TESTING . . . . . . . 8A-2
AUDIO - OPERATION . . . . . . . . . . . . . . . . . . . 8A-1
AUTOMATIC TRANSMISSION - 45RFE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 21-76
AUTOMATIC TRANSMISSION - 45RFE -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 21-77
AUTOMATIC TRANSMISSION -
AUTOMATIC TRANSMISSION FLUID -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
AUTOMATIC TRANSMISSION FLUID -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
AXLE - 186FIA - ADJ USTMENTS, FRONT . . . 3-25
AXLE - 186FIA - DESCRIPTION, FRONT . . . . 3-19
AXLE - 186FIA - INSTALLATION, FRONT . . . . 3-24
AXLE - 186FIA - OPERATION, FRONT . . . . . . 3-19
AXLE - 186FIA - REMOVAL, FRONT . . . . . . . 3-24
AXLE - 198RBI - DESCRIPTION, REAR . . . . . 3-49
AXLE - 198RBI - INSTALLATION, REAR . . . . 3-54
AXLE - 198RBI - OPERATION, REAR . . . . . . . 3-49
AXLE - 198RBI - REMOVAL, REAR . . . . . . . . 3-54
AXLE - 8 1/4 - ADJ USTMENTS, REAR . . . . . 3-92
AXLE - 8 1/4 - DESCRIPTION, REAR . . . . . . 3-86
AXLE - 8 1/4 - INSTALLATION, REAR . . . . . . 3-91
AXLE - 8 1/4 - OPERATION, REAR . . . . . . . . 3-86
AXLE - 8 1/4 - REMOVAL, REAR . . . . . . . . . . 3-91
AXLE - DESCRIPTION . . . . . . . . . . . . . . . . . . . 0-2
AXLE - DIAGNOSIS AND TESTING . . . . 3-20,3-51,
3-88
AXLE - INSTALLATION, 198 RBI . . . . . . . . . . 5-28
AXLE - INSTALLATION, 8 1/4 . . . . . . . . . . . . 5-28
AXLE - REMOVAL, 198 RBI . . . . . . . . . . . . . . 5-27
AXLE - REMOVAL, 8 1/4 . . . . . . . . . . . . . . . . 5-27
AXLE - SPECIFICATIONS, FRONT . . . . . . . . . 3-33
AXLE - SPECIFICATIONS, REAR . . . . . . . . . . 3-62
AXLE BEARINGS - INSTALLATION . . . . 3-102,3-38
AXLE BEARINGS - REMOVAL . . . . . . . 3-102,3-38
AXLE BEARING/SEAL - INSTALLATION . . . . . 3-67
AXLE BEARING/SEAL - REMOVAL . . . . . . . . . 3-66
AXLE SHAFT SEALS - INSTALLATION . 3-102,3-38
AXLE SHAFT SEALS - REMOVAL . . . . 3-101,3-37
AXLE SHAFTS - INSTALLATION . . 3-101,3-37,3-65
AXLE SHAFTS - REMOVAL . . . . . 3-101,3-37,3-65
AXLE, SPECIAL TOOLS - 8 1/4 . . . . . . . . . . . 3-98
AXLE, SPECIAL TOOLS - FRONT . . . . . . . . . . 3-34
AXLE, SPECIAL TOOLS - REAR . . . . . . . . . . . 3-63
AXLE, SPECIFICATIONS - REAR . . . . . . . . . . 3-98
BACK - FRONT - INSTALLATION, SEAT . . . 23-166
BACK - FRONT - REMOVAL, SEAT . . . . . . . 23-166
BACK - REAR - INSTALLATION, SEAT . . . . 23-168
BACK - REAR - REMOVAL, SEAT . . . . . . . 23-168
BACK COVER - FRONT - INSTALLATION,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
BACK COVER - FRONT - REMOVAL, SEAT . 23-166
BACK COVER - REAR - INSTALLATION,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-169
BACK COVER - REAR - REMOVAL, SEAT . 23-169
BACK CUSHION - FRONT -
INSTALLATION, SEAT. . . . . . . . . . . . . . . . . 23-167
BACK CUSHION - FRONT - REMOVAL,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
BACK CUSHION - REAR - INSTALLATION,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
BACK CUSHION - REAR - REMOVAL,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
BACK FRAME - REAR - INSTALLATION,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-171
BACK FRAME - REAR - REMOVAL, SEAT . 23-171
BACK LATCH / LOCK - INSTALLATION,
FOLDING REAR SEAT . . . . . . . . . . . . . . . . 23-170
BACK LATCH / LOCK - REMOVAL,
FOLDING REAR SEAT . . . . . . . . . . . . . . . . 23-170
BACK LATCH STRIKER - INSTALLATION,
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . 23-171
BACK LATCH STRIKER - REMOVAL,
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . 23-170
BACK RECLINER - FRONT -
BACK RECLINER - FRONT - REMOVAL,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-166
BACKUP LAMP SWITCH - DESCRIPTION . . 8L-15
BACKUP LAMP SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-15
BACKUP LAMP SWITCH - OPERATION . . . . 8L-15
BAFFLE SEAL - INSTALLATION,
COWL/PLENUM WINDOW . . . . . . . . . . . . . 23-187
BAFFLE SEAL - REMOVAL, COWL/
PLENUM WINDOW . . . . . . . . . . . . . . . . . . 23-187
BALANCE SHAFT - INSTALLATION . . . . . . . . 9-74
BALANCE SHAFT - REMOVAL . . . . . . . . . . . . 9-74
BALANCING - STANDARD PROCEDURE,
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-4
BALL J OINT - DESCRIPTION, UPPER
SUSPENSION ARM, BUSHINGS . . . . . . . . . . 2-20
BALL J OINT - DIAGNOSIS AND TESTING,
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
BALL J OINT - INSTALLATION, UPPER . . . . . 2-20
BALL J OINT - OPERATION, UPPER
SUSPENSION ARM, BUSHINGS . . . . . . . . . . 2-20
BALL J OINT - REMOVAL, UPPER . . . . . . . . . 2-20
BAR - INSTALLATION, STABILIZER . . . . 2-14,2-19
BAR - REMOVAL, STABILIZER . . . . . . . 2-14,2-19
BAR BUSHINGS - INSTALLATION,
STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
BAR BUSHINGS - REMOVAL, STABILIZER . . . 2-9
BARRELS - INSTALLATION, PANEL
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-29
BARRELS - REMOVAL, PANEL OUTLET . . . 24-29
BASE - DESCRIPTION, BRAKES . . . . . . . . . . . 5-2
BASE - WARNING, BRAKES . . . . . . . . . . . . . . 5-2
BASE BRAKE SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
BASE BRAKES, SPECIAL TOOLS . . . . . . . . . . . 5-7
BASE COAT/CLEAR COAT FINISH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 23-162
BATTERIES - STANDARD PROCEDURE,
RKE TRANSMITTER . . . . . . . . . . . . . . . . . . . 8N-8
BATTERY - DESCRIPTION . . . . . . . . . . . . . . . 8F-7
BATTERY - DIAGNOSIS AND TESTING . . . . . 8F-8
BATTERY CABLES - DESCRIPTION . . . . . . . 8F-18
BATTERY CABLES - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-19
BATTERY CABLES - OPERATION . . . . . . . . . 8F-18
BATTERY CHARGING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8F-8
BATTERY HOLDDOWN - DESCRIPTION . . . . 8F-17
BATTERY HOLDDOWN - INSTALLATION . . . 8F-17
BATTERY HOLDDOWN - OPERATION . . . . . 8F-17
BATTERY HOLDDOWN - REMOVAL . . . . . . . 8F-17
BATTERY SYSTEM - CLEANING . . . . . . . . . . . 8F-5
BATTERY SYSTEM - DESCRIPTION . . . . . . . . 8F-1
BATTERY SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-2
BATTERY SYSTEM - INSPECTION . . . . . . . . . 8F-6
BATTERY SYSTEM - OPERATION . . . . . . . . . 8F-2
BATTERY SYSTEM - SPECIAL TOOLS . . . . . . 8F-7
BATTERY SYSTEM - SPECIFICATIONS . . . . . . 8F-6
BATTERY TEMPERATURE SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8F-24
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8F-24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
BATTERY TRAY - DESCRIPTION . . . . . . . . . 8F-21
BATTERY TRAY - INSTALLATION . . . . . . . . . 8F-21
2 INDEX KJ
BATTERY TRAY - OPERATION . . . . . . . . . . . 8F-21
BATTERY TRAY - REMOVAL . . . . . . . . . . . . 8F-21
BEAM INDICATOR - DESCRIPTION, HIGH . . 8J -22
BEAM INDICATOR - OPERATION, HIGH . . . . 8J -22
BEAM RELAY - DESCRIPTION,
HEADLAMP HIGH . . . . . . . . . . . . . . . . . . . . 8L-33
BEAM RELAY - DESCRIPTION,
HEADLAMP LOW. . . . . . . . . . . . . . . . . . . . . 8L-39
BEAM RELAY - DIAGNOSIS AND
TESTING, HEADLAMP HIGH . . . . . . . . . . . . 8L-34
BEAM RELAY - DIAGNOSIS AND
TESTING, HEADLAMP LOW. . . . . . . . . . . . . 8L-40
BEAM RELAY - INSTALLATION,
HEADLAMP HIGH . . . . . . . . . . . . . . . . . . . . 8L-35
BEAM RELAY - INSTALLATION,
HEADLAMP LOW. . . . . . . . . . . . . . . . . . . . . 8L-41
BEAM RELAY - OPERATION, HEADLAMP
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
BEAM RELAY - OPERATION, HEADLAMP
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
BEAM RELAY - REMOVAL, HEADLAMP
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-34
BEAM RELAY - REMOVAL, HEADLAMP
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-40
BEARING - FITTING - STANDARD
PROCEDURE, CONNECTING ROD . . . . . . . . . 9-40
BEARING - INSTALLATION, CLUTCH
RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
BEARING - INSTALLATION, HUB . . . . . . . . . . . 2-9
BEARING - INSTALLATION, PILOT . . . . . . . . . 6-8
BEARING - REMOVAL, CLUTCH RELEASE . . . 6-6
BEARING - REMOVAL, HUB . . . . . . . . . . . . . . 2-9
BEARING - REMOVAL, PILOT . . . . . . . . . . . . . 6-8
BEARING, FITTING - CONNECTING ROD . . . . 9-49
BEARING, FITTING - MAIN . . . . . . . . . . . . . . 9-45
BEARINGS - INSTALLATION, AXLE . . . 3-102,3-38
BEARINGS - INSTALLATION,
DIFFERENTIAL CASE . . . . . . . . . . 3-110,3-44,3-79
BEARINGS - REMOVAL, AXLE . . . . . . . 3-102,3-38
BEARINGS - REMOVAL, DIFFERENTIAL
CASE . . . . . . . . . . . . . . . . . . . . . . 3-110,3-43,3-79
BEARING/SEAL - INSTALLATION, AXLE . . . . 3-67
BEARING/SEAL - REMOVAL, AXLE . . . . . . . . 3-66
BELT / CHAIN COVER(S) -
INSTALLATION, TIMING. . . . . . . . . . . . . . . . . 9-76
BELT / CHAIN COVER(S) - REMOVAL,
TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
BELT - DIAGNOSIS AND TESTING,
SERPENTINE DRIVE . . . . . . . . . . . . . . . . . . . 7-15
BELT & RETRACTOR - INSTALLATION,
FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . 8O-24
REAR CENTER SEAT . . . . . . . . . . . . . . . . . . 8O-33
REAR OUTBOARD SEAT . . . . . . . . . . . . . . . 8O-34
BELT & RETRACTOR - REMOVAL, FRONT
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
BELT & RETRACTOR - REMOVAL, REAR
CENTER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8O-32
BELT & RETRACTOR - REMOVAL, REAR
OUTBOARD SEAT . . . . . . . . . . . . . . . . . . . . 8O-33
BELT BUCKLE - INSTALLATION, FRONT
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-26
BELT BUCKLE - INSTALLATION, REAR
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-35
BELT BUCKLE - REMOVAL, FRONT SEAT . . 8O-25
BELT BUCKLE - REMOVAL, REAR SEAT . . . 8O-34
BELT MOLDING - INSTALLATION, FRONT
DOOR OUTER . . . . . . . . . . . . . . . . . . . . . . 23-186
BELT MOLDING - INSTALLATION, REAR
DOOR OUTER . . . . . . . . . . . . . . . . . . . . . . 23-186
BELT MOLDING - REMOVAL, FRONT
DOOR OUTER . . . . . . . . . . . . . . . . . . . . . . 23-186
BELT MOLDING - REMOVAL, REAR
DOOR OUTER . . . . . . . . . . . . . . . . . . . . . . 23-186
BELT SWITCH - DESCRIPTION, SEAT . . . . . 8O-35
BELT SWITCH - OPERATION, SEAT . . . . . . . 8O-36
BELT TENSIONER - DESCRIPTION, SEAT . . 8O-36
BELT TENSIONER - OPERATION, SEAT . . . . 8O-36
BELT TURNING LOOP ADJ USTER -
INSTALLATION, SEAT . . . . . . . . . . . . . . . . . 8O-38
BELT TURNING LOOP ADJ USTER -
REMOVAL, SEAT . . . . . . . . . . . . . . . . . . . . . 8O-37
BELTLINE WEATHERSTRIP -
INSTALLATION, SWING GATE . . . . . . . . . . 23-186
BELTLINE WEATHERSTRIP - REMOVAL,
SWING GATE . . . . . . . . . . . . . . . . . . . . . . . 23-186
BEZEL - INSTALLATION, CLUSTER . . . . . . 23-147
BEZEL - INSTALLATION, INSTRUMENT
PANEL CENTER . . . . . . . . . . . . . . . . . . . . . 23-154
BEZEL - INSTALLATION, INSTRUMENT
PANEL PASSENGER SIDE . . . . . . . . . . . . . 23-154
BEZEL - INSTALLATION, SHIFT . . . . . . . . . 23-158
BEZEL - REMOVAL, CLUSTER . . . . . . . . . . 23-147
BEZEL - REMOVAL, INSTRUMENT PANEL
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-154
BEZEL - REMOVAL, INSTRUMENT PANEL
PASSENGER SIDE . . . . . . . . . . . . . . . . . . . 23-154
BEZEL - REMOVAL, SHIFT . . . . . . . . . . . . . 23-158
BEZELS - INSTALLATION, INSTRUMENT
PANEL DRIVER SIDE . . . . . . . . . . . . . . . . . 23-154
BEZELS - REMOVAL, INSTRUMENT
PANEL DRIVER SIDE . . . . . . . . . . . . . . . . . 23-153
BLADE - DESCRIPTION, FRONT WIPER . . . 8R-13
BLADE - DESCRIPTION, REAR WIPER . . . . 8R-39
BLADE - INSTALLATION, FRONT WIPER . . . 8R-14
BLADE - INSTALLATION, REAR WIPER . . . . 8R-40
BLADE - OPERATION, FRONT WIPER . . . . . 8R-14
BLADE - OPERATION, REAR WIPER . . . . . . 8R-39
BLADE - REMOVAL, FRONT WIPER . . . . . . 8R-14
BLADE - REMOVAL, REAR WIPER . . . . . . . 8R-40
BLEEDING - STANDARD PROCEDURE,
ABS BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . 5-24
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
BLEND DOOR - INSTALLATION . . . . . . . . . . 24-35
BLEND DOOR - REMOVAL . . . . . . . . . . . . . 24-35
BLEND DOOR ACTUATOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-20
BLEND DOOR ACTUATOR - REMOVAL . . . . 24-20
BLOCK - CLEANING, ENGINE . . . . . . . . . . . . 9-39
BLOCK - DESCRIPTION, ENGINE . . . . . . . . . . 9-39
BLOCK - DESCRIPTION, J UNCTION . . . . 8W-97-4
BLOCK - DESCRIPTION, J UNCTION . . . . . . . 5-20
BLOCK - DIAGNOSIS AND TESTING,
J UNCTION. . . . . . . . . . . . . . . . . . . . . . . . 8W-97-4
BLOCK - INSPECTION, ENGINE . . . . . . . . . . . 9-40
BLOCK - INSTALLATION, J UNCTION . . . . . . . 5-20
BLOCK - OPERATION, J UNCTION . . . . . . 8W-97-4
BLOCK - OPERATION, J UNCTION . . . . . . . . . 5-20
BLOCK - REMOVAL, J UNCTION . . . . . . . . . . . 5-20
BLOCKER - INSTALLATION, KNEE . . . . . . . 23-155
BLOCKER - REMOVAL, KNEE . . . . . . . . . . 23-155
BLOWER MOTOR - DESCRIPTION . . . . . . . 24-30
BLOWER MOTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-30
BLOWER MOTOR - INSTALLATION . . . . . . . 24-31
BLOWER MOTOR - OPERATION . . . . . . . . . 24-30
BLOWER MOTOR - REMOVAL . . . . . . . . . . . 24-30
BLOWER MOTOR RELAY - DESCRIPTION . . 24-20
BLOWER MOTOR RELAY - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 24-21
BLOWER MOTOR RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-22
BLOWER MOTOR RELAY - OPERATION . . . 24-20
BLOWER MOTOR RELAY - REMOVAL . . . . . 24-21
BLOWER MOTOR RESISTOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-22
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
BLOWER MOTOR RESISTOR - REMOVAL . . 24-22
BLOWER MOTOR SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-23
BLOWER MOTOR SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 24-23
BLOWER MOTOR SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-23
BLOWER MOTOR SWITCH - OPERATION . . 24-23
BLOWER MOTOR SWITCH - REMOVAL . . . 24-23
BODY - ASSEMBLY, VALVE . . . . . . . . . . . . 21-176
BODY & CABLE - DESCRIPTION,
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
BODY & CABLE - INSTALLATION,
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-6
BODY & CABLE - OPERATION, ANTENNA . . . 8A-5
BODY & CABLE - REMOVAL, ANTENNA . . . . 8A-6
BODY - CLEANING, VALVE . . . . . . . . . . . . 21-175
BODY - DESCRIPTION, THROTTLE . . . . . . . 14-43
BODY - DESCRIPTION, VALVE . . . . . . . . . . 21-171
BODY - DISASSEMBLY, VALVE . . . . . . . . . 21-173
BODY - INSPECTION, VALVE . . . . . . . . . . . 21-175
BODY - INSTALLATION, THROTTLE . . . . . . . 14-44
BODY - INSTALLATION, VALVE . . . . . . . . . 21-177
BODY - OPERATION, THROTTLE . . . . . . . . . 14-43
BODY - OPERATION, VALVE . . . . . . . . . . . 21-171
BODY - REMOVAL, THROTTLE . . . . . . . . . . 14-43
BODY - REMOVAL, VALVE . . . . . . . . . . . . . 21-172
BODY AND CABLE - DIAGNOSIS AND
TESTING, ANTENNA . . . . . . . . . . . . . . . . . . . 8A-5
BODY CONTROL MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8E-2
BODY CONTROL MODULE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8E-7
BODY CONTROL MODULE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 8E-7
BODY CONTROL MODULE - OPERATION . . . 8E-5
BODY CONTROL MODULE - REMOVAL . . . . . 8E-7
BODY LUBRICATION - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
BODY SIDE MOLDINGS - INSTALLATION . 23-140
BODY SIDE MOLDINGS - REMOVAL . . . . . 23-140
BODY, SPECIAL TOOLS . . . . . . . . . . . . . . . . . 23-5
BOOSTER - DESCRIPTION, POWER
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
BOOSTER - DIAGNOSIS AND TESTING,
MASTER CYLINDER/POWER . . . . . . . . . 5-21,5-24
BOOSTER - INSTALLATION, POWER
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
BOOSTER - OPERATION, POWER BRAKE . . . 5-21
BOOSTER - REMOVAL, POWER BRAKE . . . . 5-22
BOOT - INSTALLATION, 4WD FLOOR
SHIFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
BOOT - REMOVAL, 4WD FLOOR SHIFT . . . 23-156
BORE HONING - STANDARD
PROCEDURE, CYLINDER . . . . . . . . . . . . . . . . 9-39
BOX - INSTALLATION, GLOVE . . . . . . . . . . 23-148
BOX - REMOVAL, GLOVE . . . . . . . . . . . . . 23-148
BOX LATCH - INSTALLATION, GLOVE . . . . 23-148
BOX LATCH - REMOVAL, GLOVE . . . . . . . . 23-148
BOX LATCH STRIKER - INSTALLATION,
GLOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-149
BOX LATCH STRIKER - REMOVAL,
GLOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-148
B-PILLAR LOWER TRIM - INSTALLATION . 23-157
B-PILLAR LOWER TRIM - REMOVAL . . . . 23-157
B-PILLAR UPPER TRIM - INSTALLATION . 23-158
B-PILLAR UPPER TRIM - REMOVAL . . . . . 23-157
BRACKET - INSTALLATION, CLEVIS . . . . . . . 2-13
BRACKET - INSTALLATION, HOOD AJ AR
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
BRACKET - INSTALLATION, PASSENGER
AIRBAG MOUNTING . . . . . . . . . . . . . . . . . . 8O-31
BRACKET - INSTALLATION, REARVIEW
MIRROR SUPPORT . . . . . . . . . . . . . . . . . . 23-161
BRACKET - REMOVAL, CLEVIS . . . . . . . . . . . 2-13
BRACKET - REMOVAL, HOOD AJ AR
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
BRACKET - REMOVAL, PASSENGER
AIRBAG MOUNTING . . . . . . . . . . . . . . . . . . 8O-31
BRAKE - ADJ USTMENT, REAR DRUM . . . . . . 5-12
BRAKE - DESCRIPTION, PARKING . . . . . . . . 5-29
BRAKE - DESCRIPTION, REAR DRUM . . . . . 5-10
BRAKE - INSTALLATION, CONTROLLER
ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10
BRAKE - OPERATION, PARKING . . . . . . . . . . 5-29
BRAKE - OPERATION, REAR DRUM . . . . . . . 5-11
BRAKE - REMOVAL, CONTROLLER
ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10
BRAKE BLEEDING - STANDARD
PROCEDURE, ABS . . . . . . . . . . . . . . . . . . . . . 5-33
BRAKE BOOSTER - DESCRIPTION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
BRAKE BOOSTER - INSTALLATION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
BRAKE BOOSTER - OPERATION, POWER . . . 5-21
BRAKE BOOSTER - REMOVAL, POWER . . . . 5-22
BRAKE CALIPER ADAPTER -
INSTALLATION, DISC. . . . . . . . . . . . . . . . . . . 5-18
BRAKE CALIPER ADAPTER - REMOVAL,
DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
BRAKE CALIPERS - ASSEMBLY, DISC . . . . . . 5-16
BRAKE CALIPERS - CLEANING, DISC . . . . . . 5-16
BRAKE CALIPERS - DESCRIPTION, DISC . . . 5-13
BRAKE CALIPERS - DISASSEMBLY, DISC . . . 5-14
BRAKE CALIPERS - INSPECTION, DISC . . . . 5-16
BRAKE CALIPERS - INSTALLATION, DISC . . . 5-17
KJ INDEX 3
BRAKE CALIPERS - OPERATION, DISC . . . . . 5-14
BRAKE CALIPERS - REMOVAL, DISC . . . . . . 5-14
BRAKE COMPONENTS, SPECIFICATIONS . . . . 5-6
BRAKE DRUM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
BRAKE DRUM MACHINING - STANDARD
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 5-27
BRAKE FLUID CONTAMINATION -
BRAKE FLUID, SPECIFICATIONS . . . . . . . . . . 5-27
BRAKE HOSE - INSTALLATION, FRONT . . . . . 5-10
BRAKE HOSE - INSTALLATION, REAR . . . . . . 5-10
BRAKE HOSE - REMOVAL, REAR . . . . . . . . . . 5-9
BRAKE INDICATOR - DESCRIPTION,
BRAKE/PARK . . . . . . . . . . . . . . . . . . . . . . . . 8J -13
BRAKE INDICATOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -14
BRAKE INDICATOR - OPERATION,
BRAKE/PARK . . . . . . . . . . . . . . . . . . . . . . . . 8J -13
BRAKE LAMP SWITCH - DESCRIPTION . . . 8L-16
BRAKE LAMP SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-17
BRAKE LAMP SWITCH - INSTALLATION . . . 8L-18
BRAKE LAMP SWITCH - OPERATION . . . . . 8L-16
BRAKE LAMP SWITCH - REMOVAL . . . . . . 8L-17
BRAKE LINE AND HOSES - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
BRAKE LINES - DESCRIPTION . . . . . . . . . . . . 5-8
BRAKE PADS - INSTALLATION, FRONT . . . . . 5-11
BRAKE PADS - REMOVAL, FRONT . . . . . . . . 5-11
BRAKE ROTOR - DIAGNOSIS AND
TESTING, DISC . . . . . . . . . . . . . . . . . . . . . . . 5-18
BRAKE ROTOR - STANDARD
PROCEDURE, DISC . . . . . . . . . . . . . . . . . . . . 5-19
BRAKE SHOES - INSTALLATION, DRUM . . . . 5-11
BRAKE SHOES - REMOVAL, DRUM . . . . . . . 5-11
BRAKE SYSTEM - DIAGNOSIS AND
TESTING, BASE . . . . . . . . . . . . . . . . . . . . . . . . 5-3
BRAKE TRANSMISSION SHIFT
INTERLOCK SYSTEM - DESCRIPTION. . . . 21-124
INTERLOCK SYSTEM - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-125
INTERLOCK SYSTEM - OPERATION . . . . . 21-125
BRAKE/PARK BRAKE INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -13
BRAKE/PARK BRAKE INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -13
BRAKES - ABS - DESCRIPTION . . . . . . . . . . . 5-32
BRAKES - ABS - OPERATION . . . . . . . . . . . . 5-32
BRAKES - ABS - SPECIFICATIONS . . . . . . . . 5-33
BRAKES - BASE - DESCRIPTION . . . . . . . . . . . 5-2
BRAKES - BASE - WARNING . . . . . . . . . . . . . . 5-2
BRAKES, SPECIAL TOOLS - BASE . . . . . . . . . 5-7
BRAKING SYSTEM - DIAGNOSIS AND
TESTING, ANTILOCK . . . . . . . . . . . . . . . . . . . 5-33
BREAK-IN - STANDARD PROCEDURE,
A/C COMPRESSOR CLUTCH . . . . . . . . . . . . 24-12
BUCKLE - INSTALLATION, FRONT SEAT
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-26
BUCKLE - INSTALLATION, REAR SEAT
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-35
BUCKLE - REMOVAL, FRONT SEAT BELT . . 8O-25
BUCKLE - REMOVAL, REAR SEAT BELT . . . 8O-34
BUILT-IN INDICATOR TEST - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8F-10
BULB - INSTALLATION, ASH RECEIVER
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-71
BULB - INSTALLATION, CARGO LAMP . . . . 8L-73
BULB - INSTALLATION, CENTER HIGH
MOUNTED STOP LAMP . . . . . . . . . . . . . . . . 8L-19
BULB - INSTALLATION, COMPASS
MINI-TRIP ILLUMINATION. . . . . . . . . . . . . . 8L-75
BULB - INSTALLATION, COURTESY
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-76
BULB - INSTALLATION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
BULB - INSTALLATION, FRONT LAMP . . . . 8L-27
BULB - INSTALLATION, FRONT POSITION
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
BULB - INSTALLATION, HEADLAMP . . . . . . 8L-32
BULB - INSTALLATION, HEATER-A/C
CONTROL ILLUMINATION . . . . . . . . . . . . . . 8L-78
BULB - INSTALLATION, LICENSE PLATE
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-45
BULB - INSTALLATION, READING LAMP . . . 8L-79
BULB - INSTALLATION, REAR LAMP . . . . . 8L-59
BULB - INSTALLATION, REPEATER LAMP . . 8L-60
BULB - INSTALLATION, TRANSMISSION
RANGE INDICATOR ILLUMINATION. . . . . . . 8L-83
BULB - INSTALLATION, VANITY LAMP . . . . 8L-84
BULB - REMOVAL, ASH RECEIVER LAMP . . 8L-71
BULB - REMOVAL, CARGO LAMP . . . . . . . . 8L-72
BULB - REMOVAL, CENTER HIGH
BULB - REMOVAL, COMPASS MINI-TRIP
ILLUMINATION . . . . . . . . . . . . . . . . . . . . . . 8L-74
BULB - REMOVAL, COURTESY LAMP . . . . . 8L-75
BULB - REMOVAL, FRONT FOG LAMP . . . . 8L-21
BULB - REMOVAL, FRONT LAMP . . . . . . . . 8L-26
BULB - REMOVAL, FRONT POSITION
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
BULB - REMOVAL, HEADLAMP . . . . . . . . . . 8L-31
BULB - REMOVAL, HEATER-A/C
CONTROL ILLUMINATION . . . . . . . . . . . . . . 8L-78
BULB - REMOVAL, LICENSE PLATE
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-44
BULB - REMOVAL, READING LAMP . . . . . . 8L-79
BULB - REMOVAL, REAR LAMP . . . . . . . . . 8L-58
BULB - REMOVAL, REPEATER LAMP . . . . . 8L-60
BULB - REMOVAL, TRANSMISSION
RANGE INDICATOR ILLUMINATION. . . . . . . 8L-82
BULB - REMOVAL, VANITY LAMP . . . . . . . . 8L-83
BUMPER - INSTALLATION, J OUNCE . . . . . . . 2-19
BUMPER - REMOVAL, J OUNCE . . . . . . . . . . . 2-19
BURNT FLUID - DIAGNOSIS AND
TESTING, CAUSES OF . . . . . . . . . . . . . . . . 21-125
BUSHING - NV3550 - INSTALLATION,
EXTENSION HOUSING. . . . . . . . . . . . . . . . . 21-74
BUSHING - NV3550 - REMOVAL,
BUSHINGS - INSTALLATION, STABILIZER
BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
BUSHINGS - REMOVAL, STABILIZER BAR . . . 2-9
BUSHINGS, AND BALL J OINT -
DESCRIPTION, UPPER SUSPENSION
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
BUSHINGS, AND BALL J OINT -
OPERATION, UPPER SUSPENSION
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
CABLE - ADJ USTMENTS, GEARSHIFT . . . . 21-130
CABLE - ADJ USTMENTS, PARK-
INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . 21-154
CABLE - DESCRIPTION . . . . . . . . . . . . . . . . . 8P-3
CABLE - DESCRIPTION, ANTENNA BODY . . . 8A-4
CABLE - DIAGNOSIS AND TESTING,
ANTENNA BODY . . . . . . . . . . . . . . . . . . . . . . 8A-5
CABLE - DIAGNOSIS AND TESTING,
GEARSHIFT . . . . . . . . . . . . . . . . . . . . . . . . 21-128
CABLE - INSTALLATION, ANTENNA BODY . . 8A-6
CABLE - INSTALLATION, GEARSHIFT . . . . 21-129
CABLE - INSTALLATION, INSTRUMENT
PANEL ANTENNA. . . . . . . . . . . . . . . . . . . . . . 8A-8
CABLE - INSTALLATION, LATCH RELEASE . 23-120
CABLE - INSTALLATION, PARK -
INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . 21-153
CABLE - INSTALLATION, THROTTLE
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-46
CABLE - OPERATION . . . . . . . . . . . . . . . . . . . 8P-3
CABLE - OPERATION, ANTENNA BODY . . . . . 8A-5
CABLE - REMOVAL, ANTENNA BODY . . . . . . 8A-6
CABLE - REMOVAL, GEARSHIFT . . . . . . . . 21-128
CABLE - REMOVAL, INSTRUMENT PANEL
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-7
CABLE - REMOVAL, LATCH RELEASE . . . . 23-120
CABLE - REMOVAL, PARK - INTERLOCK . 21-153
CABLE - REMOVAL, THROTTLE
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-45
CABLE RESISTANCE, 2.4L - SPARK PLUG . . . 8I-3
CABLES - DESCRIPTION, BATTERY . . . . . . . 8F-18
CABLES - DIAGNOSIS AND TESTING,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-19
CABLES - INSTALLATION . . . . . . . . . . . . . . . 5-30
CABLES - OPERATION, BATTERY . . . . . . . . 8F-18
CABLES - REMOVAL . . . . . . . . . . . . . . . . . . . 5-30
CALIBRATION - STANDARD PROCEDURE,
COMPASS. . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-2
CALIPER ADAPTER - INSTALLATION,
DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
CALIPER ADAPTER - REMOVAL, DISC
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
CALIPERS - ASSEMBLY, DISC BRAKE . . . . . . 5-16
CALIPERS - CLEANING, DISC BRAKE . . . . . . 5-16
CALIPERS - DESCRIPTION, DISC BRAKE . . . 5-13
CALIPERS - DISASSEMBLY, DISC BRAKE . . . 5-14
CALIPERS - INSPECTION, DISC BRAKE . . . . 5-16
CALIPERS - INSTALLATION, DISC BRAKE . . . 5-17
CALIPERS - OPERATION, DISC BRAKE . . . . . 5-14
CALIPERS - REMOVAL, DISC BRAKE . . . . . . 5-14
CAMBER AND CASTER ADJ USTMENT -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . . 2-5
CAMBER, CASTER AND TOE
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
CAMSHAFT(S) - DESCRIPTION . . . . . . . 9-23,9-33
CAMSHAFT(S) - INSTALLATION . . . . . . 9-25,9-33
CAMSHAFT(S) - REMOVAL . . . . . . . . . . 9-24,9-33
CANISTER - DESCRIPTION, VAPOR . . . . . . 25-33
CANISTER - INSTALLATION, VAPOR . . . . . . 25-33
CANISTER - OPERATION, VAPOR . . . . . . . . 25-33
CANISTER - REMOVAL, VAPOR . . . . . . . . . . 25-33
CAP - CLEANING, RADIATOR PRESSURE . . . 7-25
CAP - DESCRIPTION, FUEL FILLER . . . . . . . 25-27
CAP - DESCRIPTION, RADIATOR
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
CAP - DIAGNOSIS AND TESTING,
RADIATOR PRESSURE . . . . . . . . . . . . . . . . . 7-25
CAP - INSPECTION, RADIATOR
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
CAP - INSTALLATION, INSTRUMENT
PANEL END . . . . . . . . . . . . . . . . . . . . . . . . 23-153
CAP - OPERATION, FUEL FILLER . . . . . . . . 25-27
CAP - OPERATION, RADIATOR
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
CAP - REMOVAL, INSTRUMENT PANEL
END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-153
CAPACITIES - SPECIFICATIONS, FLUID . . . . . . 0-4
CAPACITOR - DESCRIPTION, IGNITION
COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
CAPACITOR - INSTALLATION, IGNITION
COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
CAPACITOR - OPERATION, IGNITION
COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
CAPACITOR - REMOVAL, IGNITION COIL . . . 8I-16
CAPACITY - SPECIFICATIONS, CHARGE . . . 24-42
CAPACITY TEST - DIAGNOSIS AND
CARDAN UNIVERSAL J OINTS -
ASSEMBLY, SINGLE. . . . . . . . . . . . . . . . . . . . . 3-9
CARDAN UNIVERSAL J OINTS -
DISASSEMBLY, SINGLE . . . . . . . . . . . . . . . . . . 3-8
CARGO LAMP BULB - INSTALLATION . . . . . 8L-73
CARGO LAMP BULB - REMOVAL . . . . . . . . 8L-72
CARGO LAMP SWITCH - INSTALLATION . . 8L-74
CARGO LAMP SWITCH - REMOVAL . . . . . . 8L-73
CARGO LAMP UNIT - INSTALLATION . . . . . 8L-74
CARGO LAMP UNIT - REMOVAL . . . . . . . . . 8L-74
CARPETS AND FLOOR MATS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-158
CARPETS AND FLOOR MATS - REMOVAL . 23-158
CASE - NV231 - ASSEMBLY, TRANSFER . . 21-194
CASE - NV231 - CLEANING, TRANSFER . . 21-190
CASE - NV231 - DESCRIPTION,
TRANSFER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-178
CASE - NV231 - DIAGNOSIS AND
TESTING, TRANSFER. . . . . . . . . . . . . . . . . 21-180
CASE - NV231 - DISASSEMBLY,
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-182
CASE - NV231 - INSPECTION, TRANSFER . 21-190
CASE - NV231 - INSTALLATION,
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-205
CASE - NV231 - OPERATION, TRANSFER . 21-179
CASE - NV231 - REMOVAL, TRANSFER . . 21-181
CASE - NV242 - ASSEMBLY, TRANSFER . . 21-230
CASE - NV242 - CLEANING, TRANSFER . . 21-227
TRANSFER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-215
CASE - NV242 - DIAGNOSIS AND
TESTING, TRANSFER. . . . . . . . . . . . . . . . . 21-216
CASE - NV242 - DISASSEMBLY,
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-218
CASE - NV242 - INSPECTION, TRANSFER . 21-228
CASE - NV242 - INSTALLATION,
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-243
CASE - NV242 - OPERATION, TRANSFER . 21-215
CASE - NV242 - REMOVAL, TRANSFER . . 21-217
CASE BEARINGS - INSTALLATION,
DIFFERENTIAL . . . . . . . . . . . . . . . 3-110,3-44,3-79
4 INDEX KJ
CASE BEARINGS - REMOVAL,
DIFFERENTIAL . . . . . . . . . . . . . . . 3-110,3-43,3-79
CASE, NV231 - TRANSFER . . . . . . . . . . . . 21-206
CASE, NV242 - TRANSFER . . . . . . . . . . . . 21-244
CASE SKID PLATE - INSTALLATION,
TRANSFER. . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
CASE SKID PLATE - REMOVAL,
TRANSFER. . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
CASE, SPECIFICATIONS - NV242
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-244
CASTER ADJ USTMENT - STANDARD
PROCEDURE, CAMBER . . . . . . . . . . . . . . . . . . 2-5
CASTER AND TOE ADJ USTMENT -
STANDARD PROCEDURE, CAMBER . . . . . . . . 2-5
CATALYTIC CONVERTER - DESCRIPTION . . . 11-2
CATALYTIC CONVERTER - INSPECTION . . . . 11-3
CATALYTIC CONVERTER - INSTALLATION . . . 11-3
CATALYTIC CONVERTER - REMOVAL . . . . . . 11-2
CAUSES OF BURNT FLUID - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-125
CAUTION - SERVICE CAUTIONS . . . . . . . . . 24-39
CAUTION, HALF SHAFT . . . . . . . . . . . . . . . . . 3-10
CAUTION, REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS . . . . . . . . . . . . . . . . . 24-40
CAUTIONS, CAUTION - SERVICE . . . . . . . . . 24-39
CD CHANGER - DESCRIPTION . . . . . . . . . . . 8A-7
CD CHANGER - INSTALLATION . . . . . . . . . . . 8A-7
CD CHANGER - OPERATION . . . . . . . . . . . . . 8A-7
CD CHANGER - REMOVAL . . . . . . . . . . . . . . 8A-7
CENTER - DESCRIPTION, POWER
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-97-6
CENTER - OPERATION, POWER
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-97-7
CENTER - REMOVAL, POWER
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-97-7
CENTER ASSEMBLY, ASSEMBLY -
POWER DISTRIBUTION. . . . . . . . . . . . . 8W-97-10
CENTER BEZEL - INSTALLATION,
CENTER BEZEL - REMOVAL,
CENTER DISASSEMBLY, DISASSEMBLY -
POWER DISTRIBUTION. . . . . . . . . . . . . . 8W-97-7
CENTER HIGH MOUNTED STOP LAMP
BULB - INSTALLATION . . . . . . . . . . . . . . . . 8L-19
BULB - REMOVAL . . . . . . . . . . . . . . . . . . . . 8L-18
UNIT - INSTALLATION . . . . . . . . . . . . . . . . . 8L-19
UNIT - REMOVAL . . . . . . . . . . . . . . . . . . . . 8L-19
CENTER SEAT BELT & RETRACTOR -
INSTALLATION, REAR . . . . . . . . . . . . . . . . . 8O-33
CENTER SEAT BELT & RETRACTOR -
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 8O-32
CENTERING - STANDARD PROCEDURE,
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . 8O-14
CERTIFICATION LABEL - DESCRIPTION,
VEHICLE SAFETY . . . . . . . . . . . . . . . . . . . Intro.-9
CHAIN COVER(S) - INSTALLATION,
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . 9-76
CHAIN COVER(S) - REMOVAL, TIMING
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
CHAIN WEAR, STANDARD PROCEDURE -
MEASURING TIMING. . . . . . . . . . . . . . . . . . . 9-71
CHANGER - DESCRIPTION, CD . . . . . . . . . . . 8A-7
CHANGER - INSTALLATION, CD . . . . . . . . . . 8A-7
CHANGER - OPERATION, CD . . . . . . . . . . . . . 8A-7
CHANGER - REMOVAL, CD . . . . . . . . . . . . . . 8A-7
CHANNEL - INSTALLATION, GLASS RUN . 23-123,
23-130
CHANNEL - REMOVAL, GLASS RUN . . . . 23-123,
23-130
CHARGE - STANDARD PROCEDURE,
REFRIGERANT SYSTEM . . . . . . . . . . . . . . . 24-41
CHARGE CAPACITY - SPECIFICATIONS . . . . 24-42
CHARGING - STANDARD PROCEDURE,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-8
CHARGING INDICATOR - DESCRIPTION . . . 8J -15
CHARGING INDICATOR - OPERATION . . . . . 8J -15
CHARGING SYSTEM - DESCRIPTION . . . . . 8F-22
CHARGING SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-22
CHARGING SYSTEM - OPERATION . . . . . . . 8F-22
CHART - DIAGNOSIS AND TESTING,
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . . 7-6
CHART, SPECIFICATIONS - TORQUE . . . . . 19-15,
19-19,19-8
CHART, SPECIFICATIONS - TORQUE . . . . 2-17,2-8
CHECK - STANDARD PROCEDURE, FLUID
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-126
CHECK - STANDARD PROCEDURE, OIL
PUMP VOLUME . . . . . . . . . . . . . . . . . . . . . 21-148
CHECK STRAP - INSTALLATION . . 23-121,23-128,
23-135
CHECK STRAP - REMOVAL . . . . . 23-121,23-128,
23-135
CHECK VALVE - DESCRIPTION, FRONT . . . . 8R-8
CHECK VALVE - DESCRIPTION, FUEL
TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
CHECK VALVE - DESCRIPTION, REAR . . . . 8R-34
CHECK VALVE - DESCRIPTION, VACUUM . . 24-28
CHECK VALVE - INSTALLATION, FRONT . . . . 8R-9
CHECK VALVE - INSTALLATION, FUEL
TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
CHECK VALVE - INSTALLATION, REAR . . . . 8R-35
CHECK VALVE - INSTALLATION, VACUUM . 24-28
CHECK VALVE - OPERATION, FRONT . . . . . . 8R-9
CHECK VALVE - OPERATION, FUEL TANK . . 14-28
CHECK VALVE - OPERATION, REAR . . . . . . 8R-34
CHECK VALVE - OPERATION, VACUUM . . . . 24-28
CHECK VALVE - REMOVAL, FRONT . . . . . . . 8R-9
CHECK VALVE - REMOVAL, FUEL TANK . . . 14-28
CHECK VALVE - REMOVAL, REAR . . . . . . . 8R-34
CHECK VALVE - REMOVAL, VACUUM . . . . . 24-28
CHECKING TRANSMISSION CLUTCH
OPERATION - DIAGNOSIS AND
TESTING, AIR . . . . . . . . . . . . . . . . . . . . . . . 21-80
CHECKS - DIAGNOSIS AND TESTING,
PRELIMINARY . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
CHILD TETHER ANCHOR - DESCRIPTION . . 8O-13
CHILD TETHER ANCHOR - OPERATION . . . 8O-13
CHIME WARNING SYSTEM -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8B-1
CHIME WARNING SYSTEM - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8B-6
CHIME WARNING SYSTEM - OPERATION . . . 8B-2
CHOKE AND RELAY - DESCRIPTION,
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
CHOKE AND RELAY - DIAGNOSIS AND
TESTING, AMPLIFIER . . . . . . . . . . . . . . . . . . 8A-4
CHOKE AND RELAY - INSTALLATION,
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
CHOKE AND RELAY - OPERATION,
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
CHOKE AND RELAY - REMOVAL,
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
CIGAR LIGHTER OUTLET -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 8W-97-2
CIGAR LIGHTER OUTLET - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . 8W-97-2
CIGAR LIGHTER OUTLET - OPERATION . 8W-97-2
CLEVIS BRACKET - INSTALLATION . . . . . . . . 2-13
CLEVIS BRACKET - REMOVAL . . . . . . . . . . . 2-13
CLOCKSPRING - DESCRIPTION . . . . . . . . . 8O-13
CLOCKSPRING - INSTALLATION . . . . . . . . . 8O-16
CLOCKSPRING - OPERATION . . . . . . . . . . . 8O-14
CLOCKSPRING - REMOVAL . . . . . . . . . . . . 8O-15
CLOCKSPRING CENTERING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8O-14
CLUSTER - ASSEMBLY, INSTRUMENT . . . . 8J -10
CLUSTER - DESCRIPTION, INSTRUMENT . . . 8J -2
CLUSTER - DIAGNOSIS AND TESTING,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . 8J -7
CLUSTER - DISASSEMBLY, INSTRUMENT . . . 8J -9
CLUSTER - INSTALLATION, INSTRUMENT . 8J -11
CLUSTER - OPERATION, INSTRUMENT . . . . . 8J -4
CLUSTER - REMOVAL, INSTRUMENT . . . . . . 8J -9
CLUSTER BEZEL - INSTALLATION . . . . . . . 23-147
CLUSTER BEZEL - REMOVAL . . . . . . . . . . 23-147
CLUTCH - ASSEMBLY, LOW/REVERSE . . . 21-146
CLUTCH - CLEANING, LOW/REVERSE . . . . 21-146
CLUTCH - DESCRIPTION . . . . . . . . . . . . . . . . . 6-1
CLUTCH - DIAGNOSIS AND TESTING . . . . . . . 6-2
CLUTCH - DISASSEMBLY, LOW/REVERSE . 21-145
CLUTCH - INSPECTION, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-14
CLUTCH - INSPECTION, LOW/REVERSE . . 21-146
CLUTCH - INSTALLATION, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-14
CLUTCH - OPERATION . . . . . . . . . . . . . . . . . . 6-1
CLUTCH - REMOVAL, A/C COMPRESSOR . . 24-13
CLUTCH - SPECIFICATIONS . . . . . . . . . . . . . . . 6-5
CLUTCH - WARNING . . . . . . . . . . . . . . . . . . . . 6-2
CLUTCH ASSEMBLY - ASSEMBLY, INPUT . 21-138
CLUTCH ASSEMBLY - DESCRIPTION,
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-133
CLUTCH ASSEMBLY - DISASSEMBLY,
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135
CLUTCH ASSEMBLY - OPERATION,
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135
CLUTCH BREAK-IN - STANDARD
PROCEDURE, A/C COMPRESSOR . . . . . . . . 24-12
CLUTCH COIL - DIAGNOSIS AND
TESTING, A/C COMPRESSOR . . . . . . . . . . . 24-12
CLUTCH DISC - INSTALLATION . . . . . . . . . . . . 6-6
CLUTCH DISC - REMOVAL . . . . . . . . . . . . . . . 6-6
CLUTCH OPERATION - DIAGNOSIS AND
TESTING, AIR CHECKING
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . 21-80
CLUTCH PEDAL - INSTALLATION . . . . . . . . . 6-10
CLUTCH PEDAL - REMOVAL . . . . . . . . . . . . . 6-10
CLUTCH PEDAL POSITION SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 6-11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
CLUTCH RELAY - DESCRIPTION, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-15
CLUTCH RELAY - DIAGNOSIS AND
TESTING, COMPRESSOR. . . . . . . . . . . . . . . 24-15
CLUTCH RELAY - INSTALLATION, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-16
CLUTCH RELAY - OPERATION, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-15
CLUTCH RELAY - REMOVAL, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . 24-16
CLUTCH RELEASE BEARING -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 6-6
CLUTCH RELEASE BEARING - REMOVAL . . . . 6-6
CLUTCH SWITCH OVERRIDE RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 6-10
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 6-10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
CLUTCHES - DESCRIPTION, HOLDING . . . 21-131
CLUTCHES - OPERATION, HOLDING . . . . . 21-132
CMTC LAMP REPLACEMENT -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8M-2
COAT FINISH - DESCRIPTION, BASE
COAT/CLEAR . . . . . . . . . . . . . . . . . . . . . . . 23-162
COAT/CLEAR COAT FINISH -
DESCRIPTION, BASE . . . . . . . . . . . . . . . . . 23-162
CODE - DESCRIPTION, PAINT . . . . . . . . . . 23-162
CODES - DESCRIPTION, DIAGNOSTIC
TROUBLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
CODES - SPECIFICATIONS, PAINT . . . . . . . 23-162
CODES - STANDARD PROCEDURE,
ERASING TRANSMITTER . . . . . . . . . . . . . . . 8M-8
CODES - STANDARD PROCEDURE,
SETTING TRANSMITTER . . . . . . . . . . . . . . . 8M-9
COIL - DESCRIPTION, IGNITION . . . . . . . . . . 8I-9
COIL - DIAGNOSIS AND TESTING, A/C
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . 24-12
COIL - INSTALLATION, IGNITION . . . . . . . . . 8I-10
COIL - OPERATION, IGNITION . . . . . . . . . . . . 8I-9
COIL - REMOVAL, IGNITION . . . . . . . . . . . . 8I-10
COIL CAPACITOR - DESCRIPTION,
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
COIL CAPACITOR - INSTALLATION,
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
COIL CAPACITOR - OPERATION,
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-16
COIL CAPACITOR - REMOVAL, IGNITION . . . 8I-16
COIL RESISTANCE, 2.4L - IGNITION . . . . . . . 8I-2
COIL RESISTANCE, 3.7L V-6 - IGNITION . . . . 8I-3
COLLAPSIBLE SPACER - INSTALLATION . . . . 3-70
COLLAPSIBLE SPACER - REMOVAL . . . . . . . 3-70
COLUMN - DESCRIPTION . . . . . . . . . . . . . . . 19-5
COLUMN - INSTALLATION . . . . . . . . . . . . . . . 19-7
COLUMN - REMOVAL . . . . . . . . . . . . . . . . . . 19-5
COLUMN, SPECIAL TOOLS - STEERING . . . . 19-8
COMBINATION FLASHER - DESCRIPTION . . 8L-19
COMBINATION FLASHER - OPERATION . . . 8L-19
COMBUSTION PRESSURE LEAKAGE -
DIAGNOSIS AND TESTING, CYLINDER . . . . . . 9-8
COMMUNICATION - DESCRIPTION . . . . . . . . 8E-8
COMMUNICATION - OPERATION . . . . . . . . . . 8E-8
KJ INDEX 5
COMPASS CALIBRATION - STANDARD
PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . 8M-2
COMPASS DEMAGNETIZING -
COMPASS MINI-TRIP COMPUTER -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8M-6
COMPASS MINI-TRIP ILLUMINATION
COMPASS MINI-TRIP ILLUMINATION
BULB - REMOVAL . . . . . . . . . . . . . . . . . . . . 8L-74
COMPASS VARIATION ADJ USTMENT -
COMPASS/MINI-TRIP COMPUTER -
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 8M-4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8M-8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8M-5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7
COMPRESSION PRESSURE - DIAGNOSIS
AND TESTING, CYLINDER . . . . . . . . . . . . . . . . 9-8
COMPRESSOR CLUTCH - INSPECTION,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-14
COMPRESSOR CLUTCH - INSTALLATION,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-14
COMPRESSOR CLUTCH - REMOVAL, A/C . . 24-13
COMPRESSOR CLUTCH BREAK-IN -
STANDARD PROCEDURE, A/C . . . . . . . . . . . 24-12
COMPRESSOR CLUTCH COIL -
DIAGNOSIS AND TESTING, A/C. . . . . . . . . . 24-12
COMPRESSOR CLUTCH RELAY -
DESCRIPTION, A/C . . . . . . . . . . . . . . . . . . . 24-15
INSTALLATION, A/C . . . . . . . . . . . . . . . . . . . 24-16
OPERATION, A/C . . . . . . . . . . . . . . . . . . . . . 24-15
REMOVAL, A/C . . . . . . . . . . . . . . . . . . . . . . 24-16
COMPRESSOR NOISE - DIAGNOSIS AND
TESTING, A/C . . . . . . . . . . . . . . . . . . . . . . . 24-42
COMPUTER - DESCRIPTION, COMPASS/
MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-4
COMPUTER - DIAGNOSIS AND TESTING,
COMPASS MINI-TRIP . . . . . . . . . . . . . . . . . . 8M-6
COMPUTER - INSTALLATION, COMPASS/
MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-8
COMPUTER - OPERATION, COMPASS/
MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-5
COMPUTER - REMOVAL, COMPASS/
MINI-TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7
CONDENSER - DESCRIPTION, A/C . . . . . . . 24-45
CONDENSER - INSTALLATION, A/C . . . . . . . 24-46
CONDENSER - OPERATION, A/C . . . . . . . . . 24-45
CONDENSER - REMOVAL, A/C . . . . . . . . . . 24-45
CONDITIONER - DESCRIPTION, HEATER
AND AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1
CONDITIONER - OPERATION, HEATER
AND AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
CONDITIONS - DIAGNOSIS AND
TESTING, SPARK PLUG . . . . . . . . . . . . . . . . 8I-13
CONNECT FITTING - DESCRIPTION,
QUICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
CONNECTING ROD - DESCRIPTION,
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
CONNECTING ROD BEARING - FITTING -
STANDARD PROCEDURE. . . . . . . . . . . . . . . . 9-40
CONNECTING ROD BEARING, FITTING . . . . . 9-49
CONNECTOR - DESCRIPTION, DATA LINK . 8E-10
CONNECTOR - INSTALLATION . . . . . . . 8W-01-11
CONNECTOR - INSTALLATION, TRAILER
TOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-61
CONNECTOR - OPERATION, DATA LINK . . . 8E-10
CONNECTOR - REMOVAL . . . . . . . . . . . 8W-01-11
CONNECTOR - REMOVAL, TRAILER TOW . . 8L-61
CONNECTOR, GROUND AND SPLICE
INFORMATION - DESCRIPTION. . . . . . . . 8W-01-7
CONNECTOR/GROUND/SPLICE LOCATION
- DESCRIPTION. . . . . . . . . . . . . . . . . . . . 8W-91-1
CONSOLE - DESCRIPTION, OVERHEAD . . . . 8M-1
CONSOLE - INSTALLATION, FLOOR . . . . . 23-158
CONSOLE - OPERATION, OVERHEAD . . . . . . 8M-2
CONSOLE - REMOVAL, FLOOR . . . . . . . . . 23-158
CONSOLE DUCT - INSTALLATION, FLOOR . 24-31
CONSOLE DUCT - REMOVAL, FLOOR . . . . . 24-31
CONSOLE LID LATCH - INSTALLATION,
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
CONSOLE LID LATCH - REMOVAL,
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
CONSOLE, REMOVAL - OVERHEAD . . . . . . . 8M-4
CONTAINER - DESCRIPTION, COOLANT
RECOVERY PRESS . . . . . . . . . . . . . . . . . . . . 7-19
CONTAINER - OPERATION, COOLANT
RECOVERY PRESS . . . . . . . . . . . . . . . . . . . . 7-19
CONTAMINATION - DIAGNOSIS AND
TESTING, BRAKE FLUID . . . . . . . . . . . . . . . . 5-26
CONTAMINATION - DIAGNOSIS AND
TESTING, FLUID . . . . . . . . . . . . . . . . . . . . 21-125
CONTINUITY - STANDARD PROCEDURE,
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-9
CONTROL - DESCRIPTION, A/C HEATER . . . 24-16
CONTROL - DESCRIPTION, IGNITION . . . . . . 8I-1
CONTROL - DESCRIPTION, SPEED . . . . . . . . 8P-1
CONTROL - INSTALLATION, A/C HEATER . . 24-17
CONTROL - OPERATION, IGNITION . . . . . . . . 8I-1
CONTROL - OPERATION, SPEED . . . . . . . . . . 8P-1
CONTROL - REMOVAL, A/C HEATER . . . . . . 24-17
CONTROL - TORQUE, SPEED . . . . . . . . . . . . 8P-2
CONTROL ARM - DESCRIPTION, LOWER . . . 2-21
CONTROL ARM - INSTALLATION, LOWER . . 2-10,
2-21
CONTROL ARM - INSTALLATION, UPPER . . . 2-21
CONTROL ARM - OPERATION, LOWER . . . . . 2-21
CONTROL ARM - REMOVAL, LOWER . . 2-10,2-21
CONTROL ARM - REMOVAL, UPPER . . . . . . 2-20
CONTROL ASSEMBLY WINDOW
DEFOGGER FUNCTION - DIAGNOSIS
AND TESTING, REAR HVAC . . . . . . . . . . . . . 8G-9
CONTROL CABLE - INSTALLATION,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-46
CONTROL CABLE - REMOVAL,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-45
CONTROL ILLUMINATION BULB -
INSTALLATION, HEATER-A/C . . . . . . . . . . . . 8L-78
CONTROL ILLUMINATION BULB -
REMOVAL, HEATER-A/C . . . . . . . . . . . . . . . 8L-78
CONTROL INFORMATION (VECI) LABEL -
DESCRIPTION, VEHICLE EMISSION . . . . . Intro.-8
CONTROL MODULE - DESCRIPTION,
AIRBAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-9
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-2
SIDE IMPACT AIRBAG. . . . . . . . . . . . . . . . . 8O-43
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . 8E-18
CONTROL MODULE - DIAGNOSIS AND
TESTING, BODY . . . . . . . . . . . . . . . . . . . . . . . 8E-7
CONTROL MODULE - INSTALLATION . . . . 23-183
CONTROL MODULE - INSTALLATION,
AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-12
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-7
SIDE IMPACT AIRBAG. . . . . . . . . . . . . . . . . 8O-45
CONTROL MODULE - OPERATION,
AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-10
CONTROL MODULE - OPERATION, BODY . . . 8E-5
CONTROL MODULE - OPERATION, SIDE
IMPACT AIRBAG . . . . . . . . . . . . . . . . . . . . . 8O-43
CONTROL MODULE - OPERATION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . 8E-18
CONTROL MODULE - REMOVAL . . . . . . . . 23-183
CONTROL MODULE - REMOVAL, AIRBAG . 8O-11
CONTROL MODULE - REMOVAL, BODY . . . . 8E-7
CONTROL MODULE - REMOVAL, SIDE
IMPACT AIRBAG . . . . . . . . . . . . . . . . . . . . . 8O-44
CONTROL MOTOR - DESCRIPTION, IDLE
AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
CONTROL MOTOR - INSTALLATION, IDLE
AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
CONTROL MOTOR - OPERATION, IDLE
AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
CONTROL MOTOR - REMOVAL, IDLE AIR . . 14-36
CONTROL RELAY - DESCRIPTION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-168
CONTROL RELAY - OPERATION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-168
CONTROL SWITCH - DESCRIPTION . . . . . 23-184
CONTROL SWITCH - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-184
CONTROL SWITCH - INSTALLATION . . . . . 23-184
CONTROL SWITCH - OPERATION . . . . . . . 23-184
CONTROL SWITCH - REMOVAL . . . . . . . . 23-184
CONTROL SYSTEM - DESCRIPTION,
EMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
CONTROL SYSTEM - DESCRIPTION,
EVAPORATION . . . . . . . . . . . . . . . . . . . . . . . 25-24
CONTROLLER ANTILOCK BRAKE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8E-10
CONTROLLER ANTILOCK BRAKE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10
CONVERTER - DESCRIPTION, CATALYTIC . . . 11-2
CONVERTER - DESCRIPTION, TORQUE . . . 21-162
CONVERTER - INSPECTION, CATALYTIC . . . . 11-3
CONVERTER - INSTALLATION, CATALYTIC . . 11-3
CONVERTER - INSTALLATION, TORQUE . . 21-167
CONVERTER - OPERATION, TORQUE . . . . 21-166
CONVERTER - REMOVAL, CATALYTIC . . . . . . 11-2
CONVERTER - REMOVAL, TORQUE . . . . . . 21-167
CONVERTER HOUSING FLUID LEAK -
COOLANT - DESCRIPTION, ENGINE . . . . . . . . 0-3
COOLANT LOW INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -15
COOLANT LOW INDICATOR - OPERATION . 8J -16
COOLANT RECOVERY PRESS
CONTAINER - DESCRIPTION . . . . . . . . . . . . . 7-19
CONTAINER - OPERATION. . . . . . . . . . . . . . . 7-19
COOLANT TEMPERATURE SENSOR -
DESCRIPTION, ENGINE . . . . . . . . . . . . . . . . . 7-19
INSTALLATION, ENGINE . . . . . . . . . . . . . . . . 7-21
OPERATION, ENGINE. . . . . . . . . . . . . . . . . . . 7-20
REMOVAL, ENGINE . . . . . . . . . . . . . . . . . . . . 7-20
COOLANT THERMOSTAT - OPERATION,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
COOLER - DESCRIPTION, FLUID . . . . . . . . . 19-20
COOLER - DESCRIPTION, TRANS . . . . . . . . . 7-32
COOLER - INSTALLATION, FLUID . . . . . . . . 19-20
COOLER - OPERATION, FLUID . . . . . . . . . . 19-20
COOLER - REMOVAL, FLUID . . . . . . . . . . . . 19-20
COOLING, SPECIAL TOOLS . . . . . . . . . . . . . . 7-14
COOLING SYSTEM - OPERATION . . . . . . . . . . 7-2
COOLING SYSTEM - REVERSE
FLUSHING - STANDARD PROCEDURE . . . . . 7-12
COOLING SYSTEM 3.7L ENGINE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
STANDARD PROCEDURE, DRAINING . . . . . . 7-12
STANDARD PROCEDURE, REFILLING . . . . . . 7-12
COOLING SYSTEM DIAGNOSIS CHART -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 7-6
COOLING SYSTEM LEAKS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
COOLING SYSTEM REQUIREMENTS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 24-1
COOLING SYSTEM ROUTING 3.7L
ENGINE - DESCRIPTION . . . . . . . . . . . . . . . . . 7-2
CORE - DESCRIPTION, HEATER . . . . . . . . . 24-52
CORE - INSTALLATION, HEATER . . . . . . . . . 24-53
CORE - OPERATION, HEATER . . . . . . . . . . . 24-52
CORE - REMOVAL, HEATER . . . . . . . . . . . . 24-52
CORE AND OIL GALLERY PLUGS -
STANDARD PROCEDURE, ENGINE . . . . . . . . 9-10
COURTESY LAMP BULB - INSTALLATION . . 8L-76
COURTESY LAMP BULB - REMOVAL . . . . . 8L-75
COURTESY LAMP REPLACEMENT -
COURTESY LAMP UNIT - INSTALLATION . . 8L-77
COURTESY LAMP UNIT - REMOVAL . . . . . . 8L-76
COVER - DESCRIPTION, STRUCTURAL . . . . . 9-55
COVER - FRONT - INSTALLATION, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
COVER - FRONT - INSTALLATION, SEAT
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
COVER - FRONT - REMOVAL, SEAT BACK . 23-166
COVER - FRONT - REMOVAL, SEAT
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
COVER - INSTALLATION, COWL TRIM . . . 23-157
COVER - INSTALLATION, INSTRUMENT
PANEL TOP . . . . . . . . . . . . . . . . . . . . . . . . 23-153
COVER - INSTALLATION, STRUCTURAL . . . . 9-55
COVER - OPERATION, STRUCTURAL . . . . . . 9-55
COVER - REAR - INSTALLATION, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-169
COVER - REAR - REMOVAL, SEAT BACK . 23-169
6 INDEX KJ
COVER - REMOVAL, COWL TRIM . . . . . . . 23-157
COVER - REMOVAL, INSTRUMENT
PANEL TOP . . . . . . . . . . . . . . . . . . . . . . . . 23-152
COVER - REMOVAL, STRUCTURAL . . . . . . . . 9-55
COVER(S) - DESCRIPTION, CYLINDER
HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
COVER(S) - INSTALLATION, CYLINDER
HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26,9-34
COVER(S) - INSTALLATION, TIMING
BELT / CHAIN . . . . . . . . . . . . . . . . . . . . . . . . 9-76
COVER(S) - REMOVAL, CYLINDER HEAD . . 9-25,
9-34
COVER(S) - REMOVAL, TIMING BELT /
CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
COWL GRILLE - INSTALLATION . . . . . . . . 23-140
COWL GRILLE - REMOVAL . . . . . . . . . . . . 23-140
COWL TRIM COVER - INSTALLATION . . . . 23-157
COWL TRIM COVER - REMOVAL . . . . . . . 23-157
COWL WEATHERSTRIP - INSTALLATION . 23-185
COWL WEATHERSTRIP - REMOVAL . . . . . 23-185
COWL/PLENUM SEAL - INSTALLATION . . . 23-187
COWL/PLENUM SEAL - REMOVAL . . . . . . 23-187
COWL/PLENUM WINDOW BAFFLE SEAL -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-187
COWL/PLENUM WINDOW BAFFLE SEAL -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-187
CRADLE CROSSMEMBER -
INSTALLATION, ENGINE . . . . . . . . . . . . . . . . 13-6
CRADLE CROSSMEMBER - REMOVAL,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
CRANKSHAFT - DESCRIPTION . . . . . . . . . . . 9-42
CRANKSHAFT - INSPECTION . . . . . . . . . . . . . 9-43
CRANKSHAFT - INSTALLATION . . . . . . . . . . . 9-43
CRANKSHAFT - REMOVAL . . . . . . . . . . . . . . 9-43
CRANKSHAFT OIL SEAL - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 9-47
CRANKSHAFT OIL SEAL - FRONT -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
CRANKSHAFT OIL SEAL - REAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 9-48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
CRANKSHAFT POSITION SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-30
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
CROSSMEMBER - INSTALLATION,
ENGINE CRADLE . . . . . . . . . . . . . . . . . . . . . . 13-6
CROSSMEMBER - INSTALLATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . 23-146
CROSSMEMBER - INSTALLATION, REAR . . . 13-7
CROSSMEMBER - REMOVAL, ENGINE
CRADLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
CROSSMEMBER - REMOVAL, RADIATOR . 23-146
CROSSMEMBER - REMOVAL, REAR . . . . . . . 13-7
CROSS-OVER PIPE - INSTALLATION . . . . . . . 11-3
CROSS-OVER PIPE - REMOVAL . . . . . . . . . . 11-3
CRUISE INDICATOR - DESCRIPTION . . . . . . 8J -16
CRUISE INDICATOR - OPERATION . . . . . . . 8J -17
CURTAIN AIRBAG - DESCRIPTION, SIDE . . 8O-38
CURTAIN AIRBAG - INSTALLATION, SIDE . . 8O-41
CURTAIN AIRBAG - OPERATION, SIDE . . . . 8O-39
CURTAIN AIRBAG - REMOVAL, SIDE . . . . . 8O-40
CUSHION - FRONT - INSTALLATION,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSHION - FRONT - INSTALLATION,
SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSHION - FRONT - REMOVAL, SEAT . . . 23-167
CUSHION - FRONT - REMOVAL, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSHION - REAR - INSTALLATION, SEAT . 23-171
CUSHION - REAR - INSTALLATION, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
CUSHION - REAR - REMOVAL, SEAT . . . . 23-171
CUSHION - REAR - REMOVAL, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
CUSHION COVER - FRONT -
CUSHION COVER - FRONT - REMOVAL,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSHION SIDE SHIELDS -
CUSHION SIDE SHIELDS - REMOVAL,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSTOMER PREFERENCES - STANDARD
PROCEDURE, RKE TRANSMITTER . . . . . . . . 8N-8
CV J OINT/BOOT-INNER - INSTALLATION . . . 3-17
CV J OINT/BOOT-INNER - REMOVAL . . . . . . . 3-15
CV J OINT/BOOT-OUTER - INSTALLATION . . . 3-13
CV J OINT/BOOT-OUTER - REMOVAL . . . . . . . 3-12
CYLINDER - DESCRIPTION, MASTER . . . . . . 5-24
CYLINDER - INSPECTION, MASTER . . . . . . . . 6-9
CYLINDER - INSTALLATION, FLIP-UP
GLASS SUPPORT . . . . . . . . . . . . . . . . . . . 23-139
CYLINDER - INSTALLATION, LOCK . . . . . . 23-125,
23-138
CYLINDER - INSTALLATION, LOCK . . . . . . . 19-11
CYLINDER - INSTALLATION, MASTER . . . . . 5-25
CYLINDER - INSTALLATION, SUPPORT . . . 23-120
CYLINDER - OPERATION, MASTER . . . . . . . . 5-24
CYLINDER - REMOVAL, FLIP-UP GLASS
SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . 23-139
CYLINDER - REMOVAL, LOCK . . . . 23-125,23-137
CYLINDER - REMOVAL, LOCK . . . . . . . . . . . 19-10
CYLINDER - REMOVAL, MASTER . . . . . . . . . 5-25
CYLINDER - REMOVAL, SUPPORT . . . . . . 23-120
CYLINDER BLEEDING - STANDARD
PROCEDURE, MASTER . . . . . . . . . . . . . . . . . 5-24
CYLINDER BORE HONING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
CYLINDER COMBUSTION PRESSURE
LEAKAGE - DIAGNOSIS AND TESTING . . . . . . 9-8
CYLINDER COMPRESSION PRESSURE -
CYLINDER FLUID LEVEL - STANDARD
PROCEDURES, MASTER . . . . . . . . . . . . . . . . 5-26
CYLINDER HEAD - DESCRIPTION . . . . . . . . . 9-30
CYLINDER HEAD COVER(S) -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 9-25
CYLINDER HEAD COVER(S) -
INSTALLATION. . . . . . . . . . . . . . . . . . . . 9-26,9-34
CYLINDER HEAD COVER(S) - REMOVAL . . . 9-25,
9-34
CYLINDER HEAD GASKET - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . 9-19,9-30
CYLINDER LOCK SWITCH -
DESCRIPTION, DOOR . . . . . . . . . . . . . . . . . . 8Q-9
DESCRIPTION, TAILGATE . . . . . . . . . . . . . . . 8N-9
CYLINDER LOCK SWITCH - DIAGNOSIS
AND TESTING, DOOR . . . . . . . . . . . . . . . . . 8Q-10
CYLINDER LOCK SWITCH - DIAGNOSIS
AND TESTING, TAILGATE . . . . . . . . . . . . . . . 8N-9
INSTALLATION, DOOR. . . . . . . . . . . . . . . . . 8Q-10
INSTALLATION, TAILGATE. . . . . . . . . . . . . . 8N-10
CYLINDER LOCK SWITCH - OPERATION,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
CYLINDER LOCK SWITCH - OPERATION,
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-9
CYLINDER LOCK SWITCH - REMOVAL,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
CYLINDER LOCK SWITCH - REMOVAL,
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-10
CYLINDER/POWER BOOSTER -
DIAGNOSIS AND TESTING, MASTER . . 5-21,5-24
CYLINDERS - ASSEMBLY, WHEEL . . . . . . . . . 5-29
CYLINDERS - CLEANING, WHEEL . . . . . . . . . 5-28
CYLINDERS - DISASSEMBLY, WHEEL . . . . . . 5-28
CYLINDERS - INSPECTION, WHEEL . . . . . . . 5-29
CYLINDERS - INSTALLATION, WHEEL . . . . . 5-29
CYLINDERS - REMOVAL, WHEEL . . . . . . . . . 5-28
DAMAGED OR WORN THREADS -
STANDARD PROCEDURE, REPAIR . . . . . . . . . 9-9
DAMPER - INSTALLATION, VIBRATION . . . . . 9-55
DAMPER - REMOVAL, VIBRATION . . . . . . . . 9-54
DATA LINK CONNECTOR - DESCRIPTION . . 8E-10
DATA LINK CONNECTOR - OPERATION . . . . 8E-10
DAYTIME RUNNING LAMP RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-20
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
DECOUPLER - DIAGNOSIS AND
TESTING, GENERATOR . . . . . . . . . . . . . . . . 8F-27
DECOUPLER PULLEY - DESCRIPTION,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8F-26
DECOUPLER PULLEY - INSTALLATION,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8F-30
DECOUPLER PULLEY - OPERATION,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
DECOUPLER PULLEY - REMOVAL,
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
DEFINITION - DESCRIPTION, TRIP . . . . . . . 25-19
DEFLECTOR - INSTALLATION, WIND . . . . . 23-180
DEFLECTOR - REMOVAL, WIND . . . . . . . . 23-180
DEFOGGER - DESCRIPTION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
DEFOGGER - OPERATION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
DEFOGGER FUNCTION - DIAGNOSIS AND
TESTING, REAR HVAC CONTROL
ASSEMBLY WINDOW . . . . . . . . . . . . . . . . . . 8G-9
DEFOGGER GRID - DESCRIPTION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
DEFOGGER GRID - DIAGNOSIS AND
TESTING, REAR WINDOW . . . . . . . . . . . . . . 8G-5
DEFOGGER GRID - OPERATION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
DEFOGGER RELAY - DESCRIPTION,
REAR WINDOW. . . . . . . . . . . . . . . . . . . . . . . 8G-6
DEFOGGER RELAY - DIAGNOSIS AND
DEFOGGER RELAY - INSTALLATION,
REAR WINDOW. . . . . . . . . . . . . . . . . . . . . . . 8G-7
DEFOGGER RELAY - OPERATION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-6
DEFOGGER RELAY - REMOVAL, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-7
DEFOGGER SWITCH - DESCRIPTION,
REAR WINDOW. . . . . . . . . . . . . . . . . . . . . . . 8G-8
DEFOGGER SWITCH - DIAGNOSIS AND
DEFOGGER SWITCH - OPERATION, REAR
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-8
DEFOGGER SYSTEM - DIAGNOSIS AND
DEFROST DOO - INSTALLATION, FLOOR . . 24-37
DEFROST DOOR - REMOVAL . . . . . . . . . . . 24-35
DEFROST DOOR - REMOVAL, FLOOR . . . . . 24-36
DEFROST DOOR ACTUATOR -
INSTALLATION, FLOOR . . . . . . . . . . . . . . . . 24-25
DEFROST DOOR ACTUATOR - REMOVAL,
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-24
DEFROST DUCT/DEMISTER ADAPTOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-32
DEFROST/DEMISTER DUCT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-32
DELIVERY - DESCRIPTION, FUEL . . . . . . . . . 14-2
DELIVERY - OPERATION, FUEL . . . . . . . . . . . 14-3
DEMAGNETIZING - STANDARD
PROCEDURE, COMPASS . . . . . . . . . . . . . . . 8M-2
DEMISTER OUTLETS - DESCRIPTION . . . . . 24-29
PROCEDURE, SERVICE AFTER A
SUPPLEMENTAL RESTRAINT . . . . . . . . . . . . 8O-6
DETECTION PUMP - DESCRIPTION, LEAK . 25-27
DETECTION PUMP - INSTALLATION,
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-28
DETECTION PUMP - OPERATION, LEAK . . . 25-28
DETECTION PUMP - REMOVAL, LEAK . . . . 25-28
DEVICES - STANDARD PROCEDURE,
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE. . . . . . . . . . . . . . . . . . . . . . . . 8W-01-8
DIAGNOSIS CHART - DIAGNOSIS AND
TESTING, COOLING SYSTEM . . . . . . . . . . . . . 7-6
DIAGNOSIS, DIAGNOSIS AND TESTING -
WATER DRAINAGE AND WIND NOISE . . . 23-176
DIAGNOSTIC PROCEDURES, DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 23-176
DIAGNOSTIC TROUBLE CODES -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 25-2
DIAGNOSTICS (OBD) - DIAGNOSIS AND
TESTING, ON-BOARD . . . . . . . . . . . . . . . . . . . 7-3
DIAGRAMS - DESCRIPTION, HOW TO
USE WIRING. . . . . . . . . . . . . . . . . . . . . . 8W-01-1
DIAGRAMS - HYDRAULIC SCHEMATICS,
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 21-100
DIESEL - TORQUE, EXCEPT . . . . . . . . . . . . . 8F-23
DIFFERENTIAL - ASSEMBLY . . . . . . . . 3-105,3-41
DIFFERENTIAL - DISASSEMBLY . . . . . 3-105,3-41
DIFFERENTIAL - INSTALLATION . 3-105,3-42,3-73
DIFFERENTIAL - REMOVAL . . . . . 3-104,3-40,3-71
DIFFERENTIAL - TRAC-LOK - ASSEMBLY . . 3-109,
3-77
KJ INDEX 7
DIFFERENTIAL - TRAC-LOK - CLEANING . . 3-109,
3-77
DIFFERENTIAL - TRAC-LOK -
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 3-107,3-75
DIFFERENTIAL - TRAC-LOK -
INSPECTION . . . . . . . . . . . . . . . . . . . . 3-109,3-77
DIFFERENTIAL CASE BEARINGS -
INSTALLATION. . . . . . . . . . . . . . . 3-110,3-44,3-79
DIFFERENTIAL CASE BEARINGS -
REMOVAL . . . . . . . . . . . . . . . . . . 3-110,3-43,3-79
DIMENSIONS - SPECIFICATIONS, FRAME . . . 13-3
DIMENSIONS - SPECIFICATIONS,
OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-111
DIODE - INSTALLATION . . . . . . . . . . . . 8W-01-14
DIODE - REMOVAL . . . . . . . . . . . . . . . . 8W-01-14
DIODE REPLACEMENT - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-9
DISASSEMBLY - POWER DISTRIBUTION
CENTER DISASSEMBLY . . . . . . . . . . . . . 8W-97-7
DISASSEMBLY, 4C RETAINER/BULKHEAD . 21-122
DISASSEMBLY, DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-83
DISASSEMBLY, DIFFERENTIAL . . . . . . 3-105,3-41
DISASSEMBLY, DIFFERENTIAL -
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . 3-107,3-75
DISASSEMBLY, DISASSEMBLY - POWER
DISTRIBUTION CENTER . . . . . . . . . . . . . 8W-97-7
DISASSEMBLY, DISC BRAKE CALIPERS . . . . 5-14
DISASSEMBLY, HVAC HOUSING . . . . . . . . . 24-34
DISASSEMBLY, INPUT CLUTCH
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 21-135
DISASSEMBLY, INSTRUMENT CLUSTER . . . . 8J -9
DISASSEMBLY, LOW/REVERSE CLUTCH . . 21-145
DISASSEMBLY, MANUAL - NV1500 . . . . . . . . 21-4
DISASSEMBLY, MANUAL - NV3550 . . . . . . . 21-35
DISASSEMBLY, OIL PUMP . . . . . . . . . . . . . . . 9-65
DISASSEMBLY, OIL PUMP . . . . . . . . . . . . . 21-149
DISASSEMBLY, PLANETARY GEARTRAIN . 21-159
DISASSEMBLY, SINGLE CARDAN
UNIVERSAL J OINTS . . . . . . . . . . . . . . . . . . . . 3-8
DISASSEMBLY, TRANSFER CASE -
NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-182
DISASSEMBLY, TRANSFER CASE -
NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-218
DISASSEMBLY, VALVE BODY . . . . . . . . . . . 21-173
DISASSEMBLY, WHEEL CYLINDERS . . . . . . . 5-28
DISC - INSTALLATION, CLUTCH . . . . . . . . . . . 6-6
DISC - REMOVAL, CLUTCH . . . . . . . . . . . . . . . 6-6
DISC BRAKE CALIPER ADAPTER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5-18
DISC BRAKE CALIPER ADAPTER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
DISC BRAKE CALIPERS - ASSEMBLY . . . . . . 5-16
DISC BRAKE CALIPERS - CLEANING . . . . . . 5-16
DISC BRAKE CALIPERS - DESCRIPTION . . . . 5-13
DISC BRAKE CALIPERS - DISASSEMBLY . . . 5-14
DISC BRAKE CALIPERS - INSPECTION . . . . . 5-16
DISC BRAKE CALIPERS - INSTALLATION . . . 5-17
DISC BRAKE CALIPERS - OPERATION . . . . . 5-14
DISC BRAKE CALIPERS - REMOVAL . . . . . . . 5-14
DISC BRAKE ROTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
DISC BRAKE ROTOR - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
DISCHARGE (ESD) SENSITIVE DEVICES -
STANDARD PROCEDURE,
ELECTROSTATIC . . . . . . . . . . . . . . . . . . . 8W-01-8
DISCHARGE LINE - INSTALLATION, A/C . . . 24-47
DISCHARGE LINE - REMOVAL, A/C . . . . . . . 24-46
DISPLAY TEST MODE - DESCRIPTION,
STATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
DISTRIBUTION - DESCRIPTION, POWER . 8W-97-1
DISTRIBUTION - OPERATION, POWER . . 8W-97-1
DISTRIBUTION CENTER - DESCRIPTION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-6
DISTRIBUTION CENTER - OPERATION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-7
DISTRIBUTION CENTER - REMOVAL,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-7
DISTRIBUTION CENTER ASSEMBLY,
ASSEMBLY - POWER . . . . . . . . . . . . . . 8W-97-10
DISTRIBUTION CENTER DISASSEMBLY,
DISASSEMBLY - POWER . . . . . . . . . . . . 8W-97-7
DISTRIBUTION SYSTEMS, SPECIAL
TOOLS - POWER. . . . . . . . . . . . . . . . . . . 8W-97-2
DOO - INSTALLATION, FLOOR -
DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-37
DOOR - INSTALLATION . . . . . . . . . 23-122,23-129
DOOR - INSTALLATION, BLEND . . . . . . . . . 24-35
DOOR - INSTALLATION, PANEL . . . . . . . . . . 24-36
DOOR - INSTALLATION, PASSENGER
AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-30
DOOR - INSTALLATION, RECIRC . . . . . . . . . 24-37
DOOR - REMOVAL . . . . . . . . . . . . . 23-122,23-129
DOOR - REMOVAL, BLEND . . . . . . . . . . . . . 24-35
DOOR - REMOVAL, DEFROST . . . . . . . . . . . 24-35
DOOR - REMOVAL, FLOOR - DEFROST . . . . 24-36
DOOR - REMOVAL, PASSENGER AIRBAG . . 8O-29
DOOR - REMOVAL, RECIRC . . . . . . . . . . . . 24-37
DOOR ACTUATOR - INSTALLATION,
BLEND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
FLOOR - DEFROST . . . . . . . . . . . . . . . . . . . 24-25
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
RECIRCULATION . . . . . . . . . . . . . . . . . . . . . 24-26
DOOR ACTUATOR - REMOVAL, BLEND . . . . 24-20
DOOR ACTUATOR - REMOVAL, FLOOR -
DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-24
DOOR ACTUATOR - REMOVAL, PANEL . . . . 24-24
DOOR ACTUATOR - REMOVAL,
RECIRCULATION . . . . . . . . . . . . . . . . . . . . . 24-26
DOOR AJ AR INDICATOR - DESCRIPTION . . 8J -17
DOOR AJ AR INDICATOR - OPERATION . . . . 8J -17
DOOR AJ AR SWITCH - DESCRIPTION . . . . 8L-77
DOOR AJ AR SWITCH - OPERATION. . . . . . . . 8L-77
DOOR CYLINDER LOCK SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8Q-9
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8Q-10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
DOOR GLASS - INSTALLATION . . 23-122,23-129,
23-172
DOOR GLASS - REMOVAL . . . . . . 23-122,23-129,
23-172
DOOR LOCK / UNLOCK SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8N-5
DOOR LOCK / UNLOCK SWITCH -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-4
DOOR LOCK MOTOR - DESCRIPTION . . . . . . 8N-5
DOOR LOCK MOTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5
DOOR LOCK MOTOR - OPERATION . . . . . . . 8N-5
DOOR LOCK RELAY - DESCRIPTION . . . . . . 8N-6
DOOR LOCK RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-6
DOOR LOCK RELAY - INSTALLATION . . . . . . 8N-7
DOOR LOCK RELAY - OPERATION . . . . . . . . 8N-6
DOOR LOCK RELAY - REMOVAL . . . . . . . . . 8N-6
DOOR LOCK/UNLOCK SWITCH -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8N-4
DOOR LOWER WEATHERSTRIP -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-186
DOOR LOWER WEATHERSTRIP -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
DOOR OUTER BELT MOLDING -
INSTALLATION, FRONT . . . . . . . . . . . . . . . 23-186
INSTALLATION, REAR . . . . . . . . . . . . . . . . 23-186
REMOVAL, FRONT . . . . . . . . . . . . . . . . . . . 23-186
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 23-186
DOOR PRIMARY WEATHERSTRIP -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-185
DOOR PRIMARY WEATHERSTRIP -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-185
DOOR SCUFF PLATE - INSTALLATION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-160
DOOR SCUFF PLATE - REMOVAL, REAR . . 23-160
DOOR SILL SCUFF PLATE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-157
DOOR SILL SCUFF PLATE - REMOVAL . . . 23-157
DOOR/HOUSING - INSTALLATION, FUEL
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-141
DOOR/HOUSING - REMOVAL, FUEL FILL . 23-141
DOUBLE INVERTED FLARING -
DRAIN AND FILL - STANDARD
PROCEDURE, FLUID . . . . . . . . . . . 21-208,21-246
DRAIN TUBE - INSTALLATION . . . . . . . . . . 23-181
DRAIN TUBE - REMOVAL . . . . . . . . . . . . . 23-180
DRAINAGE AND WIND NOISE
DIAGNOSIS, DIAGNOSIS AND TESTING
- WATER . . . . . . . . . . . . . . . . . . . . . . . . . . 23-176
DRAINING COOLING SYSTEM 3.7L
ENGINE - STANDARD PROCEDURE. . . . . . . . 7-12
DRAW TEST - STANDARD PROCEDURE,
IGNITION-OFF . . . . . . . . . . . . . . . . . . . . . . . 8F-14
DRIVE - DIAGNOSIS AND TESTING,
VISCOUS FAN . . . . . . . . . . . . . . . . . . . . . . . . 7-28
DRIVE BELT - DIAGNOSIS AND TESTING,
SERPENTINE . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
DRIVE MOTOR - INSTALLATION . . . . . . . . 23-182
DRIVE MOTOR - REMOVAL . . . . . . . . . . . . 23-182
DRIVER AIRBAG - DESCRIPTION . . . . . . . . 8O-17
DRIVER AIRBAG - INSTALLATION . . . . . . . 8O-20
DRIVER AIRBAG - OPERATION . . . . . . . . . . 8O-18
DRIVER AIRBAG - REMOVAL . . . . . . . . . . . 8O-19
DRIVER SEAT HEATER SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8G-11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8G-13
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8G-12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
DRIVER SIDE BEZELS - INSTALLATION,
DRIVER SIDE BEZELS - REMOVAL,
DROP - STANDARD PROCEDURE,
TESTING FOR A VOLTAGE. . . . . . . . . . . 8W-01-10
DRUM - DIAGNOSIS AND TESTING,
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
DRUM BRAKE - ADJ USTMENT, REAR . . . . . . 5-12
DRUM BRAKE - DESCRIPTION, REAR . . . . . 5-10
DRUM BRAKE - OPERATION, REAR . . . . . . . 5-11
DRUM BRAKE SHOES - INSTALLATION . . . . 5-11
DRUM BRAKE SHOES - REMOVAL . . . . . . . . 5-11
DRUM MACHINING - STANDARD
PROCEDURES, BRAKE . . . . . . . . . . . . . . . . . 5-27
DUCT - INSTALLATION, DEFROST/
DEMISTER . . . . . . . . . . . . . . . . . . . . . . . . . . 24-32
DUCT - INSTALLATION, FLOOR . . . . . . . . . . 24-32
DUCT - INSTALLATION, FLOOR CONSOLE . 24-31
DUCT - REMOVAL, FLOOR . . . . . . . . . . . . . 24-32
DUCT - REMOVAL, FLOOR CONSOLE . . . . . 24-31
DUCT/DEMISTER ADAPTOR - REMOVAL,
DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-32
EFFECTS OF INCORRECT FLUID LEVEL -
DIAGNOSIS AND TESTING . . . . . . . . . . . . 21-125
ELECTRIC - DESCRIPTION, RADIATOR
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
ELECTRIC - INSTALLATION, RADIATOR
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
ELECTRIC - INSTALLATION, WINDOW
REGULATOR . . . . . . . . . . . . . . . . . 23-126,23-134
ELECTRIC - OPERATION, RADIATOR FAN . . . 7-26
ELECTRIC - REMOVAL, RADIATOR FAN . . . . 7-26
ELECTRIC - REMOVAL, WINDOW
REGULATOR . . . . . . . . . . . . . . . . . 23-126,23-134
ELECTRICAL - DESCRIPTION . . . . . . . . . . . . 5-34
ELECTRICAL - OPERATION . . . . . . . . . . . . . . 5-34
ELECTRICAL TESTER - STANDARD
PROCEDURE, USING MIDTRONICS . . . . . . . 8F-15
SENSITIVE DEVICES - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 8W-01-8
ELEMENT - DESCRIPTION, HEATED SEAT . 8G-13
ELEMENT - DIAGNOSIS AND TESTING,
HEATED SEAT . . . . . . . . . . . . . . . . . . . . . . . 8G-13
ELEMENT - OPERATION, HEATED SEAT . . . 8G-13
EMISSION CONTROL INFORMATION
(VECI) LABEL - DESCRIPTION,
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-8
EMISSION CONTROL SYSTEM -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 25-1
END - INSTALLATION, TIE ROD . . . . . . . . . 19-16
END - REMOVAL, TIE ROD . . . . . . . . . . . . . 19-16
END CAP - INSTALLATION, INSTRUMENT
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-153
END CAP - REMOVAL, INSTRUMENT
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-153
END REMOVAL TOOL, SPECIAL TOOLS -
OUTER TIE ROD . . . . . . . . . . . . . . . . . . . . . 19-15
ENGINE - 3.7L - DESCRIPTION . . . . . . . . . . . . 9-3
ENGINE - DESCRIPTION, 3.7L . . . . . . . . . . . . 7-21
8 INDEX KJ
ENGINE - DESCRIPTION, COOLING
SYSTEM 3.7L . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
ENGINE - DESCRIPTION, COOLING
SYSTEM ROUTING 3.7L . . . . . . . . . . . . . . . . . 7-2
ENGINE - INSTALLATION, 3.7L . . . 7-17,7-18,7-22
ENGINE - REMOVAL, 3.7L . . . . . . . . . . . 7-17,7-21
ENGINE - STANDARD PROCEDURE,
DRAINING COOLING SYSTEM 3.7L . . . . . . . . 7-12
ENGINE - STANDARD PROCEDURE,
REFILLING COOLING SYSTEM 3.7L . . . . . . . 7-12
ENGINE BLOCK - CLEANING . . . . . . . . . . . . . 9-39
ENGINE BLOCK - DESCRIPTION . . . . . . . . . . 9-39
ENGINE BLOCK - INSPECTION . . . . . . . . . . . 9-40
ENGINE COOLANT - DESCRIPTION . . . . . . . . . 0-3
ENGINE COOLANT TEMPERATURE
SENSOR - DESCRIPTION . . . . . . . . . . . . . . . 7-19
SENSOR - INSTALLATION . . . . . . . . . . . . . . . 7-21
SENSOR - OPERATION . . . . . . . . . . . . . . . . . 7-20
SENSOR - REMOVAL . . . . . . . . . . . . . . . . . . . 7-20
ENGINE COOLANT THERMOSTAT -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
ENGINE CORE AND OIL GALLERY PLUGS
- STANDARD PROCEDURE . . . . . . . . . . . . . . 9-10
ENGINE CRADLE CROSSMEMBER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 13-6
ENGINE CRADLE CROSSMEMBER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
ENGINE DIAGNOSIS - INTRODUCTION -
DIAGNOSIS AND TESTING. . . . . . . . . . . . . . . . . 9-4
ENGINE DIAGNOSIS - LUBRICATION -
ENGINE DIAGNOSIS - MECHANICAL -
ENGINE DIAGNOSIS - PERFORMANCE -
ENGINE FIRING ORDER, 2.4L 4-
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-2
ENGINE FIRING ORDER, 3.7L V-6 . . . . . . . . . 8I-2
ENGINE GASKET SURFACE
PREPARATION - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
ENGINE OIL - STANDARD PROCEDURE . . . . 9-61
ENGINE OIL LEAK - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
ENGINE OIL PRESSURE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 9-60
ENGINE, SPECIAL TOOLS - 3.7L . . . . . . . . . . 9-15
ENGINE, SPECIFICATIONS - 3.7L . . . . . . . . . 9-12
ENGINE TEMPERATURE GAUGE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -18
ENGINE TEMPERATURE GAUGE -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -18
ENGINES - GENERATOR RATINGS, GAS . . . 8F-23
ENTRY MODULE - DESCRIPTION,
REMOTE KEYLESS . . . . . . . . . . . . . . . . . . . . 8N-7
ENTRY MODULE - DIAGNOSIS AND
TESTING, REMOTE KEYLESS . . . . . . . . . . . . 8N-7
ENTRY MODULE - INSTALLATION,
REMOTE KEYLESS . . . . . . . . . . . . . . . . . . . . 8N-7
ENTRY MODULE - OPERATION, REMOTE
KEYLESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
ENTRY MODULE - REMOVAL, REMOTE
KEYLESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
ENTRY TRANSMITTER - DIAGNOSIS AND
TESTING, REMOTE KEYLESS . . . . . . . . . . . . 8N-8
ENTRY TRANSMITTER -
SPECIFICATIONS, REMOTE KEYLESS . . . . . . 8N-9
EQUIPMENT - STANDARD PROCEDURE,
REFRIGERANT SYSTEM SERVICE . . . . . . . . 24-40
ERASING TRANSMITTER CODES -
EVACUATE - STANDARD PROCEDURE,
REFRIGERANT SYSTEM . . . . . . . . . . . . . . . 24-41
EVAPORATION CONTROL SYSTEM -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 25-24
EVAPORATOR - DESCRIPTION, A/C . . . . . . . 24-49
EVAPORATOR - INSTALLATION, A/C . . . . . . 24-49
EVAPORATOR - OPERATION, A/C . . . . . . . . 24-49
EVAPORATOR - REMOVAL, A/C . . . . . . . . . . 24-49
EVAP/PURGE SOLENOID - DESCRIPTION . . 25-27
EVAP/PURGE SOLENOID - INSTALLATION . 25-27
EVAP/PURGE SOLENOID - OPERATION . . . . 25-27
EVAP/PURGE SOLENOID - REMOVAL . . . . . 25-27
EXCEPT DIESEL - TORQUE . . . . . . . . . . . . . 8F-23
EXHAUST MANIFOLD - DESCRIPTION . . . . . 9-69
EXHAUST MANIFOLD - INSTALLATION . . . . . 9-70
EXHAUST MANIFOLD - REMOVAL . . . . . . . . . 9-69
EXHAUST SYSTEM - DESCRIPTION . . . . . . . 11-1
EXHAUST SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
EXTENSION HOUSING BUSHING -
NV3550 - INSTALLATION. . . . . . . . . . . . . . . 21-74
EXTENSION HOUSING BUSHING -
NV3550 - REMOVAL . . . . . . . . . . . . . . . . . . 21-73
EXTENSION HOUSING SEAL - NV1500 -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 21-32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 21-32
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 21-74
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 21-74
EXTERIOR - DESCRIPTION, LAMPS/
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-2
EXTERIOR - DIAGNOSIS AND TESTING,
LAMPS/LIGHTING . . . . . . . . . . . . . . . . . . . . . 8L-7
EXTERIOR - OPERATION, LAMPS/
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-5
EXTERIOR - SPECIFICATIONS,
LAMPS/LIGHTING . . . . . . . . . . . . . . . . . . . . 8L-15
EXTERIOR HANDLE - INSTALLATION . . . . 23-123,
23-130,23-136
EXTERIOR HANDLE - REMOVAL . 23-123,23-130,
23-136
EXTERIOR NAME PLATES -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-141
EXTERIOR NAME PLATES - REMOVAL . . . 23-140
FAN - ELECTRIC - DESCRIPTION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
FAN - ELECTRIC - INSTALLATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
FAN - ELECTRIC - OPERATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
FAN - ELECTRIC - REMOVAL, RADIATOR . . . 7-26
FAN - VISCOUS - CLEANING, RADIATOR . . . 7-29
FAN - VISCOUS - DESCRIPTION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
FAN - VISCOUS - INSPECTION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
FAN - VISCOUS - INSTALLATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
FAN - VISCOUS - OPERATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
FAN - VISCOUS - REMOVAL, RADIATOR . . . . 7-28
FAN DRIVE - DIAGNOSIS AND TESTING,
VISCOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
FASCIA - INSTALLATION, FRONT . . . . . . . . . 13-2
FASCIA - INSTALLATION, REAR . . . . . . . . . . 13-2
FASCIA - REMOVAL, FRONT . . . . . . . . . . . . . 13-1
FASCIA - REMOVAL, REAR . . . . . . . . . . . . . . 13-2
FASCIA SUPPORT - INSTALLATION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
FASCIA SUPPORT - REMOVAL, REAR . . . . . . 13-3
FASTENER IDENTIFICATION -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . Intro.-1
FENDER - INSTALLATION, FRONT . . . . . . . 23-141
FENDER - REMOVAL, FRONT . . . . . . . . . . 23-141
FILL - STANDARD PROCEDURE, FLUID
DRAIN . . . . . . . . . . . . . . . . . . . . . . 21-208,21-246
FILL - STANDARD PROCEDURE,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-128
FILL DOOR/HOUSING - INSTALLATION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-141
FILL DOOR/HOUSING - REMOVAL, FUEL . 23-141
FILL/CHECK LOCATIONS - DESCRIPTION,
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
FILLER CAP - DESCRIPTION, FUEL . . . . . . . 25-27
FILLER CAP - OPERATION, FUEL . . . . . . . . 25-27
FILTER - DESCRIPTION, FUEL . . . . . . . . . . . . 14-7
FILTER - INSTALLATION, FUEL . . . . . . . . . . . 14-8
FILTER - INSTALLATION, INLET . . . . . . . . . . 14-28
FILTER - INSTALLATION, OIL . . . . . . . . . . . . 9-63
FILTER - REMOVAL, FUEL . . . . . . . . . . . . . . . 14-7
FILTER - REMOVAL, INLET . . . . . . . . . . . . . 14-28
FILTER - REMOVAL, OIL . . . . . . . . . . . . . . . . 9-63
FILTER REPLACEMENT - STANDARD
PROCEDURE, FLUID . . . . . . . . . . . . . . . . . 21-126
FINESSE SANDING/BUFFING &
POLISHING - DESCRIPTION . . . . . . . . . . . 23-163
FINISH - DESCRIPTION, BASE
COAT/CLEAR COAT . . . . . . . . . . . . . . . . . . 23-162
FIRING ORDER, 2.4L 4-CYLINDER -
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-2
FIRING ORDER, 3.7L V-6 - ENGINE . . . . . . . . 8I-2
FITTING - CONNECTING ROD BEARING . . . . 9-49
FITTING - DESCRIPTION, QUICK
CONNECT. . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
FITTING - MAIN BEARING . . . . . . . . . . . . . . . 9-45
FITTING - STANDARD PROCEDURE,
CONNECTING ROD BEARING . . . . . . . . . . . . 9-40
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
PISTON RING . . . . . . . . . . . . . . . . . . . . . . . . 9-52
FITTINGS - STANDARD PROCEDURE,
QUICK-CONNECT . . . . . . . . . . . . . . . . . . . . . 14-10
FLARE MOLDINGS - INSTALLATION,
FRONT WHEEL OPENING . . . . . . . . . . . . . 23-145
FLARE MOLDINGS - INSTALLATION,
REAR WHEEL OPENING . . . . . . . . . . . . . . 23-145
FLARE MOLDINGS - REMOVAL, FRONT
WHEEL OPENING . . . . . . . . . . . . . . . . . . . 23-145
FLARE MOLDINGS - REMOVAL, REAR
WHEEL OPENING . . . . . . . . . . . . . . . . . . . 23-145
FLARING - STANDARD PROCEDURE,
DOUBLE INVERTED . . . . . . . . . . . . . . . . . . . . . 5-8
FLARING - STANDARD PROCEDURE, ISO . . . . 5-8
FLASHER - DESCRIPTION, COMBINATION . 8L-19
FLASHER - OPERATION, COMBINATION . . . 8L-19
FLEX PLATE - INSTALLATION . . . . . . . . . . . . 9-49
FLEX PLATE - REMOVAL . . . . . . . . . . . . . . . . 9-49
FLIP-UP GLASS - INSTALLATION . . . . . . . 23-136
FLIP-UP GLASS - REMOVAL . . . . . . . . . . . 23-136
FLIP-UP GLASS AJ AR SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-77
FLIP-UP GLASS AJ AR SWITCH -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
FLIP-UP GLASS LATCH - INSTALLATION . 23-136
FLIP-UP GLASS LATCH - REMOVAL . . . . . 23-136
FLIP-UP GLASS RELEASE SWITCH -
FLIP-UP GLASS SUPPORT CYLINDER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-139
FLIP-UP GLASS SUPPORT CYLINDER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-139
FLOOR - DEFROST DOO - INSTALLATION . . 24-37
FLOOR - DEFROST DOOR - REMOVAL . . . . 24-36
FLOOR - DEFROST DOOR ACTUATOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-25
FLOOR - DEFROST DOOR ACTUATOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-24
FLOOR CONSOLE - INSTALLATION . . . . . . 23-158
FLOOR CONSOLE - REMOVAL . . . . . . . . . . 23-158
FLOOR CONSOLE DUCT - INSTALLATION . . 24-31
FLOOR CONSOLE DUCT - REMOVAL . . . . . 24-31
FLOOR CONSOLE LID LATCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-158
FLOOR CONSOLE LID LATCH - REMOVAL . 23-158
FLOOR DUCT - INSTALLATION . . . . . . . . . . 24-32
FLOOR DUCT - REMOVAL . . . . . . . . . . . . . . 24-32
FLOOR MATS - INSTALLATION, CARPETS . 23-158
FLOOR MATS - REMOVAL, CARPETS . . . . 23-158
FLOOR SHIFT BOOT - INSTALLATION,
4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
FLOOR SHIFT BOOT - REMOVAL, 4WD . . . 23-156
FLOW AND PRESSURE - DIAGNOSIS
AND TESTING, POWER STEERING . . . . . . . . 19-3
FLOW MANAGEMENT VALVE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 14-6
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 14-7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
FLOW MANAGEMENT VALVE - REMOVAL . . . 14-6
FLUID - DESCRIPTION, AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 0-2
FLUID - DIAGNOSIS AND TESTING,
CAUSES OF BURNT . . . . . . . . . . . . . . . . . . 21-125
FLUID - OPERATION, AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 0-4
FLUID AND FILTER REPLACEMENT -
STANDARD PROCEDURE. . . . . . . . . . . . . . 21-126
FLUID CAPACITIES - SPECIFICATIONS . . . . . . 0-4
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-125
FLUID CONTAMINATION - DIAGNOSIS
AND TESTING, BRAKE. . . . . . . . . . . . . . . . . . 5-26
FLUID COOLER - DESCRIPTION . . . . . . . . . 19-20
FLUID COOLER - INSTALLATION . . . . . . . . . 19-20
FLUID COOLER - OPERATION . . . . . . . . . . . 19-20
FLUID COOLER - REMOVAL . . . . . . . . . . . . 19-20
KJ INDEX 9
FLUID DRAIN AND FILL - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . 21-208,21-246
FLUID FILL/CHECK LOCATIONS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
FLUID INDICATOR - DESCRIPTION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -35
FLUID INDICATOR - DIAGNOSIS AND
TESTING, WASHER . . . . . . . . . . . . . . . . . . . 8J -36
FLUID INDICATOR - OPERATION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -36
FLUID LEAK - DIAGNOSIS AND TESTING,
CONVERTER HOUSING . . . . . . . . . . . . . . . . 21-80
FLUID LEVEL - DIAGNOSIS AND
TESTING, EFFECTS OF INCORRECT. . . . . . 21-125
FLUID LEVEL - STANDARD
PROCEDURES, MASTER CYLINDER . . . . . . . 5-26
FLUID LEVEL CHECK - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-126
FLUID LEVEL SWITCH - DESCRIPTION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
FLUID LEVEL SWITCH - INSTALLATION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-18
FLUID LEVEL SWITCH - OPERATION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
FLUID LEVEL SWITCH - REMOVAL,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
FLUID RESERVOIR - INSTALLATION . . . . . . . 5-26
FLUID RESERVOIR - REMOVAL . . . . . . . . . . 5-26
FLUID, SPECIFICATIONS - BRAKE . . . . . . . . . 5-27
FLUID TYPES - DESCRIPTION . . . . . . . . . . . . . 0-1
FLUSH - SPECIFICATIONS, GAP . . . . . . . . 23-116
FLUSHING - STANDARD PROCEDURE,
COOLING SYSTEM - REVERSE . . . . . . . . . . . 7-12
FLYWHEEL - DESCRIPTION . . . . . . . . . . . . . . . 6-7
FLYWHEEL - DIAGNOSIS AND TESTING . . . . . 6-8
FLYWHEEL - OPERATION . . . . . . . . . . . . . . . . 6-7
FOG LAMP BULB - INSTALLATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
FOG LAMP BULB - REMOVAL, FRONT . . . . 8L-21
FOG LAMP INDICATOR - DESCRIPTION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
FOG LAMP INDICATOR - DESCRIPTION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
FOG LAMP INDICATOR - OPERATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
FOG LAMP INDICATOR - OPERATION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
FOG LAMP RELAY - DESCRIPTION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
FOG LAMP RELAY - DESCRIPTION, REAR . 8L-56
FOG LAMP RELAY - DIAGNOSIS AND
TESTING, FRONT . . . . . . . . . . . . . . . . . . . . . 8L-23
FOG LAMP RELAY - DIAGNOSIS AND
TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . 8L-57
FOG LAMP RELAY - INSTALLATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-24
FOG LAMP RELAY - INSTALLATION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-58
FOG LAMP RELAY - OPERATION, FRONT . . 8L-22
FOG LAMP RELAY - OPERATION, REAR . . . 8L-57
FOG LAMP RELAY - REMOVAL, FRONT . . . 8L-24
FOG LAMP RELAY - REMOVAL, REAR . . . . 8L-58
FOG LAMP UNIT - ADJ USTMENT, FRONT . . 8L-25
FOG LAMP UNIT - INSTALLATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-25
FOG LAMP UNIT - REMOVAL, FRONT . . . . . 8L-25
FOLDING REAR SEAT BACK LATCH /
LOCK - INSTALLATION . . . . . . . . . . . . . . . 23-170
FOLDING REAR SEAT BACK LATCH /
LOCK - REMOVAL . . . . . . . . . . . . . . . . . . . 23-170
FOUR LOW MODE INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -29
FOUR LOW MODE INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -30
FRAME - REAR - INSTALLATION, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-171
FRAME - REAR - REMOVAL, SEAT BACK . 23-171
FRAME DIMENSIONS - SPECIFICATIONS . . . 13-3
FRONT - DESCRIPTION . . . . . . . . . . . . . . . . . . 2-7
FRONT - INSTALLATION, CRANKSHAFT
OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
FRONT - INSTALLATION, PROPELLER
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
FRONT - INSTALLATION, SEAT . . . . . . . . . 23-165
FRONT - INSTALLATION, SEAT BACK . . . . 23-166
FRONT - INSTALLATION, SEAT BACK
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
RECLINER . . . . . . . . . . . . . . . . . . . . . . . . . 23-166
FRONT - INSTALLATION, SEAT CUSHION . 23-167
FRONT - INSTALLATION, SEAT CUSHION
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
FRONT - REMOVAL, CRANKSHAFT OIL
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
FRONT - REMOVAL, PROPELLER SHAFT . . . . 3-6
FRONT - REMOVAL, SEAT . . . . . . . . . . . . . 23-165
FRONT - REMOVAL, SEAT BACK . . . . . . . . 23-166
FRONT - REMOVAL, SEAT BACK COVER . . 23-166
FRONT - REMOVAL, SEAT BACK
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
FRONT - REMOVAL, SEAT BACK
RECLINER . . . . . . . . . . . . . . . . . . . . . . . . . 23-166
FRONT - REMOVAL, SEAT CUSHION . . . . . 23-167
FRONT - REMOVAL, SEAT CUSHION
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
FRONT - WARNING . . . . . . . . . . . . . . . . . . . . . 2-7
FRONT AXLE - 186FIA - ADJ USTMENTS . . . . 3-25
FRONT AXLE - 186FIA - DESCRIPTION . . . . . 3-19
FRONT AXLE - 186FIA - INSTALLATION . . . . 3-24
FRONT AXLE - 186FIA - OPERATION . . . . . . 3-19
FRONT AXLE - 186FIA - REMOVAL . . . . . . . . 3-24
FRONT AXLE - SPECIFICATIONS . . . . . . . . . . 3-33
FRONT AXLE, SPECIAL TOOLS . . . . . . . . . . . 3-34
FRONT BRAKE HOSE - INSTALLATION. . . . . . . 5-10
FRONT BRAKE PADS - INSTALLATION . . . . . 5-11
FRONT BRAKE PADS - REMOVAL . . . . . . . . . 5-11
FRONT CHECK VALVE - DESCRIPTION . . . . . 8R-8
FRONT CHECK VALVE - INSTALLATION . . . . 8R-9
FRONT CHECK VALVE - OPERATION . . . . . . . 8R-9
FRONT CHECK VALVE - REMOVAL . . . . . . . . 8R-9
FRONT DOOR OUTER BELT MOLDING -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-186
FRONT DOOR OUTER BELT MOLDING -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
FRONT FASCIA - INSTALLATION . . . . . . . . . . 13-2
FRONT FASCIA - REMOVAL . . . . . . . . . . . . . . 13-1
FRONT FENDER - INSTALLATION . . . . . . . 23-141
FRONT FENDER - REMOVAL . . . . . . . . . . . 23-141
FRONT FOG LAMP BULB -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-22
FRONT FOG LAMP BULB - REMOVAL . . . . . 8L-21
FRONT FOG LAMP INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -19
FRONT FOG LAMP INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
FRONT FOG LAMP RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-22
FRONT FOG LAMP RELAY - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-23
FRONT FOG LAMP RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-24
FRONT FOG LAMP RELAY - OPERATION . . 8L-22
FRONT FOG LAMP RELAY - REMOVAL . . . . 8L-24
FRONT FOG LAMP UNIT - ADJ USTMENT . . 8L-25
FRONT FOG LAMP UNIT - INSTALLATION . . 8L-25
FRONT FOG LAMP UNIT - REMOVAL . . . . . 8L-25
FRONT HOSE - REMOVAL . . . . . . . . . . . . . . . . 5-9
FRONT IMPACT SENSOR - DESCRIPTION . 8O-21
FRONT IMPACT SENSOR -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-22
FRONT IMPACT SENSOR - OPERATION . . . 8O-21
FRONT IMPACT SENSOR - REMOVAL . . . . 8O-22
FRONT LAMP BULB - INSTALLATION . . . . . 8L-27
FRONT LAMP BULB - REMOVAL . . . . . . . . . 8L-26
FRONT LAMP UNIT - INSTALLATION . . . . . 8L-28
FRONT LAMP UNIT - REMOVAL . . . . . . . . . 8L-27
FRONT MOUNT - INSTALLATION . . . . . . . . . . 9-57
FRONT MOUNT - REMOVAL . . . . . . . . . . . . . 9-56
FRONT OUTPUT SHAFT SEAL -
INSTALLATION. . . . . . . . . . . . . . . . 21-208,21-246
FRONT OUTPUT SHAFT SEAL -
REMOVAL . . . . . . . . . . . . . . . . . . . 21-208,21-246
FRONT POSITION LAMP BULB -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-28
FRONT POSITION LAMP BULB -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
FRONT SEAL - INSTALLATION, OIL
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
FRONT SEAL - REMOVAL, OIL PUMP . . . . 21-152
FRONT SEAT BELT & RETRACTOR -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-24
FRONT SEAT BELT & RETRACTOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
FRONT SEAT BELT BUCKLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-26
FRONT SEAT BELT BUCKLE - REMOVAL . . 8O-25
FRONT SKID PLATE - INSTALLATION . . . . . . 13-6
FRONT SKID PLATE - REMOVAL . . . . . . . . . . 13-6
FRONT SUSPENSION, SPECIAL TOOLS . . . . . 2-8
FRONT TOW HOOK - INSTALLATION . . . . . . 13-8
FRONT TOW HOOK - REMOVAL . . . . . . . . . . 13-8
FRONT WASHER HOSES/TUBES -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-10
FRONT WASHER HOSES/TUBES -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8R-10
FRONT WASHER NOZZLE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-11
FRONT WASHER NOZZLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8R-11
FRONT WASHER NOZZLE - OPERATION . . . 8R-11
FRONT WASHER NOZZLE - REMOVAL . . . . 8R-11
FRONT WHEEL OPENING FLARE
MOLDINGS - INSTALLATION . . . . . . . . . . . 23-145
FRONT WHEEL OPENING FLARE
MOLDINGS - REMOVAL . . . . . . . . . . . . . . 23-145
FRONT WHEEL SPEED SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5-34
FRONT WHEEL SPEED SENSOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
FRONT WHEELHOUSE SPLASH SHIELD -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-143
FRONT WHEELHOUSE SPLASH SHIELD -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-143
FRONT WIPER & WASHER SYSTEM -
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-7
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8R-6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 8R-7
FRONT WIPER ARM - DESCRIPTION . . . . . 8R-12
FRONT WIPER ARM - INSTALLATION . . . . . 8R-13
FRONT WIPER ARM - OPERATION . . . . . . . 8R-12
FRONT WIPER ARM - REMOVAL . . . . . . . . 8R-12
FRONT WIPER BLADE - DESCRIPTION . . . . 8R-13
FRONT WIPER BLADE - INSTALLATION . . . 8R-14
FRONT WIPER BLADE - OPERATION . . . . . 8R-14
FRONT WIPER BLADE - REMOVAL . . . . . . . 8R-14
FRONT WIPER MODULE - DESCRIPTION . . 8R-15
FRONT WIPER MODULE - INSTALLATION . 8R-16
FRONT WIPER MODULE - OPERATION . . . . 8R-15
FRONT WIPER MODULE - REMOVAL . . . . . 8R-16
FRONT WIPERS/WASHERS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8R-2
FRONT WIPERS/WASHERS - OPERATION . . 8R-4
FRONT WIPER/WASHER SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-16
FRONT WIPER/WASHER SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8R-16
FUEL DELIVERY - DESCRIPTION . . . . . . . . . . 14-2
FUEL DELIVERY - OPERATION . . . . . . . . . . . 14-3
FUEL FILL DOOR/HOUSING -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-141
FUEL FILL DOOR/HOUSING - REMOVAL . . 23-141
FUEL FILLER CAP - DESCRIPTION . . . . . . . 25-27
FUEL FILLER CAP - OPERATION . . . . . . . . . 25-27
FUEL FILTER - DESCRIPTION . . . . . . . . . . . . 14-7
FUEL FILTER - INSTALLATION . . . . . . . . . . . . 14-8
FUEL FILTER - REMOVAL . . . . . . . . . . . . . . . 14-7
FUEL GAUGE - DESCRIPTION . . . . . . . . . . . 8J -19
FUEL GAUGE - OPERATION . . . . . . . . . . . . . 8J -20
FUEL INDICATOR - DESCRIPTION, LOW . . . 8J -22
FUEL INDICATOR - OPERATION, LOW . . . . . 8J -22
FUEL INJ ECTION - DESCRIPTION . . . . . . . . 14-29
FUEL INJ ECTOR - DESCRIPTION . . . . . . . . . 14-33
FUEL INJ ECTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-33
FUEL INJ ECTOR - OPERATION . . . . . . . . . . 14-33
FUEL LEVEL SENDING UNIT -
FUEL LEVEL SENDING UNIT / SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 14-9
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
FUEL LINES - DESCRIPTION . . . . . . . . . . . . 14-10
FUEL PRESSURE LEAK DOWN TEST -
10 INDEX KJ
FUEL PRESSURE REGULATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-13
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
FUEL PUMP - DESCRIPTION . . . . . . . . . . . . 14-15
FUEL PUMP - OPERATION . . . . . . . . . . . . . 14-15
FUEL PUMP AMPERAGE TEST -
FUEL PUMP CAPACITY TEST -
FUEL PUMP MODULE - DESCRIPTION . . . . 14-18
FUEL PUMP MODULE - INSTALLATION . . . 14-19
FUEL PUMP MODULE - OPERATION . . . . . . 14-18
FUEL PUMP MODULE - REMOVAL . . . . . . . 14-18
FUEL PUMP PRESSURE TEST -
FUEL PUMP RELAY - DESCRIPTION . . . . . . 14-34
FUEL PUMP RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-34
FUEL PUMP RELAY - INSTALLATION . . . . . 14-34
FUEL PUMP RELAY - OPERATION . . . . . . . . 14-34
FUEL PUMP RELAY - REMOVAL . . . . . . . . . 14-34
FUEL PUMP RELAYS - DIAGNOSIS AND
TESTING, ASD . . . . . . . . . . . . . . . . . . . . . . . . 8I-4
FUEL RAIL - DESCRIPTION . . . . . . . . . . . . . 14-21
FUEL RAIL - INSTALLATION. . . . . . . . . . . . . . 14-24
FUEL RAIL - OPERATION . . . . . . . . . . . . . . . 14-21
FUEL RAIL - REMOVAL . . . . . . . . . . . . . . . . 14-22
FUEL SYSTEM PRESSURE RELEASE -
FUEL SYSTEM PRESSURE,
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 14-5
FUEL SYSTEM, SPECIAL TOOLS . . . . . . . . . . 14-6
FUEL TANK - DESCRIPTION . . . . . . . . . . . . 14-24
FUEL TANK - INSTALLATION . . . . . . . . . . . . 14-27
FUEL TANK - OPERATION . . . . . . . . . . . . . . 14-24
FUEL TANK - REMOVAL . . . . . . . . . . . . . . . 14-25
FUEL TANK CHECK VALVE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-28
FUEL TANK CHECK VALVE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-28
FUEL TANK CHECK VALVE - OPERATION . . 14-28
FUEL TANK CHECK VALVE - REMOVAL . . . . 14-28
FUEL TANK SKID PLATE - INSTALLATION . . . 13-9
FUEL TANK SKID PLATE - REMOVAL . . . . . . 13-9
FULL TIME INDICATOR - DESCRIPTION . . . 8J -29
FULL TIME INDICATOR - OPERATION . . . . . 8J -30
FUNCTION - DIAGNOSIS AND TESTING,
REAR HVAC CONTROL ASSEMBLY
WINDOW DEFOGGER . . . . . . . . . . . . . . . . . . 8G-9
FUNCTIONS - DESCRIPTION, CIRCUIT . . 8W-01-6
FUSE - DESCRIPTION, IOD . . . . . . . . . . . 8W-97-3
FUSE - INSTALLATION, IOD . . . . . . . . . . 8W-97-3
FUSE - OPERATION, IOD . . . . . . . . . . . . . 8W-97-3
FUSE - REMOVAL, IOD . . . . . . . . . . . . . . 8W-97-3
FUSES POWERING SEVERAL LOADS -
STANDARD PROCEDURE, TESTING
FOR A SHORT TO GROUND ON . . . . . . . 8W-01-9
GALLERY PLUGS - STANDARD
PROCEDURE, ENGINE CORE AND OIL . . . . . 9-10
GAP AND FLUSH - SPECIFICATIONS . . . . . 23-116
GAS ENGINES - GENERATOR RATINGS . . . . 8F-23
GAS POWERED - STARTER MOTOR . . . . . . 8F-39
GAS POWERED - TORQUE . . . . . . . . . . . . . 8F-38
GASKET - DIAGNOSIS AND TESTING,
CYLINDER HEAD. . . . . . . . . . . . . . . . . . 9-19,9-30
GASKET SURFACE PREPARATION -
STANDARD PROCEDURE, ENGINE . . . . . . . . . 9-9
GATE - INSTALLATION, SWING . . . . . . . . . 23-138
GATE - REMOVAL, SWING . . . . . . . . . . . . 23-138
GATE AJ AR INDICATOR - DESCRIPTION . . . 8J -20
GATE AJ AR INDICATOR - OPERATION . . . . . 8J -20
GATE BELTLINE WEATHERSTRIP -
INSTALLATION, SWING . . . . . . . . . . . . . . . 23-186
GATE BELTLINE WEATHERSTRIP -
REMOVAL, SWING. . . . . . . . . . . . . . . . . . . 23-186
GATE OPENING WEATHERSTRIP -
INSTALLATION, SWING . . . . . . . . . . . . . . . 23-186
GATE OPENING WEATHERSTRIP -
REMOVAL, SWING. . . . . . . . . . . . . . . . . . . 23-186
GAUGE - DESCRIPTION, ENGINE
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8J -18
GAUGE - DESCRIPTION, FUEL . . . . . . . . . . . 8J -19
GAUGE - OPERATION, ENGINE
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8J -18
GAUGE - OPERATION, FUEL . . . . . . . . . . . . 8J -20
GEAR - DESCRIPTION . . . . . . . . . . . . . . . . . 19-13
GEAR - INSTALLATION, PINION
GEAR/RING . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
GEAR - OPERATION . . . . . . . . . . . . . . . . . . . 19-13
GEAR - REMOVAL, PINION GEAR/RING . . . . 3-44
GEAR/RING GEAR - INSTALLATION,
PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
GEAR/RING GEAR - REMOVAL, PINION . . . . 3-44
GEAR/RING GEAR/TONE RING -
INSTALLATION, PINION. . . . . . . . . . . . 3-112,3-82
GEAR/RING GEAR/TONE RING -
REMOVAL, PINION . . . . . . . . . . . . . . . 3-110,3-79
GEARSHIFT CABLE - ADJ USTMENTS . . . . 21-130
GEARSHIFT CABLE - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-128
GEARSHIFT CABLE - INSTALLATION . . . . . 21-129
GEARSHIFT CABLE - REMOVAL . . . . . . . . 21-128
GEAR/TONE RING - INSTALLATION,
PINION GEAR/RING. . . . . . . . . . . . . . . 3-112,3-82
GEAR/TONE RING - REMOVAL, PINION
GEAR/RING . . . . . . . . . . . . . . . . . . . . . 3-110,3-79
GEARTRAIN - ASSEMBLY, PLANETARY . . . 21-160
GEARTRAIN - CLEANING, PLANETARY . . . 21-159
GEARTRAIN - DESCRIPTION,
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . 21-157
GEARTRAIN - DISASSEMBLY,
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . 21-159
GEARTRAIN - INSPECTION, PLANETARY . 21-159
GEARTRAIN - OPERATION, PLANETARY . . 21-157
GENERAL - WARNINGS . . . . . . . . . . . . . 8W-01-7
GENERATOR - DESCRIPTION . . . . . . . . . . . 8F-25
GENERATOR - INSTALLATION . . . . . . . . . . . 8F-26
GENERATOR - OPERATION . . . . . . . . . . . . . 8F-25
GENERATOR - REMOVAL . . . . . . . . . . . . . . . 8F-25
GENERATOR DECOUPLER - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8F-27
GENERATOR DECOUPLER PULLEY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8F-26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8F-30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
GENERATOR RATINGS, GAS ENGINES . . . . 8F-23
GLASS - INSTALLATION, DOOR . . 23-122,23-129,
23-172
GLASS - INSTALLATION, FLIP-UP . . . . . . . 23-136
GLASS - REMOVAL, DOOR . . . . . . 23-122,23-129,
23-172
GLASS - REMOVAL, FLIP-UP . . . . . . . . . . 23-136
GLASS AJ AR INDICATOR - DESCRIPTION . . 8J -21
GLASS AJ AR INDICATOR - OPERATION . . . 8J -21
GLASS AJ AR SWITCH - DESCRIPTION,
FLIP-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
GLASS AJ AR SWITCH - OPERATION,
FLIP-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
GLASS HEATING GRID REPAIR -
STANDARD PROCEDURE, REAR . . . . . . . . . . 8G-4
GLASS LATCH - INSTALLATION, FLIP-UP . 23-136
GLASS LATCH - REMOVAL, FLIP-UP . . . . . 23-136
GLASS PANEL - INSTALLATION . . . . . . . . 23-178
GLASS PANEL - REMOVAL . . . . . . . . . . . . 23-178
GLASS PANEL ADJ USTMENT,
ADJ USTMENTS - SUNROOF . . . . . . . . . . . 23-178
GLASS PANEL SEAL - INSTALLATION . . . . 23-178
GLASS PANEL SEAL - REMOVAL . . . . . . . 23-178
GLASS RELEASE SWITCH - DIAGNOSIS
AND TESTING, FLIP-UP . . . . . . . . . . . . . . . . 8N-5
GLASS RUN CHANNEL - INSTALLATION . 23-123,
23-130
GLASS RUN CHANNEL - REMOVAL . . . . . 23-123,
23-130
GLASS SUPPORT CYLINDER -
INSTALLATION, FLIP-UP . . . . . . . . . . . . . . 23-139
GLASS SUPPORT CYLINDER -
REMOVAL, FLIP-UP . . . . . . . . . . . . . . . . . . 23-139
GLOVE BOX - INSTALLATION . . . . . . . . . . 23-148
GLOVE BOX - REMOVAL . . . . . . . . . . . . . . 23-148
GLOVE BOX LATCH - INSTALLATION . . . . 23-148
GLOVE BOX LATCH - REMOVAL . . . . . . . . 23-148
GLOVE BOX LATCH STRIKER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-149
GLOVE BOX LATCH STRIKER - REMOVAL . 23-148
GRAB HANDLE - INSTALLATION,
A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . 23-156
GRAB HANDLE - REMOVAL, A-PILLAR
TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
GRID - DESCRIPTION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
GRID - DIAGNOSIS AND TESTING, REAR
GRID - OPERATION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
GRID REPAIR - STANDARD PROCEDURE,
REAR GLASS HEATING. . . . . . . . . . . . . . . . . 8G-4
GRILLE - INSTALLATION . . . . . . . . . . . . . . 23-142
GRILLE - INSTALLATION, COWL . . . . . . . . 23-140
GRILLE - REMOVAL . . . . . . . . . . . . . . . . . . 23-142
GRILLE - REMOVAL, COWL . . . . . . . . . . . 23-140
GRILLE OPENING REINFORCEMENT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-142
GRILLE OPENING REINFORCEMENT -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-142
GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT TO . . . . . . . . . . 8W-01-9
GROUND AND SPLICE INFORMATION -
DESCRIPTION, CONNECTOR . . . . . . . . . . 8W-01-7
GROUND ON FUSES POWERING
SEVERAL LOADS - STANDARD
PROCEDURE, TESTING FOR A SHORT
TO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-9
GROUND STRAP - DESCRIPTION, RADIO
NOISE SUPPRESSION. . . . . . . . . . . . . . . . . . 8A-9
GROUND STRAP - INSTALLATION,
RADIO NOISE SUPPRESSION . . . . . . . . . . . 8A-11
GROUND STRAP - OPERATION, RADIO
NOISE SUPPRESSION . . . . . . . . . . . . . . . . . 8A-10
GROUND STRAP - REMOVAL, RADIO
NOISE SUPPRESSION . . . . . . . . . . . . . . . . . 8A-10
GROUNDS - DESCRIPTION, POWER . . . . . . 8E-13
GUARD - DESCRIPTION, THERMAL . . . . . . 8F-20
GUARD - INSTALLATION, THERMAL . . . . . . 8F-20
GUARD - OPERATION, THERMAL . . . . . . . . 8F-20
GUARD - REMOVAL, THERMAL . . . . . . . . . . 8F-20
GUIDE ASSEMBLY - INSTALLATION . . . . . 23-179
GUIDE ASSEMBLY - REMOVAL . . . . . . . . . 23-179
GUIDE SEALS - DESCRIPTION, VALVE . 9-29,9-38
GUIDES - DESCRIPTION, VALVE . . . . . . 9-19,9-30
HALF SHAFT - CAUTION . . . . . . . . . . . . . . . . 3-10
HALF SHAFT - DIAGNOSIS AND TESTING . . 3-10
HALF SHAFT - INSTALLATION . . . . . . . . . . . . 3-11
HALF SHAFT - REMOVAL . . . . . . . . . . . . . . . 3-10
HALF SHAFT, SPECIFICATIONS . . . . . . . . . . . 3-11
HANDLE - INSTALLATION, A-PILLAR
TRIM AND GRAB. . . . . . . . . . . . . . . . . . . . 23-156
HANDLE - INSTALLATION, ASSIST . . . . . . 23-157
HANDLE - INSTALLATION, EXTERIOR . . . 23-123,
23-130,23-136
HANDLE - INSTALLATION, LATCH
RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . 23-120
HANDLE - REMOVAL, A-PILLAR TRIM
AND GRAB. . . . . . . . . . . . . . . . . . . . . . . . . 23-156
HANDLE - REMOVAL, ASSIST . . . . . . . . . . 23-157
HANDLE - REMOVAL, EXTERIOR . 23-123,23-130,
23-136
HANDLE - REMOVAL, LATCH RELEASE . . 23-120
HANDLING NON-DEPLOYED
SUPPLEMENTAL RESTRAINTS -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8O-6
HARNESS - DIAGNOSIS AND TESTING,
WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-7
HAZARD SWITCH - DESCRIPTION . . . . . . . 8L-29
HAZARD SWITCH - INSTALLATION . . . . . . . 8L-30
HAZARD SWITCH - OPERATION . . . . . . . . . 8L-29
HAZARD SWITCH - REMOVAL . . . . . . . . . . 8L-30
HCU (HYDRAULIC CONTROL UNIT) -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 5-35
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5-36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
HEAD - DESCRIPTION, CYLINDER . . . . . . . . 9-30
HEAD COVER(S) - DESCRIPTION,
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
HEAD COVER(S) - INSTALLATION,
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 9-26,9-34
HEAD COVER(S) - REMOVAL, CYLINDER . . 9-25,
9-34
KJ INDEX 11
HEAD GASKET - DIAGNOSIS AND
TESTING, CYLINDER . . . . . . . . . . . . . . . 9-19,9-30
HEADLAMP BULB - INSTALLATION . . . . . . . 8L-32
HEADLAMP BULB - REMOVAL . . . . . . . . . . 8L-31
HEADLAMP HIGH BEAM RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-33
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8L-34
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-34
HEADLAMP LEVELING MOTOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-35
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
HEADLAMP LEVELING SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-37
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
HEADLAMP LOW BEAM RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-39
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-40
HEADLAMP UNIT - ADJ USTMENT . . . . . . . . 8L-42
HEADLAMP UNIT - INSTALLATION . . . . . . . 8L-42
HEADLAMP UNIT - REMOVAL . . . . . . . . . . . 8L-41
HEADLINER - INSTALLATION . . . . . . . . . . 23-159
HEADLINER - REMOVAL . . . . . . . . . . . . . . 23-159
HEADREST - INSTALLATION . . . . . . . . . . . 23-164
HEADREST - REMOVAL . . . . . . . . . . . . . . . 23-164
HEADREST SLEEVE - INSTALLATION . . . . 23-164
HEADREST SLEEVE - REMOVAL . . . . . . . . 23-164
HEAT SHIELDS - DESCRIPTION . . . . . . . . . . 11-4
HEAT STAKING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
HEATED MIRRORS - DESCRIPTION . . . . . . . 8G-1
HEATED MIRRORS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-1
HEATED MIRRORS - OPERATION . . . . . . . . . 8G-1
HEATED SEAT ELEMENT - DESCRIPTION . . 8G-13
HEATED SEAT ELEMENT - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8G-13
HEATED SEAT ELEMENT - OPERATION . . . . 8G-13
HEATED SEAT MODULE - DESCRIPTION . . . 8E-21
HEATED SEAT MODULE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8E-22
HEATED SEAT MODULE - INSTALLATION . . 8E-24
HEATED SEAT MODULE - OPERATION . . . . 8E-21
HEATED SEAT MODULE - REMOVAL . . . . . . 8E-24
HEATED SEAT SENSOR - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8G-14
HEATED SEAT SWITCH - DIAGNOSIS
AND TESTING. . . . . . . . . . . . . . . . . . 8G-12,8G-14
HEATED SEAT SYSTEM - DESCRIPTION . . . 8G-10
HEATED SEAT SYSTEM - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8G-11
HEATED SEAT SYSTEM - OPERATION . . . . 8G-10
HEATER AND AIR CONDITIONER -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 24-1
HEATER AND AIR CONDITIONER -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
HEATER CONTROL - DESCRIPTION, A/C . . . 24-16
HEATER CONTROL - INSTALLATION, A/C . . 24-17
HEATER CONTROL - REMOVAL, A/C . . . . . . 24-17
HEATER CORE - DESCRIPTION . . . . . . . . . . 24-52
HEATER CORE - INSTALLATION . . . . . . . . . 24-53
HEATER CORE - OPERATION . . . . . . . . . . . . 24-52
HEATER CORE - REMOVAL . . . . . . . . . . . . . 24-52
HEATER PERFORMANCE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 24-6
HEATER SWITCH - DESCRIPTION,
DRIVER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8G-11
HEATER SWITCH - DESCRIPTION,
PASSENGER SEAT. . . . . . . . . . . . . . . . . . . . 8G-14
HEATER SWITCH - INSTALLATION,
DRIVER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8G-13
HEATER SWITCH - INSTALLATION,
PASSENGER SEAT. . . . . . . . . . . . . . . . . . . . 8G-15
HEATER SWITCH - OPERATION, DRIVER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-12
HEATER SWITCH - OPERATION,
PASSENGER SEAT. . . . . . . . . . . . . . . . . . . . 8G-14
HEATER SWITCH - REMOVAL, DRIVER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
HEATER SWITCH - REMOVAL,
PASSENGER SEAT. . . . . . . . . . . . . . . . . . . . 8G-15
HEATER-A/C CONTROL ILLUMINATION
HEATER-A/C CONTROL ILLUMINATION
BULB - REMOVAL . . . . . . . . . . . . . . . . . . . . 8L-78
HEATING GRID REPAIR - STANDARD
PROCEDURE, REAR GLASS . . . . . . . . . . . . . 8G-4
HEIGHT MEASUREMENT - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
HIGH AND LOW LIMITS - DESCRIPTION . . 25-20
HIGH BEAM INDICATOR - DESCRIPTION . . 8J -22
HIGH BEAM INDICATOR - OPERATION . . . . 8J -22
HIGH BEAM RELAY - DESCRIPTION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
HIGH BEAM RELAY - DIAGNOSIS AND
TESTING, HEADLAMP . . . . . . . . . . . . . . . . . . . 8L-34
HIGH BEAM RELAY - INSTALLATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-35
HIGH BEAM RELAY - OPERATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
HIGH BEAM RELAY - REMOVAL,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-34
HIGH MOUNTED STOP LAMP BULB -
INSTALLATION, CENTER . . . . . . . . . . . . . . . 8L-19
HIGH MOUNTED STOP LAMP BULB -
REMOVAL, CENTER . . . . . . . . . . . . . . . . . . . 8L-18
HIGH MOUNTED STOP LAMP UNIT -
INSTALLATION, CENTER . . . . . . . . . . . . . . . 8L-19
HIGH MOUNTED STOP LAMP UNIT -
REMOVAL, CENTER . . . . . . . . . . . . . . . . . . . 8L-19
HIGH PRESSURE RELIEF VALVE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 24-42
HIGH PRESSURE RELIEF VALVE -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
HIGH PRESSURE SWITCH -
DESCRIPTION, A/C . . . . . . . . . . . . . . . . . . . 24-17
HIGH PRESSURE SWITCH - DIAGNOSIS
AND TESTING, A/C . . . . . . . . . . . . . . . . . . . 24-18
HIGH PRESSURE SWITCH -
INSTALLATION, A/C . . . . . . . . . . . . . . . . . . . 24-18
HIGH PRESSURE SWITCH - OPERATION,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
HIGH PRESSURE SWITCH - REMOVAL,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
HIGH/LOW RELAY - DESCRIPTION,
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-23
HIGH/LOW RELAY - DIAGNOSIS AND
TESTING, WIPER. . . . . . . . . . . . . . . . . . . . . 8R-24
HIGH/LOW RELAY - INSTALLATION,
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-24
HIGH/LOW RELAY - OPERATION, WIPER . . 8R-23
HIGH/LOW RELAY - REMOVAL, WIPER . . . 8R-24
HINGE - INSTALLATION . . 23-119,23-123,23-131,
23-137
HINGE - REMOVAL . . . . . . 23-119,23-123,23-131,
23-137
HITCH - INSTALLATION, TRAILER . . . . . . . . . 13-9
HITCH - REMOVAL, TRAILER . . . . . . . . . . . . 13-9
HOISTING RECOMMENDATIONS -
HOLDDOWN - DESCRIPTION, BATTERY . . . 8F-17
HOLDDOWN - INSTALLATION, BATTERY . . . 8F-17
HOLDDOWN - OPERATION, BATTERY . . . . . 8F-17
HOLDDOWN - REMOVAL, BATTERY . . . . . . 8F-17
HOLDING CLUTCHES - DESCRIPTION . . . . 21-131
HOLDING CLUTCHES - OPERATION . . . . . 21-132
HOLE REPAIR - DESCRIPTION,
THREADED . . . . . . . . . . . . . . . . . . . . . . . . Intro.-4
HONING - STANDARD PROCEDURE,
CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . 9-39
HOOD - INSTALLATION . . . . . . . . . . . . . . . 23-119
HOOD - REMOVAL . . . . . . . . . . . . . . . . . . . 23-119
HOOD AJ AR SWITCH - DESCRIPTION . . . . 8Q-11
HOOD AJ AR SWITCH - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-12
HOOD AJ AR SWITCH - INSTALLATION . . . . 8Q-12
HOOD AJ AR SWITCH - OPERATION . . . . . . 8Q-12
HOOD AJ AR SWITCH - REMOVAL . . . . . . . 8Q-12
HOOD AJ AR SWITCH BRACKET -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-13
HOOD AJ AR SWITCH BRACKET -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
HOOD AJ AR SWITCH STRIKER -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-14
HOOD AJ AR SWITCH STRIKER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
HOOK - INSTALLATION, FRONT TOW . . . . . . 13-8
HOOK - INSTALLATION, REAR TOW . . . . . . . 13-8
HOOK - REMOVAL, FRONT TOW . . . . . . . . . . 13-8
HOOK - REMOVAL, REAR TOW . . . . . . . . . . . 13-8
HORN - DIAGNOSIS AND TESTING . . . . . . . 8H-2
HORN - INSTALLATION . . . . . . . . . . . . . . . . . 8H-3
HORN - REMOVAL . . . . . . . . . . . . . . . . . . . . 8H-3
HORN RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3
HORN RELAY - INSTALLATION . . . . . . . . . . . 8H-3
HORN RELAY - REMOVAL . . . . . . . . . . . . . . 8H-3
HORN SWITCH - DESCRIPTION . . . . . . . . . . 8H-4
HORN SWITCH - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-4
HORN SYSTEM - DESCRIPTION . . . . . . . . . . 8H-1
HORN SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-1
HORN SYSTEM - OPERATION . . . . . . . . . . . . 8H-1
HOSE - INSTALLATION, FRONT BRAKE . . . . . 5-10
HOSE - INSTALLATION, PRESSURE . . . . . . 19-21
HOSE - INSTALLATION, REAR BRAKE . . . . . . 5-10
HOSE - REMOVAL, FRONT . . . . . . . . . . . . . . . 5-9
HOSE - REMOVAL, PRESSURE . . . . . . . . . . 19-21
HOSE - REMOVAL, REAR BRAKE . . . . . . . . . . 5-9
HOSE CLAMPS - DESCRIPTION . . . . . . . . . . . 7-2
HOSE CLAMPS - OPERATION . . . . . . . . . . . . . 7-3
HOSE (GEAR TO THE COOLER) -
INSTALLATION, RETURN . . . . . . . . . . . . . . . 19-22
HOSE (GEAR TO THE COOLER) -
REMOVAL, RETURN . . . . . . . . . . . . . . . . . . 19-21
HOSE (RESERVOIR TO THE COOLER) -
INSTALLATION, RETURN . . . . . . . . . . . . . . . 19-22
HOSE (RESERVOIR TO THE COOLER) -
REMOVAL, RETURN . . . . . . . . . . . . . . . . . . 19-21
HOSES - DIAGNOSIS AND TESTING,
BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
HOSES/LINES/TUBES PRECAUTIONS -
CAUTION, REFRIGERANT . . . . . . . . . . . . . . 24-40
HOSES/TUBES - DESCRIPTION, FRONT
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-10
HOSES/TUBES - DESCRIPTION, REAR
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-35
HOSES/TUBES - OPERATION, FRONT
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-10
HOSES/TUBES - OPERATION, REAR
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-36
HOUSING - ASSEMBLY, HVAC . . . . . . . . . . . 24-34
HOUSING - DISASSEMBLY, HVAC . . . . . . . . 24-34
HOUSING - INSTALLATION, HVAC . . . . . . . . 24-34
HOUSING - REMOVAL, HVAC . . . . . . . . . . . 24-33
HOUSING BUSHING - NV3550 -
INSTALLATION, EXTENSION . . . . . . . . . . . . 21-74
HOUSING BUSHING - NV3550 -
REMOVAL, EXTENSION . . . . . . . . . . . . . . . . 21-73
HOUSING FLUID LEAK - DIAGNOSIS AND
TESTING, CONVERTER . . . . . . . . . . . . . . . . 21-80
HOUSING SEAL - INSTALLATION,
ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . 21-124
HOUSING SEAL - NV1500 -
HOUSING SEAL - NV1500 - REMOVAL,
EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . 21-32
HOUSING SEAL - NV3550 -
HOUSING SEAL - NV3550 - REMOVAL,
EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . 21-74
HOUSING SEAL - REMOVAL, ADAPTER . . 21-124
HOW TO USE WIRING DIAGRAMS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 8W-01-1
HUB / BEARING - INSTALLATION . . . . . . . . . . 2-9
HUB / BEARING - REMOVAL . . . . . . . . . . . . . . 2-9
12 INDEX KJ
HVAC CONTROL ASSEMBLY WINDOW
DEFOGGER FUNCTION - DIAGNOSIS
AND TESTING, REAR . . . . . . . . . . . . . . . . . . 8G-9
HVAC HOUSING - ASSEMBLY . . . . . . . . . . . 24-34
HVAC HOUSING - DISASSEMBLY . . . . . . . . 24-34
HVAC HOUSING - INSTALLATION . . . . . . . . 24-34
HVAC HOUSING - REMOVAL . . . . . . . . . . . . 24-33
HYDRAULIC LASH ADJ USTER -
DIAGNOSIS AND TESTING . . . . . . . . . . 9-19,9-30
HYDRAULIC PRESSURE TEST -
HYDRAULIC SCHEMATICS, SCHEMATICS
AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . 21-100
HYDROMETER TEST - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8F-11
IDENTIFICATION - DESCRIPTION,
FASTENER . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-1
IDENTIFICATION AND INFORMATION -
DESCRIPTION, SECTION. . . . . . . . . . . . . 8W-01-6
IDENTIFICATION NUMBER -
DESCRIPTION, VEHICLE . . . . . . . . . . . . . . Intro.-8
IDLE AIR CONTROL MOTOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-35
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
IDLE AIR CONTROL MOTOR - REMOVAL . . 14-36
IDLER SHAFT - INSTALLATION . . . . . . . . . . . 9-77
IDLER SHAFT - REMOVAL . . . . . . . . . . . . . . . 9-77
IGNITION CIRCUIT SENSE -
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 8E-13
IGNITION CIRCUIT SENSE - OPERATION . . 8E-15
IGNITION COIL - DESCRIPTION . . . . . . . . . . . 8I-9
IGNITION COIL - INSTALLATION . . . . . . . . . 8I-10
IGNITION COIL - OPERATION . . . . . . . . . . . . . 8I-9
IGNITION COIL - REMOVAL . . . . . . . . . . . . . 8I-10
IGNITION COIL CAPACITOR -
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 8I-16
IGNITION COIL CAPACITOR -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8I-16
IGNITION COIL CAPACITOR - OPERATION . . 8I-16
IGNITION COIL CAPACITOR - REMOVAL . . . 8I-16
IGNITION COIL RESISTANCE, 2.4L . . . . . . . . . 8I-2
IGNITION COIL RESISTANCE, 3.7L V-6 . . . . . 8I-3
IGNITION CONTROL - DESCRIPTION . . . . . . . 8I-1
IGNITION CONTROL - OPERATION . . . . . . . . . 8I-1
IGNITION SWITCH - DESCRIPTION . . . . . . . . 19-8
IGNITION SWITCH - DESCRIPTION,
KEY-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-10
IGNITION SWITCH - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-8
IGNITION SWITCH - DIAGNOSIS AND
TESTING, KEY-IN . . . . . . . . . . . . . . . . . . . . . 19-10
IGNITION SWITCH INSTALLATION,
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 19-9
IGNITION SWITCH REMOVAL, REMOVAL . . . 19-9
IGNITION SYSTEM - TORQUE . . . . . . . . . . . . 8I-3
IGNITION TIMING - SPECIFICATIONS . . . . . . 8I-2
IGNITION-OFF DRAW TEST - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8F-14
ILLUMINATION BULB - INSTALLATION,
COMPASS MINI-TRIP . . . . . . . . . . . . . . . . . 8L-75
HEATER-A/C CONTROL . . . . . . . . . . . . . . . . 8L-78
TRANSMISSION RANGE INDICATOR . . . . . . 8L-83
ILLUMINATION BULB - REMOVAL,
COMPASS MINI-TRIP . . . . . . . . . . . . . . . . . 8L-74
HEATER-A/C CONTROL . . . . . . . . . . . . . . . . 8L-78
TRANSMISSION RANGE INDICATOR . . . . . . 8L-82
IMMOBILIZER MODULE - DESCRIPTION,
SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8E-15
IMMOBILIZER MODULE - INSTALLATION,
SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8E-18
IMMOBILIZER MODULE - OPERATION,
SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8E-16
IMMOBILIZER MODULE - REMOVAL,
SENTRY KEY . . . . . . . . . . . . . . . . . . . . . . . . 8E-17
IMPACT AIRBAG CONTROL MODULE -
DESCRIPTION, SIDE . . . . . . . . . . . . . . . . . . 8O-43
INSTALLATION, SIDE . . . . . . . . . . . . . . . . . 8O-45
OPERATION, SIDE . . . . . . . . . . . . . . . . . . . . 8O-43
REMOVAL, SIDE . . . . . . . . . . . . . . . . . . . . . 8O-44
IMPACT SENSOR - DESCRIPTION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-21
IMPACT SENSOR - INSTALLATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-22
IMPACT SENSOR - OPERATION, FRONT . . . 8O-21
IMPACT SENSOR - REMOVAL, FRONT . . . . 8O-22
INCORRECT FLUID LEVEL - DIAGNOSIS
AND TESTING, EFFECTS OF. . . . . . . . . . . . 21-125
INDICATOR - DESCRIPTION, ABS . . . . . . . . 8J -11
INDICATOR - DESCRIPTION, AIRBAG . . . . . 8J -12
INDICATOR - DESCRIPTION, BRAKE/
PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 8J -13
INDICATOR - DESCRIPTION, CHARGING . . . 8J -15
INDICATOR - DESCRIPTION, COOLANT
LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -15
INDICATOR - DESCRIPTION, CRUISE . . . . . 8J -16
INDICATOR - DESCRIPTION, DOOR AJ AR . . 8J -17
INDICATOR - DESCRIPTION, FOUR LOW
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -29
INDICATOR - DESCRIPTION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
INDICATOR - DESCRIPTION, FULL TIME . . . 8J -29
INDICATOR - DESCRIPTION, GATE AJ AR . . 8J -20
INDICATOR - DESCRIPTION, GLASS
AJ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -21
INDICATOR - DESCRIPTION, HIGH BEAM . . 8J -22
INDICATOR - DESCRIPTION, LOW FUEL . . . 8J -22
INDICATOR - DESCRIPTION, LOW OIL
PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . 8J -23
INDICATOR - DESCRIPTION, OVERDRIVE
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -26
INDICATOR - DESCRIPTION, PART TIME . . 8J -29
INDICATOR - DESCRIPTION, REAR FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
INDICATOR - DESCRIPTION, SEATBELT . . . 8J -27
INDICATOR - DESCRIPTION, SECURITY . . . 8J -28
INDICATOR - DESCRIPTION, SKIS . . . . . . . . 8J -31
INDICATOR - DESCRIPTION, TRANS
TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -33
INDICATOR - DESCRIPTION, TURN
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -34
INDICATOR - DESCRIPTION, WAIT-TO-
START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -35
INDICATOR - DESCRIPTION, WASHER
FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -35
INDICATOR - DESCRIPTION, WATER-IN-
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -37
INDICATOR - DIAGNOSIS AND TESTING,
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -14
INDICATOR - DIAGNOSIS AND TESTING,
WASHER FLUID. . . . . . . . . . . . . . . . . . . . . . 8J -36
INDICATOR - OPERATION, ABS . . . . . . . . . . 8J -11
INDICATOR - OPERATION, AIRBAG . . . . . . . 8J -12
INDICATOR - OPERATION, BRAKE/PARK
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -13
INDICATOR - OPERATION, CHARGING . . . . 8J -15
INDICATOR - OPERATION, COOLANT
LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -16
INDICATOR - OPERATION, CRUISE . . . . . . . 8J -17
INDICATOR - OPERATION, DOOR AJ AR . . . 8J -17
INDICATOR - OPERATION, FOUR LOW
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -30
INDICATOR - OPERATION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
INDICATOR - OPERATION, FULL TIME . . . . 8J -30
INDICATOR - OPERATION, GATE AJ AR . . . . 8J -20
INDICATOR - OPERATION, GLASS AJ AR . . . 8J -21
INDICATOR - OPERATION, HIGH BEAM . . . . 8J -22
INDICATOR - OPERATION, LOW FUEL . . . . . 8J -22
INDICATOR - OPERATION, LOW OIL
PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . 8J -23
INDICATOR - OPERATION, OVERDRIVE
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -26
INDICATOR - OPERATION, PART TIME . . . . 8J -29
INDICATOR - OPERATION, REAR FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
INDICATOR - OPERATION, SEATBELT . . . . . 8J -28
INDICATOR - OPERATION, SECURITY . . . . . 8J -28
INDICATOR - OPERATION, SKIS . . . . . . . . . 8J -31
INDICATOR - OPERATION, TRANS TEMP . . 8J -34
INDICATOR - OPERATION, TURN SIGNAL . . 8J -34
INDICATOR - OPERATION, WAIT-TO-
START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -35
INDICATOR - OPERATION, WASHER
FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -36
INDICATOR - OPERATION, WATER-IN-
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -37
INDICATOR ILLUMINATION BULB -
INSTALLATION, TRANSMISSION
RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-83
INDICATOR ILLUMINATION BULB -
REMOVAL, TRANSMISSION RANGE . . . . . . 8L-82
INDICATOR LAMP (MIL) - DESCRIPTION,
MALFUNCTION. . . . . . . . . . . . . . . . . . . . . . . 8J -24
INDICATOR LAMP (MIL) - OPERATION,
MALFUNCTION. . . . . . . . . . . . . . . . . . . . . . . 8J -24
INDICATOR TEST - STANDARD
PROCEDURE, BUILT-IN . . . . . . . . . . . . . . . . 8F-10
INDICATORS - DIAGNOSIS AND
TESTING, TREAD WEAR . . . . . . . . . . . . . . . . 22-8
INFLATION - DIAGNOSIS AND TESTING,
TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
INITIAL OPERATION - STANDARD
PROCEDURE, POWER STEERING
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-18
INITIALIZATION - STANDARD
PROCEDURE, SKIS . . . . . . . . . . . . . . . . . . . . 8Q-8
INJ ECTION - DESCRIPTION, FUEL . . . . . . . . 14-29
INJ ECTOR - DESCRIPTION, FUEL . . . . . . . . 14-33
INJ ECTOR - DIAGNOSIS AND TESTING,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-33
INJ ECTOR - OPERATION, FUEL . . . . . . . . . . 14-33
INLET FILTER - INSTALLATION . . . . . . . . . . 14-28
INLET FILTER - REMOVAL . . . . . . . . . . . . . . 14-28
INPUT - OPERATION, ASD SENSE - PCM . . . 8I-4
INPUT CLUTCH ASSEMBLY - ASSEMBLY . 21-138
INPUT CLUTCH ASSEMBLY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-133
INPUT CLUTCH ASSEMBLY -
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-135
INPUT CLUTCH ASSEMBLY - OPERATION . 21-135
INPUT SPEED SENSOR - DESCRIPTION . . 21-143
INPUT SPEED SENSOR - INSTALLATION . 21-143
INPUT SPEED SENSOR - OPERATION . . . . 21-143
INPUT SPEED SENSOR - REMOVAL . . . . . 21-143
INSTRUMENT CLUSTER - ASSEMBLY . . . . . 8J -10
INSTRUMENT CLUSTER - DESCRIPTION . . . 8J -2
INSTRUMENT CLUSTER - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8J -7
INSTRUMENT CLUSTER - DISASSEMBLY . . . 8J -9
INSTRUMENT CLUSTER - INSTALLATION . . 8J -11
INSTRUMENT CLUSTER - OPERATION . . . . . 8J -4
INSTRUMENT CLUSTER - REMOVAL . . . . . . 8J -9
INSTRUMENT PANEL ANTENNA CABLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8A-8
INSTRUMENT PANEL ANTENNA CABLE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-7
INSTRUMENT PANEL ASSEMBLY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-151
INSTRUMENT PANEL ASSEMBLY -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-149
INSTRUMENT PANEL CENTER BEZEL -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-154
INSTRUMENT PANEL CENTER BEZEL -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-154
INSTRUMENT PANEL DRIVER SIDE
BEZELS - INSTALLATION. . . . . . . . . . . . . . 23-154
INSTRUMENT PANEL DRIVER SIDE
BEZELS - REMOVAL . . . . . . . . . . . . . . . . . 23-153
INSTRUMENT PANEL END CAP -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-153
INSTRUMENT PANEL END CAP -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-153
INSTRUMENT PANEL PASSENGER SIDE
BEZEL - INSTALLATION. . . . . . . . . . . . . . . 23-154
BEZEL - REMOVAL . . . . . . . . . . . . . . . . . . 23-154
INSTRUMENT PANEL TOP COVER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-153
INSTRUMENT PANEL TOP COVER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-152
INTAKE AIR TEMPERATURE SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-36
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-37
INTAKE MANIFOLD - DESCRIPTION . . . . . . . 9-68
INTAKE MANIFOLD - INSTALLATION . . . . . . . 9-69
INTAKE MANIFOLD - REMOVAL . . . . . . . . . . 9-68
KJ INDEX 13
INTAKE MANIFOLD LEAKS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 9-68
INTAKE/EXHAUST VALVES & SEATS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 9-26
INSTALLATION. . . . . . . . . . . . . . . . . . . . 9-28,9-36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 9-27,9-35
INTERIOR - DESCRIPTION, LAMPS/
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-65
INTERIOR - DIAGNOSIS AND TESTING,
LAMPS/LIGHTING . . . . . . . . . . . . . . . . . . . . 8L-68
INTERIOR - OPERATION, LAMPS/
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-67
INTERIOR - SPECIFICATIONS,
LAMPS/LIGHTING . . . . . . . . . . . . . . . . . . . . 8L-71
INTERLOCK CABLE - INSTALLATION,
PARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-153
INTERLOCK CABLE - REMOVAL, PARK . . . 21-153
INTERLOCK SYSTEM - DESCRIPTION,
BRAKE TRANSMISSION SHIFT . . . . . . . . . 21-124
INTERLOCK SYSTEM - DIAGNOSIS AND
TESTING, BRAKE TRANSMISSION
SHIFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-125
INTERLOCK SYSTEM - OPERATION,
BRAKE TRANSMISSION SHIFT . . . . . . . . . 21-125
INTERMEDIATE SHAFT - INSTALLATION . . . 19-11
INTERMEDIATE SHAFT - REMOVAL . . . . . . 19-11
INTERNATIONAL SYMBOLS -
INTERNATIONAL SYMBOLS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
INTRODUCTION - DIAGNOSIS AND
TESTING, ENGINE DIAGNOSIS . . . . . . . . . . . . 9-4
INTRUSION TRANSCEIVER MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8Q-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8Q-16
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8Q-15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-15
INVERTED FLARING - STANDARD
PROCEDURE, DOUBLE . . . . . . . . . . . . . . . . . . 5-8
IOD FUSE - DESCRIPTION . . . . . . . . . . . 8W-97-3
IOD FUSE - INSTALLATION . . . . . . . . . . . 8W-97-3
IOD FUSE - OPERATION . . . . . . . . . . . . . 8W-97-3
IOD FUSE - REMOVAL . . . . . . . . . . . . . . 8W-97-3
ISO FLARING - STANDARD PROCEDURE . . . . 5-8
J OINT - DESCRIPTION, UPPER
SUSPENSION ARM, BUSHINGS, AND
BALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
J OINT - DIAGNOSIS AND TESTING,
LOWER BALL . . . . . . . . . . . . . . . . . . . . . . . . 2-10
J OINT - INSTALLATION, UPPER BALL . . . . . 2-20
J OINT - OPERATION, UPPER
BALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
J OINT - REMOVAL, UPPER BALL . . . . . . . . . 2-20
J OINT/BOOT-INNER - INSTALLATION, CV . . . 3-17
J OINT/BOOT-INNER - REMOVAL, CV . . . . . . . 3-15
J OINT/BOOT-OUTER - INSTALLATION, CV . . . 3-13
J OINT/BOOT-OUTER - REMOVAL, CV . . . . . . 3-12
J OINTS - ASSEMBLY, SINGLE CARDAN
UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
J OINTS - DISASSEMBLY, SINGLE
CARDAN UNIVERSAL . . . . . . . . . . . . . . . . . . . 3-8
J OUNCE BUMPER - INSTALLATION . . . . . . . 2-19
J OUNCE BUMPER - REMOVAL . . . . . . . . . . . 2-19
J UMP STARTING PROCEDURE -
J UNCTION BLOCK - DESCRIPTION . . . . . 8W-97-4
J UNCTION BLOCK - DESCRIPTION . . . . . . . . 5-20
J UNCTION BLOCK - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-4
J UNCTION BLOCK - INSTALLATION . . . . . . . 5-20
J UNCTION BLOCK - OPERATION . . . . . . 8W-97-4
J UNCTION BLOCK - OPERATION . . . . . . . . . . 5-20
J UNCTION BLOCK - REMOVAL . . . . . . . . . . . 5-20
KEY - DESCRIPTION, TRANSPONDER . . . . 8Q-18
KEY - OPERATION, TRANSPONDER . . . . . . 8Q-18
KEY IMMOBILIZER MODULE -
DESCRIPTION, SENTRY . . . . . . . . . . . . . . . . 8E-15
INSTALLATION, SENTRY . . . . . . . . . . . . . . . 8E-18
OPERATION, SENTRY . . . . . . . . . . . . . . . . . 8E-16
KEY IMMOBILIZER MODULE - REMOVAL,
SENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-17
KEY TRANSPONDER PROGRAMMING -
STANDARD PROCEDURE, SENTRY . . . . . . . . 8Q-8
KEY-IN IGNITION SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 19-10
KEY-IN IGNITION SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 19-10
KEYLESS ENTRY MODULE -
DESCRIPTION, REMOTE . . . . . . . . . . . . . . . . 8N-7
KEYLESS ENTRY MODULE - DIAGNOSIS
AND TESTING, REMOTE . . . . . . . . . . . . . . . . 8N-7
KEYLESS ENTRY MODULE -
INSTALLATION, REMOTE . . . . . . . . . . . . . . . 8N-7
KEYLESS ENTRY MODULE - OPERATION,
REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
KEYLESS ENTRY MODULE - REMOVAL,
REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
KEYLESS ENTRY TRANSMITTER -
DIAGNOSIS AND TESTING, REMOTE . . . . . . 8N-8
KEYLESS ENTRY TRANSMITTER -
SPECIFICATIONS, REMOTE . . . . . . . . . . . . . . 8N-9
KNEE BLOCKER - INSTALLATION . . . . . . . 23-155
KNEE BLOCKER - REMOVAL . . . . . . . . . . . 23-155
KNOCK SENSOR - DESCRIPTION . . . . . . . . . 8I-11
KNOCK SENSOR - INSTALLATION . . . . . . . . 8I-12
KNOCK SENSOR - OPERATION . . . . . . . . . . 8I-11
KNOCK SENSOR - REMOVAL . . . . . . . . . . . . 8I-12
KNUCKLE - INSTALLATION . . . . . . . . . . . . . . . 2-9
KNUCKLE - REMOVAL . . . . . . . . . . . . . . . . . . . 2-9
LABEL - DESCRIPTION, VEHICLE
EMISSION CONTROL INFORMATION
(VECI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-8
LABEL - DESCRIPTION, VEHICLE SAFETY
CERTIFICATION . . . . . . . . . . . . . . . . . . . . . Intro.-9
LACE - INSTALLATION, OPENING TRIM . . 23-180
LACE - REMOVAL, OPENING TRIM . . . . . . 23-180
LAMP BULB - INSTALLATION, ASH
RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-71
LAMP BULB - INSTALLATION, CARGO . . . . 8L-73
LAMP BULB - INSTALLATION, CENTER
HIGH MOUNTED STOP . . . . . . . . . . . . . . . . 8L-19
LAMP BULB - INSTALLATION,
COURTESY . . . . . . . . . . . . . . . . . . . . . . . . . 8L-76
LAMP BULB - INSTALLATION, FRONT . . . . 8L-27
LAMP BULB - INSTALLATION, FRONT
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
LAMP BULB - INSTALLATION, FRONT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
LAMP BULB - INSTALLATION, LICENSE
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-45
LAMP BULB - INSTALLATION, READING . . . 8L-79
LAMP BULB - INSTALLATION, REAR . . . . . 8L-59
LAMP BULB - INSTALLATION, REPEATER . . 8L-60
LAMP BULB - INSTALLATION, VANITY . . . . 8L-84
LAMP BULB - REMOVAL, ASH RECEIVER . . 8L-71
LAMP BULB - REMOVAL, CARGO . . . . . . . . 8L-72
LAMP BULB - REMOVAL, CENTER HIGH
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-18
LAMP BULB - REMOVAL, COURTESY . . . . . 8L-75
LAMP BULB - REMOVAL, FRONT . . . . . . . . 8L-26
LAMP BULB - REMOVAL, FRONT FOG . . . . 8L-21
LAMP BULB - REMOVAL, FRONT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
LAMP BULB - REMOVAL, LICENSE
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-44
LAMP BULB - REMOVAL, READING . . . . . . 8L-79
LAMP BULB - REMOVAL, REAR . . . . . . . . . 8L-58
LAMP BULB - REMOVAL, REPEATER . . . . . 8L-60
LAMP BULB - REMOVAL, VANITY . . . . . . . . 8L-83
LAMP INDICATOR - DESCRIPTION,
FRONT FOG . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
LAMP INDICATOR - DESCRIPTION, REAR
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
LAMP INDICATOR - OPERATION, FRONT
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -19
LAMP INDICATOR - OPERATION, REAR
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
LAMP (MIL) - DESCRIPTION,
MALFUNCTION INDICATOR . . . . . . . . . . . . . 8J -24
LAMP (MIL) - OPERATION,
MALFUNCTION INDICATOR . . . . . . . . . . . . . 8J -24
LAMP RELAY - DESCRIPTION, DAYTIME
RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
LAMP RELAY - DESCRIPTION, FRONT
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
LAMP RELAY - DESCRIPTION, PARK . . . . . 8L-54
LAMP RELAY - DESCRIPTION, REAR FOG . 8L-56
LAMP RELAY - DIAGNOSIS AND
TESTING, FRONT FOG . . . . . . . . . . . . . . . . . 8L-23
TESTING, PARK . . . . . . . . . . . . . . . . . . . . . . 8L-55
TESTING, REAR FOG. . . . . . . . . . . . . . . . . . 8L-57
LAMP RELAY - INSTALLATION, DAYTIME
RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
LAMP RELAY - INSTALLATION, FRONT
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-24
LAMP RELAY - INSTALLATION, PARK . . . . . 8L-56
LAMP RELAY - INSTALLATION, REAR
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-58
LAMP RELAY - OPERATION, DAYTIME
RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
LAMP RELAY - OPERATION, FRONT FOG . . 8L-22
LAMP RELAY - OPERATION, PARK . . . . . . . 8L-54
LAMP RELAY - OPERATION, REAR FOG . . . 8L-57
LAMP RELAY - REMOVAL, DAYTIME
RUNNING. . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
LAMP RELAY - REMOVAL, FRONT FOG . . . 8L-24
LAMP RELAY - REMOVAL, PARK . . . . . . . . 8L-55
LAMP RELAY - REMOVAL, REAR FOG . . . . 8L-58
LAMP REPLACEMENT - STANDARD
PROCEDURE, CMTC . . . . . . . . . . . . . . . . . . . 8M-2
LAMP REPLACEMENT - STANDARD
PROCEDURE, COURTESY . . . . . . . . . . . . . . . 8M-2
LAMP SWITCH - DESCRIPTION, BACKUP . . 8L-15
LAMP SWITCH - DESCRIPTION, BRAKE . . . 8L-16
LAMP SWITCH - DIAGNOSIS AND
TESTING, BACKUP. . . . . . . . . . . . . . . . . . . . . 8L-15
LAMP SWITCH - DIAGNOSIS AND
TESTING, BRAKE . . . . . . . . . . . . . . . . . . . . . 8L-17
LAMP SWITCH - INSTALLATION, BRAKE . . 8L-18
LAMP SWITCH - INSTALLATION, CARGO . . 8L-74
LAMP SWITCH - INSTALLATION,
READING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-80
LAMP SWITCH - OPERATION, BACKUP . . . 8L-15
LAMP SWITCH - OPERATION, BRAKE . . . . . 8L-16
LAMP SWITCH - REMOVAL, BRAKE . . . . . . 8L-17
LAMP SWITCH - REMOVAL, CARGO . . . . . . 8L-73
LAMP SWITCH - REMOVAL, READING . . . . 8L-80
LAMP UNIT - ADJ USTMENT, FRONT FOG . . 8L-25
LAMP UNIT - INSTALLATION, ASH
RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-72
LAMP UNIT - INSTALLATION, CARGO . . . . . 8L-74
LAMP UNIT - INSTALLATION, CENTER
HIGH MOUNTED STOP . . . . . . . . . . . . . . . . 8L-19
LAMP UNIT - INSTALLATION, COURTESY . . 8L-77
LAMP UNIT - INSTALLATION, FRONT . . . . . 8L-28
LAMP UNIT - INSTALLATION, FRONT
FOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-25
LAMP UNIT - INSTALLATION, LICENSE
PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-46
LAMP UNIT - INSTALLATION, READING . . . 8L-81
LAMP UNIT - INSTALLATION, REAR . . . . . . 8L-60
LAMP UNIT - INSTALLATION, REPEATER . . 8L-61
LAMP UNIT - REMOVAL, ASH RECEIVER . . 8L-72
LAMP UNIT - REMOVAL, CARGO . . . . . . . . 8L-74
LAMP UNIT - REMOVAL, CENTER HIGH
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-19
LAMP UNIT - REMOVAL, COURTESY . . . . . 8L-76
LAMP UNIT - REMOVAL, FRONT . . . . . . . . . 8L-27
LAMP UNIT - REMOVAL, FRONT FOG . . . . . 8L-25
LAMP UNIT - REMOVAL, LICENSE PLATE . . 8L-45
LAMP UNIT - REMOVAL, READING . . . . . . . 8L-81
LAMP UNIT - REMOVAL, REAR . . . . . . . . . . 8L-59
LAMP UNIT - REMOVAL, REPEATER . . . . . . 8L-60
LAMPS/LIGHTING - EXTERIOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8L-2
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8L-7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 8L-15
LAMPS/LIGHTING - INTERIOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8L-67
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 8L-71
LASH ADJ USTER - DIAGNOSIS AND
TESTING, HYDRAULIC. . . . . . . . . . . . . . 9-19,9-30
LATCH - ACCESS PANEL - DESCRIPTION . 23-139
LATCH - ACCESS PANEL - INSTALLATION . 23-139
14 INDEX KJ
LATCH - ACCESS PANEL - REMOVAL . . . . 23-139
LATCH - INSTALLATION . . 23-120,23-124,23-131,
23-137
LATCH - INSTALLATION, FLIP-UP GLASS . 23-136
LATCH - INSTALLATION, FLOOR
CONSOLE LID . . . . . . . . . . . . . . . . . . . . . . 23-158
LATCH - INSTALLATION, GLOVE BOX . . . . 23-148
LATCH / LOCK - INSTALLATION,
FOLDING REAR SEAT BACK . . . . . . . . . . . 23-170
LATCH / LOCK - REMOVAL, FOLDING
REAR SEAT BACK . . . . . . . . . . . . . . . . . . . 23-170
LATCH - REMOVAL . . . . . . 23-120,23-124,23-131,
23-137
LATCH - REMOVAL, FLIP-UP GLASS . . . . . 23-136
LATCH - REMOVAL, FLOOR CONSOLE
LID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
LATCH - REMOVAL, GLOVE BOX . . . . . . . . 23-148
LATCH RELEASE CABLE - INSTALLATION . 23-120
LATCH RELEASE CABLE - REMOVAL . . . . 23-120
LATCH RELEASE HANDLE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-120
LATCH RELEASE HANDLE - REMOVAL . . . 23-120
LATCH STRIKER - INSTALLATION . . . . . . 23-124,
23-132,23-137
LATCH STRIKER - INSTALLATION, GLOVE
BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-149
LATCH STRIKER - INSTALLATION, REAR
SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . 23-171
LATCH STRIKER - REMOVAL . . . . 23-124,23-132,
23-137
LATCH STRIKER - REMOVAL, GLOVE
BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-148
LATCH STRIKER - REMOVAL, REAR
SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . 23-170
LEAK - DIAGNOSIS AND TESTING,
CONVERTER HOUSING FLUID. . . . . . . . . . . 21-80
LEAK - DIAGNOSIS AND TESTING,
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
LEAK DETECTION PUMP - DESCRIPTION . . 25-27
LEAK DETECTION PUMP - INSTALLATION . 25-28
LEAK DETECTION PUMP - OPERATION . . . . 25-28
LEAK DETECTION PUMP - REMOVAL . . . . . 25-28
LEAK DOWN TEST - DIAGNOSIS AND
TESTING, FUEL PRESSURE. . . . . . . . . . . . . . 14-3
LEAKAGE - DIAGNOSIS AND TESTING,
CYLINDER COMBUSTION PRESSURE . . . . . . . 9-8
LEAKS - DIAGNOSIS AND TESTING,
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 7-4
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . 9-68
REAR SEAL AREA . . . . . . . . . . . . . . . . . . . . . 9-61
WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2
LEAKS - STANDARD PROCEDURE,
REPAIRING . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
LEARN - STANDARD PROCEDURE, TCM
QUICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21
LEFT POWER SEAT SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8N-16
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8N-17
LEFT POWER SEAT SWITCH - REMOVAL . . 8N-18
LEFT SIDE - INSTALLATION . . . . . . . . . 2-12,2-15
LEFT SIDE - REMOVAL . . . . . . . . . . . . . 2-11,2-15
LEVEL - DIAGNOSIS AND TESTING,
EFFECTS OF INCORRECT FLUID . . . . . . . . 21-125
LEVEL - STANDARD PROCEDURE,
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . 24-54
LEVEL - STANDARD PROCEDURES,
MASTER CYLINDER FLUID . . . . . . . . . . . . . . 5-26
LEVEL CHECK - STANDARD
PROCEDURE, FLUID . . . . . . . . . . . . . . . . . 21-126
LEVEL SENDING UNIT - DIAGNOSIS AND
TESTING, FUEL . . . . . . . . . . . . . . . . . . . . . . . 14-9
LEVEL SENDING UNIT / SENSOR -
DESCRIPTION, FUEL . . . . . . . . . . . . . . . . . . . 14-9
INSTALLATION, FUEL . . . . . . . . . . . . . . . . . 14-10
OPERATION, FUEL . . . . . . . . . . . . . . . . . . . . . 14-9
REMOVAL, FUEL . . . . . . . . . . . . . . . . . . . . . . 14-9
LEVEL SWITCH - DESCRIPTION,
WASHER FLUID . . . . . . . . . . . . . . . . . . . . . 8R-17
LEVEL SWITCH - INSTALLATION,
WASHER FLUID . . . . . . . . . . . . . . . . . . . . . 8R-18
LEVEL SWITCH - OPERATION, WASHER
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
LEVEL SWITCH - REMOVAL, WASHER
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
LEVELING MOTOR - DESCRIPTION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-35
LEVELING MOTOR - INSTALLATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
LEVELING MOTOR - OPERATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
LEVELING MOTOR - REMOVAL,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
LEVELING SWITCH - DESCRIPTION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-37
LEVELING SWITCH - DIAGNOSIS AND
TESTING, HEADLAMP . . . . . . . . . . . . . . . . . 8L-37
LEVELING SWITCH - INSTALLATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
LEVELING SWITCH - OPERATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-37
LEVELING SWITCH - REMOVAL,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
LEVER - INSTALLATION . . . . . . . . . . . . . . . . 5-31
LEVER - INSTALLATION, SHIFT . . . 21-214,21-249
LEVER - REMOVAL . . . . . . . . . . . . . . . . . . . . 5-31
LEVER - REMOVAL, SHIFT . . . . . . 21-213,21-248
LHD - INSTALLATION . . . . . . . . . . . . . . . 8W-97-6
LHD - REMOVAL . . . . . . . . . . . . . . . . . . . . 8W-97-5
LICENSE PLATE LAMP BULB -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-45
LICENSE PLATE LAMP BULB - REMOVAL . . 8L-44
LICENSE PLATE LAMP UNIT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-46
LICENSE PLATE LAMP UNIT - REMOVAL . . 8L-45
LID LATCH - INSTALLATION, FLOOR
CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
LID LATCH - REMOVAL, FLOOR
CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
LIGHTER OUTLET - DESCRIPTION,
CIGAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-2
LIGHTER OUTLET - DIAGNOSIS AND
TESTING, CIGAR . . . . . . . . . . . . . . . . . . . 8W-97-2
LIGHTER OUTLET - OPERATION, CIGAR . 8W-97-2
LIMITS - DESCRIPTION, HIGH AND LOW . . 25-20
LINE - DESCRIPTION, REFRIGERANT . . . . . 24-38
LINE - INSTALLATION, A/C DISCHARGE . . . 24-47
LINE - INSTALLATION, A/C LIQUID . . . . . . . 24-47
LINE - INSTALLATION, A/C SUCTION . . . . . 24-49
LINE - REMOVAL, A/C DISCHARGE . . . . . . . 24-46
LINE - REMOVAL, A/C LIQUID . . . . . . . . . . . 24-47
LINE - REMOVAL, A/C SUCTION . . . . . . . . . 24-48
LINE AND HOSES - DIAGNOSIS AND
TESTING, BRAKE. . . . . . . . . . . . . . . . . . . . . . . 5-8
LINE PRESSURE (LP) SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-144
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-144
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-144
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 21-144
LINES - DESCRIPTION, BRAKE . . . . . . . . . . . . 5-8
LINES - DESCRIPTION, FUEL . . . . . . . . . . . 14-10
LINES - DESCRIPTION, VACUUM . . . . . . . . 25-33
LINK - INSTALLATION, STABILIZER . . . . . . . 2-14
LINK - REMOVAL, STABILIZER . . . . . . . . . . . 2-14
LINK CONNECTOR - DESCRIPTION, DATA . 8E-10
LINK CONNECTOR - OPERATION, DATA . . . 8E-10
LINKAGE - INSTALLATION . . . . . . . . . . . . . . . . 6-9
LINKAGE - REMOVAL . . . . . . . . . . . . . . . . . . . 6-8
LINKAGE - STANDARD PROCEDURE,
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 19-16
LIQUID LINE - INSTALLATION, A/C . . . . . . . 24-47
LIQUID LINE - REMOVAL, A/C . . . . . . . . . . . 24-47
LOAD TEST - STANDARD PROCEDURE . . . . 8F-12
LOAD VALUE - DESCRIPTION . . . . . . . . . . . 25-20
LOADS - STANDARD PROCEDURE,
TESTING FOR A SHORT TO GROUND
ON FUSES POWERING SEVERAL . . . . . . 8W-01-9
LOCATION - DESCRIPTION, CONNECTOR/
GROUND/SPLICE. . . . . . . . . . . . . . . . . . . 8W-91-1
LOCATIONS - DESCRIPTION, FLUID
FILL/CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
LOCATIONS - SPECIFICATIONS, SEALER . . 23-87
LOCATIONS - SPECIFICATIONS, WELD
AND STRUCTURAL ADHESIVE . . . . . . . . . . . 23-9
LOCK - INSTALLATION, FOLDING REAR
SEAT BACK LATCH . . . . . . . . . . . . . . . . . . 23-170
LOCK - REMOVAL, FOLDING REAR SEAT
BACK LATCH . . . . . . . . . . . . . . . . . . . . . . . 23-170
LOCK / UNLOCK SWITCH -
INSTALLATION, DOOR . . . . . . . . . . . . . . . . . 8N-5
LOCK / UNLOCK SWITCH - REMOVAL,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-4
LOCK CYLINDER - INSTALLATION . . . . . . 23-125,
23-138
LOCK CYLINDER - INSTALLATION . . . . . . . 19-11
LOCK CYLINDER - REMOVAL . . . . 23-125,23-137
LOCK CYLINDER - REMOVAL . . . . . . . . . . . 19-10
LOCK MOTOR - DESCRIPTION, DOOR . . . . . 8N-5
LOCK MOTOR - DIAGNOSIS AND
TESTING, DOOR . . . . . . . . . . . . . . . . . . . . . . 8N-5
LOCK MOTOR - OPERATION, DOOR . . . . . . . 8N-5
LOCK OUT - ADJ USTMENT . . . . . . . . . . . . . . 5-30
LOCK RELAY - DESCRIPTION, DOOR . . . . . . 8N-6
LOCK RELAY - DIAGNOSIS AND
TESTING, DOOR . . . . . . . . . . . . . . . . . . . . . . 8N-6
LOCK RELAY - INSTALLATION, DOOR . . . . . 8N-7
LOCK RELAY - OPERATION, DOOR . . . . . . . . 8N-6
LOCK RELAY - REMOVAL, DOOR . . . . . . . . . 8N-6
LOCK SWITCH - DESCRIPTION, DOOR
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-9
LOCK SWITCH - DESCRIPTION,
TAILGATE CYLINDER. . . . . . . . . . . . . . . . . . . 8N-9
LOCK SWITCH - DIAGNOSIS AND
TESTING, DOOR CYLINDER . . . . . . . . . . . . 8Q-10
LOCK SWITCH - DIAGNOSIS AND
TESTING, TAILGATE CYLINDER . . . . . . . . . . 8N-9
LOCK SWITCH - INSTALLATION, DOOR
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
LOCK SWITCH - INSTALLATION,
TAILGATE CYLINDER. . . . . . . . . . . . . . . . . . 8N-10
LOCK SWITCH - OPERATION, DOOR
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
LOCK SWITCH - OPERATION, TAILGATE
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-9
LOCK SWITCH - REMOVAL, DOOR
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
LOCK SWITCH - REMOVAL, TAILGATE
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-10
LOCKS - DESCRIPTION, POWER . . . . . . . . . 8N-1
LOCKS - DIAGNOSIS AND TESTING,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-3
LOCKS - OPERATION, POWER . . . . . . . . . . . 8N-3
LOCK/UNLOCK SWITCH - DIAGNOSIS
AND TESTING, DOOR . . . . . . . . . . . . . . . . . . 8N-4
LOOP ADJ USTER - INSTALLATION, SEAT
BELT TURNING . . . . . . . . . . . . . . . . . . . . . . 8O-38
LOOP ADJ USTER - REMOVAL, SEAT
BELT TURNING . . . . . . . . . . . . . . . . . . . . . . 8O-37
LOW BEAM RELAY - DESCRIPTION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
LOW BEAM RELAY - DIAGNOSIS AND
TESTING, HEADLAMP . . . . . . . . . . . . . . . . . 8L-40
LOW BEAM RELAY - INSTALLATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-41
LOW BEAM RELAY - OPERATION,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
LOW BEAM RELAY - REMOVAL,
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-40
LOW FUEL INDICATOR - DESCRIPTION . . . 8J -22
LOW FUEL INDICATOR - OPERATION . . . . . 8J -22
LOW INDICATOR - DESCRIPTION,
COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -15
LOW INDICATOR - OPERATION,
COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -16
LOW LIMITS - DESCRIPTION, HIGH . . . . . . 25-20
LOW MODE INDICATOR - DESCRIPTION,
FOUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -29
LOW MODE INDICATOR - OPERATION,
FOUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -30
LOW OIL PRESSURE INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -23
LOW OIL PRESSURE INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -23
LOW PRESSURE SWITCH -
DESCRIPTION, A/C . . . . . . . . . . . . . . . . . . . 24-18
LOW PRESSURE SWITCH - DIAGNOSIS
AND TESTING, A/C . . . . . . . . . . . . . . . . . . . 24-19
LOW PRESSURE SWITCH -
INSTALLATION, A/C . . . . . . . . . . . . . . . . . . . 24-19
KJ INDEX 15
LOW PRESSURE SWITCH - OPERATION,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
LOW PRESSURE SWITCH - REMOVAL,
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
LOWER BALL J OINT - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
LOWER CONTROL ARM - DESCRIPTION . . . 2-21
LOWER CONTROL ARM - INSTALLATION . . 2-10,
2-21
LOWER CONTROL ARM - OPERATION . . . . . 2-21
LOWER CONTROL ARM - REMOVAL . . 2-10,2-21
LOWER TRIM - INSTALLATION,
B-PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-157
LOWER TRIM - REMOVAL, B-PILLAR . . . . 23-157
LOWER WEATHERSTRIP -
INSTALLATION, DOOR . . . . . . . . . . . . . . . . 23-186
LOWER WEATHERSTRIP - REMOVAL,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
LOW/REVERSE CLUTCH - ASSEMBLY . . . . 21-146
LOW/REVERSE CLUTCH - CLEANING . . . . 21-146
LOW/REVERSE CLUTCH - DISASSEMBLY . 21-145
LOW/REVERSE CLUTCH - INSPECTION . . 21-146
LUBRICATION - DESCRIPTION . . . . . . . . . . . 9-57
LUBRICATION - DIAGNOSIS AND
LUBRICATION - OPERATION . . . . . . . . . . . . . 9-58
LUBRICATION - STANDARD PROCEDURE,
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
LUGGAGE RACK - INSTALLATION . . . . . . . 23-144
LUGGAGE RACK - REMOVAL . . . . . . . . . . . . 23-144
MACHINING - STANDARD PROCEDURES,
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . 5-27
MAIN BEARING, FITTING . . . . . . . . . . . . . . . . 9-45
MAINTENANCE SCHEDULES -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
MALFUNCTION INDICATOR LAMP (MIL) -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -24
MALFUNCTION INDICATOR LAMP (MIL) -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -24
MANAGEMENT VALVE - DESCRIPTION,
FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
MANAGEMENT VALVE - INSTALLATION,
FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
MANAGEMENT VALVE - OPERATION,
FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
MANAGEMENT VALVE - REMOVAL,
FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
MANAGER - DESCRIPTION, TASK . . . . . . . . 25-17
MANAGER - OPERATION, TASK . . . . . . . . . 25-21
MANIFOLD - DESCRIPTION, EXHAUST . . . . . 9-69
MANIFOLD - DESCRIPTION, INTAKE . . . . . . . 9-68
MANIFOLD - INSTALLATION, EXHAUST . . . . 9-70
MANIFOLD - INSTALLATION, INTAKE . . . . . . 9-69
MANIFOLD - REMOVAL, EXHAUST . . . . . . . . 9-69
MANIFOLD - REMOVAL, INTAKE . . . . . . . . . . 9-68
MANIFOLD LEAKS - DIAGNOSIS AND
TESTING, INTAKE . . . . . . . . . . . . . . . . . . . . . 9-68
MANUAL - INSTALLATION, WINDOW
REGULATOR . . . . . . . . . . . . 23-126,23-133 21-34
MANUAL - REMOVAL, WINDOW
REGULATOR . . . . . . . . . . . . . . . . . 23-126,23-133
MANUAL BLEEDING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
MANUAL, NV1500 . . . . . . . . . . . . . . . . . . . . 21-30
MANUAL, NV3550 . . . . . . . . . . . . . . . . . . . . 21-71
MANUAL SEAT RISER - INSTALLATION . . 23-168
MANUAL SEAT RISER - REMOVAL . . . . . . 23-167
MANUAL TRANSMISSION -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
MANUAL TRANSMISSION - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . 21-2,21-33
MAP SENSOR - DESCRIPTION . . . . . . . . . . 14-38
MAP SENSOR - INSTALLATION . . . . . . . . . . 14-40
MAP SENSOR - OPERATION . . . . . . . . . . . . 14-38
MAP SENSOR - REMOVAL . . . . . . . . . . . . . 14-39
MASTER CYLINDER - DESCRIPTION . . . . . . 5-24
MASTER CYLINDER - INSPECTION . . . . . . . . . 6-9
MASTER CYLINDER - INSTALLATION . . . . . . 5-25
MASTER CYLINDER - OPERATION . . . . . . . . 5-24
MASTER CYLINDER - REMOVAL . . . . . . . . . . 5-25
MASTER CYLINDER BLEEDING -
MASTER CYLINDER FLUID LEVEL -
STANDARD PROCEDURES. . . . . . . . . . . . . . . 5-26
MASTER CYLINDER/POWER BOOSTER -
DIAGNOSIS AND TESTING . . . . . . . . . . 5-21,5-24
MATCH MOUNTING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-3
MATS - INSTALLATION, CARPETS AND
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
MATS - REMOVAL, CARPETS AND
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-158
MEASUREMENT - STANDARD
PROCEDURE, HEIGHT . . . . . . . . . . . . . . . . . . . 2-4
MEASURING TIMING CHAIN WEAR,
MECHANICAL - DIAGNOSIS AND
MECHANISM - DESCRIPTION, SHIFT . . . . 21-160
MECHANISM - INSTALLATION, SHIFT . . . . 21-160
MECHANISM - OPERATION, SHIFT . . . . . . 21-160
MECHANISM - REMOVAL, SHIFT . . . . . . . 21-160
METRIC SYSTEM - DESCRIPTION . . . . . . Intro.-5
MICRO-RELAY - DESCRIPTION . . . . . . . 8W-97-14
MICRO-RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-14
MICRO-RELAY - INSTALLATION . . . . . . 8W-97-14
MICRO-RELAY - OPERATION . . . . . . . . 8W-97-14
MICRO-RELAY - REMOVAL . . . . . . . . . . 8W-97-14
MIDTRONICS ELECTRICAL TESTER -
STANDARD PROCEDURE, USING . . . . . . . . 8F-15
MINI-TRIP COMPUTER - DIAGNOSIS
AND TESTING, COMPASS . . . . . . . . . . . . . . 8M-6
MINI-TRIP ILLUMINATION BULB -
INSTALLATION, COMPASS . . . . . . . . . . . . . 8L-75
MINI-TRIP ILLUMINATION BULB -
REMOVAL, COMPASS . . . . . . . . . . . . . . . . . 8L-74
MIRROR - INSTALLATION, SIDE VIEW . . . 23-145
MIRROR - REMOVAL, REAR VIEW . . . . . . 23-161
MIRROR - REMOVAL, SIDE VIEW . . . . . . . 23-145
MIRROR - REMOVAL, SIDEVIEW . . . . . . . . 8N-13
MIRROR SUPPORT BRACKET -
INSTALLATION, REARVIEW . . . . . . . . . . . . 23-161
MIRROR SWITCH - DIAGNOSIS AND
TESTING, POWER . . . . . . . . . . . . . . . . . . . . 8N-12
MIRROR SWITCH - INSTALLATION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-13
MIRROR SWITCH - REMOVAL, POWER . . . 8N-13
MIRRORS - DESCRIPTION, HEATED . . . . . . . 8G-1
MIRRORS - DESCRIPTION, POWER . . . . . . 8N-11
MIRRORS - DIAGNOSIS AND TESTING,
HEATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-1
MIRRORS - DIAGNOSIS AND TESTING,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-11
MIRRORS - OPERATION, HEATED . . . . . . . . 8G-1
MIRRORS - OPERATION, POWER . . . . . . . . 8N-11
MODE - DESCRIPTION, CIRCUIT
ACTUATION TEST . . . . . . . . . . . . . . . . . . . . . 25-2
MODE - DESCRIPTION, STATE DISPLAY
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
MODE INDICATOR - DESCRIPTION, FOUR
LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -29
MODE INDICATOR - OPERATION, FOUR
LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -30
MODES OF OPERATION - DESCRIPTION . . . 8E-11
MODULE - DESCRIPTION, AIRBAG
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-9
MODULE - DESCRIPTION, BODY
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-2
MODULE - DESCRIPTION, FRONT WIPER . 8R-15
MODULE - DESCRIPTION, FUEL PUMP . . . . 14-18
MODULE - DESCRIPTION, HEATED SEAT . . 8E-21
MODULE - DESCRIPTION, INTRUSION
TRANSCEIVER. . . . . . . . . . . . . . . . . . . . . . . 8Q-14
MODULE - DESCRIPTION, REMOTE
KEYLESS ENTRY . . . . . . . . . . . . . . . . . . . . . . 8N-7
MODULE - DESCRIPTION, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . 8E-15
MODULE - DESCRIPTION, SIDE IMPACT
AIRBAG CONTROL . . . . . . . . . . . . . . . . . . . 8O-43
MODULE - DESCRIPTION,
TRANSMISSION CONTROL . . . . . . . . . . . . . 8E-18
MODULE - DIAGNOSIS AND TESTING,
BODY CONTROL . . . . . . . . . . . . . . . . . . . . . . 8E-7
HEATED SEAT . . . . . . . . . . . . . . . . . . . . . . . 8E-22
REMOTE KEYLESS ENTRY . . . . . . . . . . . . . . 8N-7
MODULE - INSTALLATION, AIRBAG
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-12
MODULE - INSTALLATION, BODY
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-7
MODULE - INSTALLATION, CONTROL . . . . 23-183
MODULE - INSTALLATION, FRONT
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-16
MODULE - INSTALLATION, FUEL PUMP . . . 14-19
MODULE - INSTALLATION, HEATED SEAT . . 8E-24
MODULE - INSTALLATION, INTRUSION
TRANSCEIVER. . . . . . . . . . . . . . . . . . . . . . . 8Q-16
MODULE - INSTALLATION, REMOTE
KEYLESS ENTRY . . . . . . . . . . . . . . . . . . . . . . 8N-7
MODULE - INSTALLATION, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . 8E-18
MODULE - INSTALLATION, SIDE IMPACT
AIRBAG CONTROL . . . . . . . . . . . . . . . . . . . 8O-45
MODULE - OPERATION, AIRBAG
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-10
MODULE - OPERATION, BODY CONTROL . . . 8E-5
MODULE - OPERATION, FRONT WIPER . . . 8R-15
MODULE - OPERATION, FUEL PUMP . . . . . 14-18
MODULE - OPERATION, HEATED SEAT . . . . 8E-21
MODULE - OPERATION, INTRUSION
TRANSCEIVER. . . . . . . . . . . . . . . . . . . . . . . 8Q-15
MODULE - OPERATION, REMOTE
KEYLESS ENTRY . . . . . . . . . . . . . . . . . . . . . . 8N-7
MODULE - OPERATION, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . 8E-16
MODULE - OPERATION, SIDE IMPACT
AIRBAG CONTROL . . . . . . . . . . . . . . . . . . . 8O-43
MODULE - OPERATION, TRANSMISSION
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-18
MODULE - REMOVAL, AIRBAG CONTROL . 8O-11
MODULE - REMOVAL, BODY CONTROL . . . . 8E-7
MODULE - REMOVAL, CONTROL . . . . . . . 23-183
MODULE - REMOVAL, FRONT WIPER . . . . 8R-16
MODULE - REMOVAL, FUEL PUMP . . . . . . . 14-18
MODULE - REMOVAL, HEATED SEAT . . . . . 8E-24
MODULE - REMOVAL, INTRUSION
TRANSCEIVER. . . . . . . . . . . . . . . . . . . . . . . 8Q-15
MODULE - REMOVAL, REMOTE KEYLESS
ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
MODULE - REMOVAL, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . 8E-17
MODULE - REMOVAL, SIDE IMPACT
AIRBAG CONTROL . . . . . . . . . . . . . . . . . . . 8O-44
MODULE ASSEMBLY - INSTALLATION . . . 23-181
MODULE ASSEMBLY - REMOVAL . . . . . . . 23-181
MOLDING - INSTALLATION, FRONT
DOOR OUTER BELT . . . . . . . . . . . . . . . . . . 23-186
MOLDING - INSTALLATION, REAR DOOR
OUTER BELT . . . . . . . . . . . . . . . . . . . . . . . 23-186
MOLDING - REMOVAL, FRONT DOOR
OUTER BELT . . . . . . . . . . . . . . . . . . . . . . . 23-186
MOLDING - REMOVAL, REAR DOOR
OUTER BELT . . . . . . . . . . . . . . . . . . . . . . . 23-186
MOLDINGS - INSTALLATION, BODY SIDE . 23-140
MOLDINGS - INSTALLATION, FRONT
WHEEL OPENING FLARE . . . . . . . . . . . . . . 23-145
MOLDINGS - INSTALLATION, REAR
WHEEL OPENING FLARE . . . . . . . . . . . . . . 23-145
MOLDINGS - REMOVAL, BODY SIDE . . . . 23-140
MOLDINGS - REMOVAL, FRONT WHEEL
OPENING FLARE . . . . . . . . . . . . . . . . . . . . 23-145
MOLDINGS - REMOVAL, REAR WHEEL
OPENING FLARE . . . . . . . . . . . . . . . . . . . . 23-145
MONITORED SYSTEMS - DESCRIPTION . . . 25-17
MONITORS - DESCRIPTION,
COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . 25-19
MOTOR - DESCRIPTION, BLOWER . . . . . . . 24-30
MOTOR - DESCRIPTION, DOOR LOCK . . . . . 8N-5
MOTOR - DESCRIPTION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-35
MOTOR - DESCRIPTION, IDLE AIR
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
MOTOR - DESCRIPTION, REAR WIPER . . . 8R-41
MOTOR - DIAGNOSIS AND TESTING,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-30
DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-39
MOTOR - INSTALLATION, BLOWER . . . . . . 24-31
MOTOR - INSTALLATION, DRIVE . . . . . . . . 23-182
MOTOR - INSTALLATION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
MOTOR - INSTALLATION, IDLE AIR
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
MOTOR - INSTALLATION, REAR WIPER . . . 8R-42
MOTOR - INSTALLATION, STARTER . . . . . . 8F-41
MOTOR - OPERATION, BLOWER . . . . . . . . . 24-30
MOTOR - OPERATION, DOOR LOCK . . . . . . . 8N-5
MOTOR - OPERATION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
16 INDEX KJ
MOTOR - OPERATION, IDLE AIR
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
MOTOR - OPERATION, REAR WIPER . . . . . 8R-41
MOTOR - REMOVAL, BLOWER . . . . . . . . . . 24-30
MOTOR - REMOVAL, DRIVE . . . . . . . . . . . 23-182
MOTOR - REMOVAL, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-36
MOTOR - REMOVAL, IDLE AIR CONTROL . . 14-36
MOTOR - REMOVAL, REAR WIPER . . . . . . 8R-42
MOTOR - REMOVAL, STARTER . . . . . . . . . . 8F-39
MOTOR - REMOVAL, WINDOW . . . . . . . . . . 8N-22
MOTOR, GAS POWERED - STARTER . . . . . . 8F-39
MOTOR RELAY - DESCRIPTION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
MOTOR RELAY - DESCRIPTION,
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-41
MOTOR RELAY - DIAGNOSIS AND
TESTING, BLOWER . . . . . . . . . . . . . . . . . . . 24-21
MOTOR RELAY - INSTALLATION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR RELAY - INSTALLATION,
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-43
MOTOR RELAY - OPERATION, BLOWER . . . 24-20
MOTOR RELAY - OPERATION, STARTER . . . 8F-42
MOTOR RELAY - REMOVAL, BLOWER . . . . 24-21
MOTOR RELAY - REMOVAL, STARTER . . . . 8F-43
MOTOR RESISTOR - DESCRIPTION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR RESISTOR - DIAGNOSIS AND
TESTING, BLOWER. . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR RESISTOR - INSTALLATION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR RESISTOR - OPERATION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR RESISTOR - REMOVAL,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
MOTOR SWITCH - DESCRIPTION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
MOTOR SWITCH - DIAGNOSIS AND
TESTING, BLOWER . . . . . . . . . . . . . . . . . . . 24-23
MOTOR SWITCH - INSTALLATION,
BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
MOTOR SWITCH - OPERATION, BLOWER . . 24-23
MOTOR SWITCH - REMOVAL, BLOWER . . . 24-23
MOUNT - INSTALLATION, FRONT . . . . . . . . . 9-57
MOUNT - INSTALLATION, REAR . . . . . . . . . . 9-57
MOUNT - REMOVAL, FRONT . . . . . . . . . . . . . 9-56
MOUNT - REMOVAL, REAR . . . . . . . . . . . . . . 9-57
MOUNTED STOP LAMP BULB -
INSTALLATION, CENTER HIGH . . . . . . . . . . 8L-19
MOUNTED STOP LAMP BULB -
REMOVAL, CENTER HIGH . . . . . . . . . . . . . . 8L-18
MOUNTED STOP LAMP UNIT -
INSTALLATION, CENTER HIGH . . . . . . . . . . 8L-19
MOUNTED STOP LAMP UNIT -
REMOVAL, CENTER HIGH . . . . . . . . . . . . . . 8L-19
MOUNTING - STANDARD PROCEDURE,
MATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-3
MOUNTING - STANDARD PROCEDURE,
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-10
MOUNTING BRACKET - INSTALLATION,
PASSENGER AIRBAG . . . . . . . . . . . . . . . . . 8O-31
MOUNTING BRACKET - REMOVAL,
PASSENGER AIRBAG . . . . . . . . . . . . . . . . . 8O-31
MUFFLER - DESCRIPTION . . . . . . . . . . . . . . . 11-4
MUFFLER - INSTALLATION . . . . . . . . . . . . . . 11-5
MUFFLER - REMOVAL . . . . . . . . . . . . . . . . . . 11-5
MULTI-FUNCTION SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8L-46
MULTI-FUNCTION SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-50
MULTI-FUNCTION SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-53
MULTI-FUNCTION SWITCH - OPERATION . . 8L-48
MULTI-FUNCTION SWITCH - REMOVAL . . . 8L-53
NAME PLATES - INSTALLATION,
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . 23-141
NAME PLATES - REMOVAL, EXTERIOR . . . 23-140
NOISE - DIAGNOSIS AND TESTING, A/C
COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . 24-42
NOISE - DIAGNOSIS AND TESTING,
WIND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
NOISE DIAGNOSIS, DIAGNOSIS AND
TESTING - WATER DRAINAGE AND
WIND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-176
NOISE OR VIBRATION - DIAGNOSIS AND
TESTING, TIRE . . . . . . . . . . . . . . . . . . . . . . . 22-8
NOISE SUPPRESSION GROUND STRAP -
DESCRIPTION, RADIO. . . . . . . . . . . . . . . . . . 8A-9
INSTALLATION, RADIO . . . . . . . . . . . . . . . . 8A-11
OPERATION, RADIO . . . . . . . . . . . . . . . . . . 8A-10
REMOVAL, RADIO. . . . . . . . . . . . . . . . . . . . 8A-10
NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS - STANDARD
PROCEDURE, HANDLING . . . . . . . . . . . . . . . 8O-6
NON-MONITORED CIRCUITS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 25-20
NOZZLE - DESCRIPTION, FRONT
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-11
NOZZLE - DESCRIPTION, REAR WASHER . 8R-36
NOZZLE - INSTALLATION, FRONT
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-11
NOZZLE - INSTALLATION, REAR
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-37
NOZZLE - OPERATION, FRONT WASHER . . 8R-11
NOZZLE - OPERATION, REAR WASHER . . . 8R-36
NOZZLE - REMOVAL, FRONT WASHER . . . . 8R-11
NOZZLE - REMOVAL, REAR WASHER . . . . 8R-36
NUMBER - DESCRIPTION, VEHICLE
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . Intro.-8
NV1500 - ASSEMBLY, MANUAL . . . . . . . . . 21-13
NV1500 - CLEANING, MANUAL . . . . . . . . . . 21-10
NV1500 - DESCRIPTION, MANUAL . . . . . . . . 21-1
NV1500 - DISASSEMBLY, MANUAL . . . . . . . . 21-4
NV1500 - INSPECTION, MANUAL . . . . . . . . . . 21-11
NV1500 - INSTALLATION, EXTENSION
HOUSING SEAL . . . . . . . . . . . . . . . . . . . . . . 21-32
NV1500 - INSTALLATION, MANUAL . . . . . . 21-29
NV1500 - MANUAL . . . . . . . . . . . . . . . . . . . 21-30
NV1500 - OPERATION, MANUAL . . . . . . . . . . 21-1
NV1500 - REMOVAL, EXTENSION
HOUSING SEAL . . . . . . . . . . . . . . . . . . . . . . 21-32
NV1500 - REMOVAL, MANUAL . . . . . . . . . . . 21-3
NV1500 - SPECIFICATIONS . . . . . . . . . . . . . 21-30
NV231 - ASSEMBLY, TRANSFER CASE . . . 21-194
NV231 - CLEANING, TRANSFER CASE . . . 21-190
NV231 - DESCRIPTION, TRANSFER CASE . . . 0-3
NV231 - DESCRIPTION, TRANSFER CASE . 21-178
NV231 - DIAGNOSIS AND TESTING,
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-180
NV231 - DISASSEMBLY, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-182
NV231 - INSPECTION, TRANSFER CASE . . 21-190
NV231 - INSTALLATION, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-205
NV231 - OPERATION, TRANSFER CASE . . 21-179
NV231 - REMOVAL, TRANSFER CASE . . . . 21-181
NV231 - TRANSFER CASE . . . . . . . . . . . . . 21-206
NV242 - ASSEMBLY, TRANSFER CASE . . . 21-230
NV242 - CLEANING, TRANSFER CASE . . . 21-227
NV242 - DESCRIPTION, TRANSFER CASE . . . 0-3
NV242 - DESCRIPTION, TRANSFER CASE . 21-215
NV242 - DIAGNOSIS AND TESTING,
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-216
NV242 - DISASSEMBLY, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-218
NV242 - INSPECTION, TRANSFER CASE . . 21-228
NV242 - INSTALLATION, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-243
NV242 - OPERATION, TRANSFER CASE . . 21-215
NV242 - REMOVAL, TRANSFER CASE . . . . 21-217
NV242 - TRANSFER CASE . . . . . . . . . . . . . 21-244
NV242 TRANSFER CASE,
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 21-244
NV3550 - ASSEMBLY, MANUAL . . . . . . . . . 21-48
NV3550 - CLEANING, MANUAL . . . . . . . . . . 21-46
NV3550 - DESCRIPTION, MANUAL . . . . . . . 21-33
NV3550 - DISASSEMBLY, MANUAL . . . . . . . 21-35
NV3550 - INSPECTION, MANUAL . . . . . . . . 21-46
HOUSING BUSHING. . . . . . . . . . . . . . . . . . . 21-74
HOUSING SEAL . . . . . . . . . . . . . . . . . . . . . . 21-74
NV3550 - INSTALLATION, MANUAL . . . . . . 21-70
NV3550 - MANUAL . . . . . . . . . . . . . . . . . . . 21-71
NV3550 - OPERATION, MANUAL . . . . . . . . . 21-33
HOUSING BUSHING. . . . . . . . . . . . . . . . . . . 21-73
HOUSING SEAL . . . . . . . . . . . . . . . . . . . . . . 21-74
NV3550 - REMOVAL, MANUAL . . . . . . . . . . 21-34
ODOMETER - DESCRIPTION . . . . . . . . . . . . 8J -25
ODOMETER - OPERATION . . . . . . . . . . . . . . 8J -25
OFF INDICATOR - DESCRIPTION,
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . . 8J -26
OFF INDICATOR - OPERATION,
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . . 8J -26
OIL - DESCRIPTION, REFRIGERANT . . . . . . 24-53
OIL - OPERATION, REFRIGERANT . . . . . . . . 24-54
OIL - STANDARD PROCEDURE, ENGINE . . . . 9-61
OIL FILTER - INSTALLATION . . . . . . . . . . . . . 9-63
OIL FILTER - REMOVAL . . . . . . . . . . . . . . . . . 9-63
OIL GALLERY PLUGS - STANDARD
PROCEDURE, ENGINE CORE . . . . . . . . . . . . . 9-10
OIL LEAK - DIAGNOSIS AND TESTING,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
OIL LEVEL - STANDARD PROCEDURE,
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . 24-54
OIL PAN - CLEANING . . . . . . . . . . . . . . . . . . 9-63
OIL PAN - DESCRIPTION . . . . . . . . . . . . . . . . 9-63
OIL PAN - INSPECTION . . . . . . . . . . . . . . . . . 9-63
OIL PAN - INSTALLATION . . . . . . . . . . . . . . . 9-64
OIL PAN - REMOVAL . . . . . . . . . . . . . . . . . . . 9-63
OIL PRESSURE - DIAGNOSIS AND
TESTING, ENGINE . . . . . . . . . . . . . . . . . . . . . 9-60
OIL PRESSURE INDICATOR -
DESCRIPTION, LOW . . . . . . . . . . . . . . . . . . 8J -23
OIL PRESSURE INDICATOR -
OPERATION, LOW . . . . . . . . . . . . . . . . . . . . 8J -23
OIL PRESSURE SENSOR/SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 9-65
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 9-65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
OIL PUMP - ASSEMBLY . . . . . . . . . . . . . . . . 9-67
OIL PUMP - ASSEMBLY . . . . . . . . . . . . . . 21-151
OIL PUMP - CLEANING . . . . . . . . . . . . . . . 21-150
OIL PUMP - DESCRIPTION . . . . . . . . . . . . 21-147
OIL PUMP - DISASSEMBLY . . . . . . . . . . . . . 9-65
OIL PUMP - DISASSEMBLY . . . . . . . . . . . . 21-149
OIL PUMP - INSPECTION . . . . . . . . . . . . . . . 9-66
OIL PUMP - INSPECTION . . . . . . . . . . . . . 21-150
OIL PUMP - INSTALLATION . . . . . . . . . . . . . 9-67
OIL PUMP - OPERATION . . . . . . . . . . . . . . 21-147
OIL PUMP - REMOVAL . . . . . . . . . . . . . . . . . 9-65
OIL PUMP FRONT SEAL - INSTALLATION . 21-152
OIL PUMP FRONT SEAL - REMOVAL . . . . 21-152
OIL PUMP VOLUME CHECK - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-148
OIL SEAL - FRONT - INSTALLATION,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 9-47
OIL SEAL - FRONT - REMOVAL,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 9-46
OIL SEAL - REAR - INSTALLATION,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 9-48
OIL SEAL - REAR - REMOVAL,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 9-48
ON-BOARD DIAGNOSTICS (OBD) -
ON/OFF RELAY - DESCRIPTION, WIPER . . . 8R-25
ON/OFF RELAY - DIAGNOSIS AND
TESTING, WIPER. . . . . . . . . . . . . . . . . . . . . 8R-26
ON/OFF RELAY - INSTALLATION, WIPER . . 8R-26
ON/OFF RELAY - OPERATION, WIPER . . . . 8R-25
ON/OFF RELAY - REMOVAL, WIPER . . . . . . 8R-26
OPEN-CIRCUIT VOLTAGE TEST -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8F-12
OPENING DIMENSIONS -
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 23-111
OPENING FLARE MOLDINGS -
INSTALLATION, FRONT WHEEL . . . . . . . . . 23-145
INSTALLATION, REAR WHEEL . . . . . . . . . . 23-145
REMOVAL, FRONT WHEEL . . . . . . . . . . . . 23-145
REMOVAL, REAR WHEEL . . . . . . . . . . . . . 23-145
OPENING REINFORCEMENT -
INSTALLATION, GRILLE. . . . . . . . . . . . . . . 23-142
OPENING REINFORCEMENT - REMOVAL,
GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-142
OPENING TRIM LACE - INSTALLATION . . . 23-180
OPENING TRIM LACE - REMOVAL . . . . . . 23-180
OPENING WEATHERSTRIP -
INSTALLATION, SWING GATE . . . . . . . . . . 23-186
OPENING WEATHERSTRIP - REMOVAL,
SWING GATE . . . . . . . . . . . . . . . . . . . . . . . 23-186
KJ INDEX 17
OPERATION - DESCRIPTION, MODES OF . . 8E-11
OPERATION - DIAGNOSIS AND TESTING,
AIR CHECKING TRANSMISSION
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-80
ORDER, 2.4L 4-CYLINDER - ENGINE
FIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-2
ORDER, 3.7L V-6 - ENGINE FIRING . . . . . . . . 8I-2
ORIFICE TUBE - DESCRIPTION, A/C . . . . . . 24-50
ORIFICE TUBE - INSTALLATION, A/C . . . . . . 24-50
ORIFICE TUBE - OPERATION, A/C . . . . . . . . 24-50
ORIFICE TUBE - REMOVAL, A/C . . . . . . . . . 24-50
ORVR - DESCRIPTION . . . . . . . . . . . . . . . . . 25-29
ORVR - OPERATION . . . . . . . . . . . . . . . . . . 25-29
OUT - ADJ USTMENT, LOCK . . . . . . . . . . . . . . 5-30
OUTBOARD SEAT BELT & RETRACTOR -
INSTALLATION, REAR . . . . . . . . . . . . . . . . . 8O-34
OUTBOARD SEAT BELT & RETRACTOR -
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 8O-33
OUTER BELT MOLDING - INSTALLATION,
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . 23-186
OUTER BELT MOLDING - INSTALLATION,
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . 23-186
OUTER BELT MOLDING - REMOVAL,
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . 23-186
OUTER BELT MOLDING - REMOVAL,
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . 23-186
OUTER TIE ROD END REMOVAL TOOL,
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . 19-15
OUTLET - DESCRIPTION, CIGAR
LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-2
OUTLET - DESCRIPTION, POWER . . . . . . 8W-97-11
OUTLET - DIAGNOSIS AND TESTING,
CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . 8W-97-2
OUTLET - DIAGNOSIS AND TESTING,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-11
OUTLET - INSTALLATION, POWER . . . . 8W-97-13
OUTLET - OPERATION, CIGAR LIGHTER . 8W-97-2
OUTLET - OPERATION, POWER . . . . . . 8W-97-11
OUTLET - REMOVAL, POWER . . . . . . . . 8W-97-12
OUTLET BARRELS - INSTALLATION,
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-29
OUTLET BARRELS - REMOVAL, PANEL . . . 24-29
OUTLETS - DESCRIPTION, DEMISTER . . . . 24-29
OUTPUT - DESCRIPTION, PCM . . . . . . . . . . . 8I-4
OUTPUT - OPERATION, PCM . . . . . . . . . . . . 14-33
OUTPUT - OPERATION, PCM . . . . . . . . . . . . . 8I-4
OUTPUT SHAFT SEAL - INSTALLATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . 21-208,21-246
OUTPUT SHAFT SEAL - INSTALLATION,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-212
OUTPUT SHAFT SEAL - REMOVAL,
FRONT . . . . . . . . . . . . . . . . . . . . . . 21-208,21-246
OUTPUT SHAFT SEAL - REMOVAL, REAR . 21-210
OUTPUT SPEED SENSOR - DESCRIPTION . 21-152
OUTPUT SPEED SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-152
OUTPUT SPEED SENSOR - OPERATION . . 21-152
OUTPUT SPEED SENSOR - REMOVAL . . . 21-152
OVERDRIVE OFF INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -26
OVERDRIVE OFF INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -26
OVERDRIVE SWITCH - DESCRIPTION . . . . 21-153
OVERDRIVE SWITCH - OPERATION . . . . . 21-153
OVERHEAD CONSOLE - DESCRIPTION . . . . 8M-1
OVERHEAD CONSOLE - OPERATION . . . . . . 8M-2
OVERHEAD CONSOLE, REMOVAL . . . . . . . . 8M-4
OVERRIDE RELAY - DESCRIPTION,
CLUTCH SWITCH. . . . . . . . . . . . . . . . . . . . . . 6-10
OVERRIDE RELAY - INSTALLATION,
CLUTCH SWITCH. . . . . . . . . . . . . . . . . . . . . . 6-10
OVERRIDE RELAY - OPERATION,
CLUTCH SWITCH. . . . . . . . . . . . . . . . . . . . . . 6-10
OVERRIDE RELAY - REMOVAL, CLUTCH
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
OXYGEN SENSOR - DESCRIPTION . . . . . . . 14-40
OXYGEN SENSOR - INSTALLATION . . . . . . . 14-43
OXYGEN SENSOR - OPERATION . . . . . . . . . 14-40
OXYGEN SENSOR - REMOVAL . . . . . . . . . . 14-41
PADS - INSTALLATION, FRONT BRAKE . . . . . 5-11
PADS - REMOVAL, FRONT BRAKE . . . . . . . . 5-11
PAINT CODE - DESCRIPTION . . . . . . . . . . 23-162
PAINT CODES - SPECIFICATIONS . . . . . . . 23-162
PAINT TOUCH-UP - DESCRIPTION . . . . . . 23-163
PAN - CLEANING, OIL . . . . . . . . . . . . . . . . . . 9-63
PAN - DESCRIPTION, OIL . . . . . . . . . . . . . . . 9-63
PAN - INSPECTION, OIL . . . . . . . . . . . . . . . . 9-63
PAN - INSTALLATION, OIL . . . . . . . . . . . . . . . 9-64
PAN - REMOVAL, OIL . . . . . . . . . . . . . . . . . . 9-63
PANEL - DESCRIPTION, LATCH - ACCESS . 23-139
PANEL - INSTALLATION, GLASS . . . . . . . . 23-178
PANEL - INSTALLATION, LATCH -
ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-139
PANEL - INSTALLATION, QUARTER TRIM . 23-159
PANEL - INSTALLATION, TRIM . . . 23-126,23-132,
23-138
PANEL - REMOVAL, GLASS . . . . . . . . . . . . 23-178
PANEL - REMOVAL, LATCH - ACCESS . . . 23-139
PANEL - REMOVAL, QUARTER TRIM . . . . 23-159
PANEL - REMOVAL, TRIM . 23-125,23-132,23-138
PANEL ADJ USTMENT, ADJ USTMENTS -
SUNROOF GLASS . . . . . . . . . . . . . . . . . . . 23-178
PANEL ANTENNA CABLE -
INSTALLATION, INSTRUMENT. . . . . . . . . . . . 8A-8
PANEL ANTENNA CABLE - REMOVAL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . 8A-7
PANEL ASSEMBLY - INSTALLATION,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-151
PANEL ASSEMBLY - REMOVAL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-149
PANEL CENTER BEZEL - INSTALLATION,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-154
PANEL CENTER BEZEL - REMOVAL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-154
PANEL DOOR - INSTALLATION . . . . . . . . . . 24-36
PANEL DOOR ACTUATOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-25
PANEL DOOR ACTUATOR - REMOVAL . . . . 24-24
PANEL DRIVER SIDE BEZELS -
INSTALLATION, INSTRUMENT . . . . . . . . . . 23-154
PANEL DRIVER SIDE BEZELS -
REMOVAL, INSTRUMENT . . . . . . . . . . . . . 23-153
PANEL END CAP - INSTALLATION,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-153
PANEL END CAP - REMOVAL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-153
PANEL OUTLET BARRELS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-29
PANEL OUTLET BARRELS - REMOVAL . . . . 24-29
PANEL PASSENGER SIDE BEZEL -
INSTALLATION, INSTRUMENT . . . . . . . . . . 23-154
PANEL PASSENGER SIDE BEZEL -
REMOVAL, INSTRUMENT . . . . . . . . . . . . . 23-154
PANEL SEAL - INSTALLATION, GLASS . . . 23-178
PANEL SEAL - REMOVAL, GLASS . . . . . . . 23-178
PANEL TOP COVER - INSTALLATION,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-153
PANEL TOP COVER - REMOVAL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . 23-152
PARK - INTERLOCK CABLE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-153
PARK - INTERLOCK CABLE - REMOVAL . . 21-153
PARK LAMP RELAY - DESCRIPTION . . . . . . 8L-54
PARK LAMP RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-55
PARK LAMP RELAY - INSTALLATION . . . . . 8L-56
PARK LAMP RELAY - OPERATION . . . . . . . 8L-54
PARK LAMP RELAY - REMOVAL . . . . . . . . . 8L-55
PARK RAMP - INSTALLATION, WIPER
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
PARK RAMP - REMOVAL, WIPER ARM . . . 8R-43
PARKING BRAKE - DESCRIPTION . . . . . . . . . 5-29
PARKING BRAKE - OPERATION . . . . . . . . . . . 5-29
PARK-INTERLOCK CABLE -
ADJ USTMENTS . . . . . . . . . . . . . . . . . . . . . 21-154
PART TIME INDICATOR - DESCRIPTION . . . 8J -29
PART TIME INDICATOR - OPERATION . . . . . 8J -29
PASSENGER AIRBAG - DESCRIPTION . . . . 8O-27
PASSENGER AIRBAG - INSTALLATION . . . . 8O-29
PASSENGER AIRBAG - OPERATION . . . . . . 8O-27
PASSENGER AIRBAG - REMOVAL . . . . . . . . 8O-28
PASSENGER AIRBAG DOOR -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-30
PASSENGER AIRBAG DOOR - REMOVAL . . 8O-29
PASSENGER AIRBAG MOUNTING
BRACKET - INSTALLATION . . . . . . . . . . . . . 8O-31
PASSENGER AIRBAG MOUNTING
BRACKET - REMOVAL . . . . . . . . . . . . . . . . . 8O-31
PASSENGER SEAT HEATER SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8G-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8G-15
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8G-14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-15
PASSENGER SIDE BEZEL -
INSTALLATION, INSTRUMENT PANEL . . . . 23-154
PASSENGER SIDE BEZEL - REMOVAL,
PATTERNS - DIAGNOSIS AND TESTING,
TIRE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
PCM - DESCRIPTION . . . . . . . . . . . . . . . . . . 8E-11
PCM - OPERATION . . . . . . . . . . . . . . . . . . . 8E-14
PCM INPUT - OPERATION, ASD SENSE . . . . . 8I-4
PCM OUTPUT - DESCRIPTION . . . . . . . . . . . . 8I-4
PCM OUTPUT - OPERATION . . . . . . . . . . . . 14-33
PCM OUTPUT - OPERATION . . . . . . . . . . . . . 8I-4
PCM/SKIM PROGRAMMING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-1
PCV VALVE - DESCRIPTION . . . . . . . . . . . . 25-29
PCV VALVE - DIAGNOSIS AND TESTING . . . 25-31
PCV VALVE - INSTALLATION . . . . . . . . . . . . 25-32
PCV VALVE - OPERATION . . . . . . . . . . . . . . 25-31
PCV VALVE - REMOVAL . . . . . . . . . . . . . . . 25-32
PEDAL - DESCRIPTION . . . . . . . . . . . . . . . . . 5-20
PEDAL - INSTALLATION . . . . . . . . . . . . . . . . 5-20
PEDAL - INSTALLATION, ACCELERATOR . . . 14-30
PEDAL - INSTALLATION, CLUTCH . . . . . . . . . 6-10
PEDAL - OPERATION . . . . . . . . . . . . . . . . . . . 5-20
PEDAL - REMOVAL . . . . . . . . . . . . . . . . . . . . 5-20
PEDAL - REMOVAL, ACCELERATOR . . . . . . 14-29
PEDAL - REMOVAL, CLUTCH . . . . . . . . . . . . 6-10
PEDAL POSITION SWITCH -
DESCRIPTION, CLUTCH. . . . . . . . . . . . . . . . . 6-11
PEDAL POSITION SWITCH - DIAGNOSIS
AND TESTING, CLUTCH. . . . . . . . . . . . . . . . . 6-11
PEDAL POSITION SWITCH - OPERATION,
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
PERFORMANCE - DIAGNOSIS AND
TESTING, A/C . . . . . . . . . . . . . . . . . . . . . . . . 24-2
TESTING, HEATER . . . . . . . . . . . . . . . . . . . . . 24-6
PILOT BEARING - INSTALLATION . . . . . . . . . . 6-8
PILOT BEARING - REMOVAL . . . . . . . . . . . . . . 6-8
PINION GEAR/RING GEAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 3-46
PINION GEAR/RING GEAR - REMOVAL . . . . . 3-44
PINION GEAR/RING GEAR/TONE RING -
INSTALLATION. . . . . . . . . . . . . . . . . . . 3-112,3-82
PINION GEAR/RING GEAR/TONE RING -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . 3-110,3-79
PINION SEAL - INSTALLATION . . 3-103,3-39,3-68
PINION SEAL - REMOVAL . . . . . . 3-102,3-38,3-68
PIPE - INSTALLATION, CROSS-OVER . . . . . . 11-3
PIPE - REMOVAL, CROSS-OVER . . . . . . . . . . 11-3
PISTON & CONNECTING ROD -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 9-49
PISTON FITTING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
PISTON RING FITTING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
PISTONS - DESCRIPTION . . . . . . . . . . . . . 21-155
PISTONS - OPERATION . . . . . . . . . . . . . . . 21-155
PLANETARY GEARTRAIN - ASSEMBLY . . . 21-160
PLANETARY GEARTRAIN - CLEANING . . . . 21-159
PLANETARY GEARTRAIN - DESCRIPTION . 21-157
PLANETARY GEARTRAIN -
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-159
PLANETARY GEARTRAIN - INSPECTION . . 21-159
PLANETARY GEARTRAIN - OPERATION . . 21-157
PLATE - INSTALLATION, DOOR SILL
SCUFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-157
PLATE - INSTALLATION, FLEX . . . . . . . . . . . . 9-49
PLATE - INSTALLATION, FRONT SKID . . . . . . 13-6
PLATE - INSTALLATION, FUEL TANK
SKID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
PLATE - INSTALLATION, REAR DOOR
SCUFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-160
PLATE - INSTALLATION, TRANSFER
CASE SKID . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
PLATE - REMOVAL, DOOR SILL SCUFF . . . 23-157
PLATE - REMOVAL, FLEX . . . . . . . . . . . . . . . 9-49
PLATE - REMOVAL, FRONT SKID . . . . . . . . . 13-6
PLATE - REMOVAL, FUEL TANK SKID . . . . . . 13-9
PLATE - REMOVAL, REAR DOOR SCUFF . . 23-160
PLATE - REMOVAL, TRANSFER CASE
SKID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
PLATE LAMP BULB - INSTALLATION,
LICENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-45
PLATE LAMP BULB - REMOVAL,
LICENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-44
18 INDEX KJ
PLATE LAMP UNIT - INSTALLATION,
LICENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-46
PLATE LAMP UNIT - REMOVAL, LICENSE . . 8L-45
PLATES - INSTALLATION, EXTERIOR
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-141
PLATES - REMOVAL, EXTERIOR NAME . . . 23-140
PLUG - CLEANING SPARK PLUGS,
SPARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-15
PLUG - DESCRIPTION, SPARK . . . . . . . . . . . 8I-12
PLUG - INSTALLATION, SPARK . . . . . . . . . . 8I-15
PLUG - OPERATION, SPARK . . . . . . . . . . . . 8I-12
PLUG - REMOVAL, SPARK . . . . . . . . . . . . . . 8I-15
PLUG CABLE RESISTANCE, 2.4L - SPARK . . . 8I-3
PLUG CONDITIONS - DIAGNOSIS AND
TESTING, SPARK . . . . . . . . . . . . . . . . . . . . . 8I-13
PLUGS - STANDARD PROCEDURE,
ENGINE CORE AND OIL GALLERY . . . . . . . . 9-10
PLUGS, SPARK PLUG - CLEANING
SPARK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-15
PLUGS, SPECIFICATIONS - SPARK . . . . . . . . 8I-3
POLISHING - DESCRIPTION, FINESSE
SANDING/BUFFING . . . . . . . . . . . . . . . . . . 23-163
PORT - DESCRIPTION, REFRIGERANT
SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . 24-2
PORT - OPERATION, REFRIGERANT
SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . 24-2
POSITION LAMP BULB - INSTALLATION,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
POSITION LAMP BULB - REMOVAL,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-28
POSITION SENSOR - DESCRIPTION. 21-209,21-247
POSITION SENSOR - DESCRIPTION,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-30
POSITION SENSOR - DESCRIPTION,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
POSITION SENSOR - INSTALLATION . . . . 21-210,
21-247
POSITION SENSOR - INSTALLATION,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-32
POSITION SENSOR - INSTALLATION,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-48
POSITION SENSOR - OPERATION . 21-209,21-247
POSITION SENSOR - OPERATION,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-31
POSITION SENSOR - OPERATION,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
POSITION SENSOR - REMOVAL . . 21-210,21-247
POSITION SENSOR - REMOVAL,
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-31
POSITION SENSOR - REMOVAL,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
POSITION SWITCH - DESCRIPTION,
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . 6-11
POSITION SWITCH - DIAGNOSIS AND
TESTING, CLUTCH PEDAL . . . . . . . . . . . . . . . 6-11
POSITION SWITCH - OPERATION,
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . 6-11
POTENTIAL - STANDARD PROCEDURE,
TESTING OF VOLTAGE . . . . . . . . . . . . . . 8W-01-9
POWER BRAKE BOOSTER -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 5-21
POWER BRAKE BOOSTER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5-23
POWER BRAKE BOOSTER - OPERATION . . . 5-21
POWER BRAKE BOOSTER - REMOVAL . . . . . 5-22
POWER DISTRIBUTION - DESCRIPTION . 8W-97-1
POWER DISTRIBUTION - OPERATION . . 8W-97-1
POWER DISTRIBUTION CENTER -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 8W-97-6
OPERATION. . . . . . . . . . . . . . . . . . . . . . . 8W-97-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-7
POWER DISTRIBUTION CENTER
ASSEMBLY, ASSEMBLY . . . . . . . . . . . . . 8W-97-10
POWER DISTRIBUTION CENTER
DISASSEMBLY, DISASSEMBLY . . . . . . . . 8W-97-7
POWER DISTRIBUTION SYSTEMS,
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . 8W-97-2
POWER GROUNDS - DESCRIPTION . . . . . . 8E-13
POWER LOCKS - DESCRIPTION . . . . . . . . . . 8N-1
POWER LOCKS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-3
POWER LOCKS - OPERATION . . . . . . . . . . . . 8N-3
POWER MIRROR SWITCH - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8N-12
POWER MIRROR SWITCH -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-13
POWER MIRROR SWITCH - REMOVAL . . . 8N-13
POWER MIRRORS - DESCRIPTION . . . . . . 8N-11
POWER MIRRORS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-11
POWER MIRRORS - OPERATION . . . . . . . . 8N-11
POWER OUTLET - DESCRIPTION . . . . . 8W-97-11
POWER OUTLET - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-11
POWER OUTLET - INSTALLATION . . . . 8W-97-13
POWER OUTLET - OPERATION . . . . . . . 8W-97-11
POWER OUTLET - REMOVAL . . . . . . . . 8W-97-12
POWER SEAT SWITCH - DESCRIPTION,
LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-16
POWER SEAT SWITCH - DESCRIPTION,
RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
POWER SEAT SWITCH - DIAGNOSIS
AND TESTING, LEFT . . . . . . . . . . . . . . . . . . 8N-17
POWER SEAT SWITCH - DIAGNOSIS
AND TESTING, RIGHT . . . . . . . . . . . . . . . . . 8N-19
POWER SEAT SWITCH - INSTALLATION,
LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-18
POWER SEAT SWITCH - INSTALLATION,
RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
POWER SEAT SWITCH - OPERATION,
LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-17
POWER SEAT SWITCH - OPERATION,
RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
POWER SEAT SWITCH - REMOVAL, LEFT . 8N-18
POWER SEAT SWITCH - REMOVAL,
RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
POWER SEATS - DESCRIPTION. . . . . . . . . . . 8N-14
POWER SEATS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-15
POWER SEATS - OPERATION . . . . . . . . . . . 8N-15
POWER STEERING FLOW AND
PRESSURE - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-3
POWER STEERING PRESSURE SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 19-22
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 19-22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 19-22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 19-22
POWER STEERING PUMP - INITIAL
OPERATION - STANDARD PROCEDURE . . . 19-18
POWER STEERING PUMP, SPECIAL
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
POWER STEERING SYSTEM -
POWER WINDOWS - DESCRIPTION . . . . . . 8N-21
POWER WINDOWS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-21
POWER WINDOWS - OPERATION . . . . . . . . 8N-21
POWERED - STARTER MOTOR, GAS . . . . . . 8F-39
POWERED - TORQUE, GAS . . . . . . . . . . . . . 8F-38
POWERING SEVERAL LOADS -
FOR A SHORT TO GROUND ON FUSES . 8W-01-9
PRECAUTIONS - CAUTION,
REFRIGERANT HOSES/LINES/TUBES. . . . . . 24-40
PRECAUTIONS - OPERATION, SERVICE . . . . 19-5
PRECAUTIONS AND WARNINGS,
WARNING - SAFETY . . . . . . . . . . . . . . . . . . . 23-1
PRECAUTIONS, WARNING -
WINDSHIELD SAFETY . . . . . . . . . . . . . . . . 23-173
PREFERENCES - STANDARD
PROCEDURE, RKE TRANSMITTER
CUSTOMER . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-8
PRELIMINARY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-78
PRELIMINARY CHECKS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
PREPARATION - STANDARD
PROCEDURE, ENGINE GASKET
SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
PRESS CONTAINER - DESCRIPTION,
COOLANT RECOVERY . . . . . . . . . . . . . . . . . . 7-19
PRESS CONTAINER - OPERATION,
COOLANT RECOVERY . . . . . . . . . . . . . . . . . . 7-19
PRESSURE - DIAGNOSIS AND TESTING,
CYLINDER COMPRESSION . . . . . . . . . . . . . . . 9-8
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
POWER STEERING FLOW . . . . . . . . . . . . . . . 19-3
PRESSURE BLEEDING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
PRESSURE CAP - CLEANING, RADIATOR . . . 7-25
PRESSURE CAP - DESCRIPTION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
PRESSURE CAP - DIAGNOSIS AND
TESTING, RADIATOR . . . . . . . . . . . . . . . . . . . 7-25
PRESSURE CAP - INSPECTION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
PRESSURE CAP - OPERATION,
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
PRESSURE HOSE - INSTALLATION . . . . . . . 19-21
PRESSURE HOSE - REMOVAL . . . . . . . . . . 19-21
PRESSURE INDICATOR - DESCRIPTION,
LOW OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -23
PRESSURE INDICATOR - OPERATION,
LOW OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -23
PRESSURE LEAK DOWN TEST -
DIAGNOSIS AND TESTING, FUEL . . . . . . . . . 14-3
PRESSURE LEAKAGE - DIAGNOSIS AND
TESTING, CYLINDER COMBUSTION . . . . . . . . 9-8
PRESSURE (LP) SENSOR -
DESCRIPTION, LINE . . . . . . . . . . . . . . . . . 21-144
PRESSURE (LP) SENSOR -
INSTALLATION, LINE . . . . . . . . . . . . . . . . . 21-144
PRESSURE (LP) SENSOR - OPERATION,
LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-144
PRESSURE (LP) SENSOR - REMOVAL,
LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-144
PRESSURE REGULATOR - DESCRIPTION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
PRESSURE REGULATOR -
INSTALLATION, FUEL. . . . . . . . . . . . . . . . . . . 14-14
PRESSURE REGULATOR - OPERATION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
PRESSURE REGULATOR - REMOVAL,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
PRESSURE RELEASE - STANDARD
PROCEDURE, FUEL SYSTEM. . . . . . . . . . . . . 14-4
PRESSURE RELIEF VALVE -
DESCRIPTION, HIGH . . . . . . . . . . . . . . . . . . 24-42
PRESSURE RELIEF VALVE - OPERATION,
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
PRESSURE SENSOR/SWITCH -
DESCRIPTION, OIL . . . . . . . . . . . . . . . . . . . . 9-65
INSTALLATION, OIL . . . . . . . . . . . . . . . . . . . . 9-65
OPERATION, OIL . . . . . . . . . . . . . . . . . . . . . . 9-65
REMOVAL, OIL . . . . . . . . . . . . . . . . . . . . . . . 9-65
PRESSURE, SPECIFICATIONS - FUEL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
PRESSURE SWITCH - DESCRIPTION, A/C
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-17
PRESSURE SWITCH - DESCRIPTION, A/C
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - DESCRIPTION,
POWER STEERING . . . . . . . . . . . . . . . . . . . 19-22
PRESSURE SWITCH - DIAGNOSIS AND
TESTING, A/C HIGH. . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - DIAGNOSIS AND
TESTING, A/C LOW . . . . . . . . . . . . . . . . . . . 24-19
PRESSURE SWITCH - INSTALLATION,
A/C HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
A/C LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
POWER STEERING . . . . . . . . . . . . . . . . . . . 19-22
PRESSURE SWITCH - OPERATION, A/C
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - OPERATION, A/C
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - OPERATION,
POWER STEERING . . . . . . . . . . . . . . . . . . . 19-22
PRESSURE SWITCH - REMOVAL, A/C
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
PRESSURE SWITCH - REMOVAL, A/C
LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
PRESSURE SWITCH - REMOVAL,
POWER STEERING . . . . . . . . . . . . . . . . . . . 19-22
PRESSURE TEST - DIAGNOSIS AND
PRESSURE TEST - DIAGNOSIS AND
TESTING, HYDRAULIC. . . . . . . . . . . . . . . . . 21-79
PRIMARY WEATHERSTRIP -
INSTALLATION, DOOR . . . . . . . . . . . . . . . . 23-185
KJ INDEX 19
PRIMARY WEATHERSTRIP - REMOVAL,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-185
PROGRAMING - STANDARD
PROCEDURE, RKE TRANSMITTER . . . . . . . . 8N-9
PROGRAMMING - STANDARD
PROCEDURE, PCM/SKIM. . . . . . . . . . . . . . . . 8E-1
PROCEDURE, SENTRY KEY
TRANSPONDER. . . . . . . . . . . . . . . . . . . . . . . 8Q-8
PROPELLER SHAFT - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PROPELLER SHAFT - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 3-6
PROPELLER SHAFT - FRONT - REMOVAL . . . 3-6
PROPELLER SHAFT - REAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 3-7
PROPELLER SHAFT - REAR - REMOVAL . . . . 3-7
PROPELLER SHAFT ANGLE - STANDARD
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
PROPELLER SHAFT, SPECIFICATIONS . . . . . . . 3-6
PROPORTIONING VALVE - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 5-20
PULLEY - DESCRIPTION, GENERATOR
DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . 8F-26
PULLEY - INSTALLATION . . . . . . . . . . . . . . 19-23
PULLEY - INSTALLATION, GENERATOR
DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . 8F-30
PULLEY - OPERATION, GENERATOR
DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
PULLEY - REMOVAL . . . . . . . . . . . . . . . . . . 19-23
PULLEY - REMOVAL, GENERATOR
DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . 8F-27
PUMP - ASSEMBLY, OIL . . . . . . . . . . . . . . . . 9-67
PUMP - ASSEMBLY, OIL . . . . . . . . . . . . . . 21-151
PUMP - CLEANING, OIL . . . . . . . . . . . . . . 21-150
PUMP - DESCRIPTION . . . . . . . . . . . . . . . . 19-17
PUMP - DESCRIPTION, FUEL . . . . . . . . . . . 14-15
PUMP - DESCRIPTION, LEAK DETECTION . 25-27
PUMP - DESCRIPTION, OIL . . . . . . . . . . . . 21-147
PUMP - DESCRIPTION, WATER . . . . . . . . . . 7-29
PUMP - DISASSEMBLY, OIL . . . . . . . . . . . . . 9-65
PUMP - DISASSEMBLY, OIL . . . . . . . . . . . 21-149
PUMP - INITIAL OPERATION -
STANDARD PROCEDURE, POWER
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 19-18
PUMP - INSPECTION, OIL . . . . . . . . . . . . . . . 9-66
PUMP - INSPECTION, OIL . . . . . . . . . . . . . 21-150
PUMP - INSTALLATION, LEAK
DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . 25-28
PUMP - INSTALLATION, OIL . . . . . . . . . . . . . 9-67
PUMP - OPERATION . . . . . . . . . . . . . . . . . . 19-17
PUMP - OPERATION, FUEL . . . . . . . . . . . . . 14-15
PUMP - OPERATION, LEAK DETECTION . . . 25-28
PUMP - OPERATION, OIL . . . . . . . . . . . . . 21-147
PUMP - OPERATION, WATER . . . . . . . . . . . . 7-30
PUMP - REMOVAL, LEAK DETECTION . . . . 25-28
PUMP - REMOVAL, OIL . . . . . . . . . . . . . . . . . 9-65
PUMP AMPERAGE TEST - DIAGNOSIS
AND TESTING, FUEL . . . . . . . . . . . . . . . . . . 14-16
PUMP CAPACITY TEST - DIAGNOSIS
AND TESTING, FUEL . . . . . . . . . . . . . . . . . . 14-15
PUMP FRONT SEAL - INSTALLATION,
OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
PUMP FRONT SEAL - REMOVAL, OIL . . . . 21-152
PUMP MODULE - DESCRIPTION, FUEL . . . . 14-18
PUMP MODULE - INSTALLATION, FUEL . . . 14-19
PUMP MODULE - OPERATION, FUEL . . . . . 14-18
PUMP MODULE - REMOVAL, FUEL . . . . . . . 14-18
PUMP PRESSURE TEST - DIAGNOSIS
AND TESTING, FUEL . . . . . . . . . . . . . . . . . . 14-15
PUMP RELAY - DESCRIPTION, FUEL . . . . . 14-34
PUMP RELAY - DIAGNOSIS AND
TESTING, FUEL . . . . . . . . . . . . . . . . . . . . . . 14-34
PUMP RELAY - INSTALLATION, FUEL . . . . . 14-34
PUMP RELAY - OPERATION, FUEL . . . . . . . 14-34
PUMP RELAY - REMOVAL, FUEL . . . . . . . . 14-34
PUMP RELAYS - DIAGNOSIS AND
TESTING, ASD AND FUEL . . . . . . . . . . . . . . . 8I-4
PUMP, SPECIAL TOOLS - POWER
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
PUMP VOLUME CHECK - STANDARD
PROCEDURE, OIL . . . . . . . . . . . . . . . . . . . 21-148
PUMP/MOTOR - DESCRIPTION, WASHER . 8R-18
PUMP/MOTOR - INSTALLATION,
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-20
PUMP/MOTOR - OPERATION, WASHER . . . 8R-19
PUMP/MOTOR - REMOVAL, WASHER . . . . 8R-19
QUARTER TRIM PANEL - INSTALLATION . 23-159
QUARTER TRIM PANEL - REMOVAL . . . . . 23-159
QUARTER WINDOW - INSTALLATION . . . . 23-172
QUARTER WINDOW - REMOVAL . . . . . . . . 23-172
QUICK CONNECT FITTING -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 14-10
QUICK LEARN - STANDARD
PROCEDURE, TCM . . . . . . . . . . . . . . . . . . . 8E-21
QUICK-CONNECT FITTINGS - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 14-10
RACK - INSTALLATION, LUGGAGE . . . . . . 23-144
RACK - REMOVAL, LUGGAGE . . . . . . . . . . 23-144
RADIAL-PLY TIRES - DESCRIPTION . . . . . . . 22-6
RADIATOR - CLEANING . . . . . . . . . . . . . . . . . 7-24
RADIATOR - DESCRIPTION . . . . . . . . . . . . . . 7-22
RADIATOR - FAN - VISCOUS - CLEANING . . 7-29
RADIATOR - FAN - VISCOUS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 7-27
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 7-29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
RADIATOR - FAN - VISCOUS - REMOVAL . . . 7-28
RADIATOR - INSPECTION . . . . . . . . . . . . . . . 7-24
RADIATOR - INSTALLATION . . . . . . . . . . . . . 7-24
RADIATOR - REMOVAL . . . . . . . . . . . . . . . . . 7-23
RADIATOR CROSSMEMBER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-146
RADIATOR CROSSMEMBER - REMOVAL . 23-146
RADIATOR FAN - ELECTRIC -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 7-26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 7-27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
RADIATOR FAN - ELECTRIC - REMOVAL . . . 7-26
RADIATOR PRESSURE CAP - CLEANING . . . 7-25
RADIATOR PRESSURE CAP -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 7-25
RADIATOR PRESSURE CAP - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 7-25
RADIATOR PRESSURE CAP -
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
RADIATOR PRESSURE CAP - OPERATION . . 7-25
RADIO - DESCRIPTION . . . . . . . . . . . . . . . . . 8A-8
RADIO - INSTALLATION . . . . . . . . . . . . . . . . 8A-9
RADIO - OPERATION . . . . . . . . . . . . . . . . . . . 8A-8
RADIO - REMOVAL . . . . . . . . . . . . . . . . . . . . 8A-9
RADIO NOISE SUPPRESSION GROUND
STRAP - DESCRIPTION. . . . . . . . . . . . . . . . . 8A-9
STRAP - INSTALLATION . . . . . . . . . . . . . . . 8A-11
STRAP - OPERATION . . . . . . . . . . . . . . . . . 8A-10
STRAP - REMOVAL . . . . . . . . . . . . . . . . . . . 8A-10
RAIL - DESCRIPTION, FUEL . . . . . . . . . . . . 14-21
RAIL - INSTALLATION, FUEL . . . . . . . . . . . . 14-24
RAIL - OPERATION, FUEL . . . . . . . . . . . . . . 14-21
RAIL - REMOVAL, FUEL . . . . . . . . . . . . . . . 14-22
RAIL WEATHERSTRIP/RETAINER -
INSTALLATION, SIDE . . . . . . . . . . . . . . . . . 23-186
RAIL WEATHERSTRIP/RETAINER -
REMOVAL, SIDE . . . . . . . . . . . . . . . . . . . . 23-186
RAMP - INSTALLATION, WIPER ARM
PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
RAMP - REMOVAL, WIPER ARM PARK . . . 8R-43
RANGE INDICATOR ILLUMINATION BULB
- INSTALLATION, TRANSMISSION. . . . . . . . 8L-83
RANGE INDICATOR ILLUMINATION BULB
- REMOVAL, TRANSMISSION . . . . . . . . . . . 8L-82
RANGE SENSOR - DESCRIPTION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-168
RANGE SENSOR - OPERATION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-168
RATINGS, GAS ENGINES - GENERATOR . . . 8F-23
RBI AXLE - INSTALLATION, 198 . . . . . . . . . . 5-28
RBI AXLE - REMOVAL, 198 . . . . . . . . . . . . . . 5-27
READING LAMP BULB - INSTALLATION . . . 8L-79
READING LAMP BULB - REMOVAL . . . . . . . 8L-79
READING LAMP SWITCH -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-80
READING LAMP SWITCH - REMOVAL . . . . . 8L-80
READING LAMP UNIT - INSTALLATION . . . 8L-81
READING LAMP UNIT - REMOVAL . . . . . . . 8L-81
REAR - DESCRIPTION . . . . . . . . . . . . . . . . . . 2-16
REAR - INSTALLATION, CRANKSHAFT
OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
REAR - INSTALLATION, PROPELLER
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
REAR - INSTALLATION, SEAT . . . . . . . . . . 23-168
REAR - INSTALLATION, SEAT BACK . . . . . 23-168
REAR - INSTALLATION, SEAT BACK
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-169
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-171
REAR - INSTALLATION, SEAT CUSHION . . 23-171
REAR - REMOVAL, CRANKSHAFT OIL
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
REAR AXLE - 198RBI - DESCRIPTION . . . . . 3-49
REAR AXLE - 198RBI - INSTALLATION . . . . . 3-54
REAR AXLE - 198RBI - OPERATION . . . . . . . 3-49
REAR AXLE - 198RBI - REMOVAL . . . . . . . . 3-54
REAR AXLE - 8 1/4 - ADJ USTMENTS . . . . . . 3-92
REAR AXLE - 8 1/4 - DESCRIPTION . . . . . . . 3-86
REAR AXLE - 8 1/4 - INSTALLATION . . . . . . 3-91
REAR AXLE - 8 1/4 - OPERATION . . . . . . . . . 3-86
REAR AXLE - 8 1/4 - REMOVAL . . . . . . . . . . 3-91
REAR AXLE - SPECIFICATIONS . . . . . . . . . . . 3-62
REAR AXLE, SPECIAL TOOLS . . . . . . . . . . . . 3-63
REAR AXLE, SPECIFICATIONS . . . . . . . . . . . . 3-98
REAR BRAKE HOSE - INSTALLATION . . . . . . 5-10
REAR BRAKE HOSE - REMOVAL . . . . . . . . . . . 5-9
REAR CENTER SEAT BELT &
RETRACTOR - INSTALLATION. . . . . . . . . . . 8O-33
RETRACTOR - REMOVAL . . . . . . . . . . . . . . 8O-32
REAR CHECK VALVE - DESCRIPTION . . . . . 8R-34
REAR CHECK VALVE - INSTALLATION . . . . 8R-35
REAR CHECK VALVE - OPERATION . . . . . . . 8R-34
REAR CHECK VALVE - REMOVAL . . . . . . . . 8R-34
REAR CROSSMEMBER - INSTALLATION . . . . 13-7
REAR CROSSMEMBER - REMOVAL . . . . . . . 13-7
REAR DOOR OUTER BELT MOLDING -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-186
REAR DOOR OUTER BELT MOLDING -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
REAR DOOR SCUFF PLATE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-160
REAR DOOR SCUFF PLATE - REMOVAL . . 23-160
REAR DRUM BRAKE - ADJ USTMENT . . . . . . 5-12
REAR DRUM BRAKE - DESCRIPTION . . . . . . 5-10
REAR DRUM BRAKE - OPERATION . . . . . . . . 5-11
REAR FASCIA - INSTALLATION . . . . . . . . . . . 13-2
REAR FASCIA - REMOVAL . . . . . . . . . . . . . . . 13-2
REAR FASCIA SUPPORT - INSTALLATION . . 13-3
REAR FASCIA SUPPORT - REMOVAL . . . . . . 13-3
REAR FOG LAMP INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -27
REAR FOG LAMP INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -27
REAR FOG LAMP RELAY - DESCRIPTION . . 8L-56
REAR FOG LAMP RELAY - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8L-57
REAR FOG LAMP RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-58
REAR FOG LAMP RELAY - OPERATION . . . 8L-57
REAR FOG LAMP RELAY - REMOVAL . . . . . 8L-58
REAR GLASS HEATING GRID REPAIR -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8G-4
REAR HVAC CONTROL ASSEMBLY
WINDOW DEFOGGER FUNCTION -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8G-9
REAR LAMP BULB - INSTALLATION . . . . . . 8L-59
REAR LAMP BULB - REMOVAL . . . . . . . . . . 8L-58
REAR LAMP UNIT - INSTALLATION . . . . . . 8L-60
REAR LAMP UNIT - REMOVAL . . . . . . . . . . 8L-59
REAR MOUNT - INSTALLATION . . . . . . . . . . 9-57
REAR MOUNT - REMOVAL . . . . . . . . . . . . . . 9-57
REAR OUTBOARD SEAT BELT &
RETRACTOR - INSTALLATION. . . . . . . . . . . 8O-34
REAR OUTBOARD SEAT BELT &
RETRACTOR - REMOVAL . . . . . . . . . . . . . . 8O-33
REAR OUTPUT SHAFT SEAL -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-212
REAR OUTPUT SHAFT SEAL - REMOVAL . 21-210
REAR SEAL AREA LEAKS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 9-61
REAR SEAT BACK LATCH / LOCK -
INSTALLATION, FOLDING . . . . . . . . . . . . . 23-170
REAR SEAT BACK LATCH / LOCK -
REMOVAL, FOLDING . . . . . . . . . . . . . . . . . 23-170
20 INDEX KJ
REAR SEAT BACK LATCH STRIKER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-171
REAR SEAT BACK LATCH STRIKER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
REAR SEAT BELT BUCKLE -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-35
REAR SEAT BELT BUCKLE - REMOVAL . . . 8O-34
REAR SUSPENSION - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
REAR TOW HOOK - INSTALLATION . . . . . . . 13-8
REAR TOW HOOK - REMOVAL . . . . . . . . . . . 13-8
REAR VIEW MIRROR - REMOVAL . . . . . . . 23-161
REAR WASHER HOSES/TUBES -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-35
REAR WASHER HOSES/TUBES -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8R-36
REAR WASHER NOZZLE - DESCRIPTION . . 8R-36
REAR WASHER NOZZLE - INSTALLATION . 8R-37
REAR WASHER NOZZLE - OPERATION . . . . 8R-36
REAR WASHER NOZZLE - REMOVAL . . . . . 8R-36
REAR WHEEL OPENING FLARE
MOLDINGS - INSTALLATION . . . . . . . . . . . 23-145
MOLDINGS - REMOVAL . . . . . . . . . . . . . . 23-145
REAR WHEEL SPEED SENSOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 5-35
REAR WHEEL SPEED SENSOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
REAR WHEELHOUSE SPLASH SHIELD -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-144
REAR WHEELHOUSE SPLASH SHIELD -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-144
REAR WINDOW DEFOGGER -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
REAR WINDOW DEFOGGER -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
REAR WINDOW DEFOGGER GRID -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8G-5
REAR WINDOW DEFOGGER RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8G-6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8G-7
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8G-6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-7
REAR WINDOW DEFOGGER SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8G-8
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8G-8
REAR WINDOW DEFOGGER SYSTEM -
REAR WIPER & WASHER SYSTEM -
CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . 8R-32
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8R-30
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 8R-33
REAR WIPER ARM - DESCRIPTION . . . . . . 8R-37
REAR WIPER ARM - INSTALLATION . . . . . . 8R-38
REAR WIPER ARM - OPERATION . . . . . . . . 8R-38
REAR WIPER ARM - REMOVAL . . . . . . . . . 8R-38
REAR WIPER BLADE - DESCRIPTION . . . . . 8R-39
REAR WIPER BLADE - INSTALLATION . . . . 8R-40
REAR WIPER BLADE - OPERATION . . . . . . 8R-39
REAR WIPER BLADE - REMOVAL . . . . . . . . 8R-40
REAR WIPER MOTOR - DESCRIPTION . . . . 8R-41
REAR WIPER MOTOR - INSTALLATION . . . 8R-42
REAR WIPER MOTOR - OPERATION . . . . . . 8R-41
REAR WIPER MOTOR - REMOVAL . . . . . . . 8R-42
REAR WIPERS/WASHERS -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-27
REAR WIPERS/WASHERS - OPERATION . . 8R-29
REAR WIPER/WASHER SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-43
REAR WIPER/WASHER SWITCH -
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
REARVIEW MIRROR SUPPORT BRACKET
- INSTALLATION . . . . . . . . . . . . . . . . . . . . 23-161
RECEIVER LAMP BULB - INSTALLATION,
ASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-71
RECEIVER LAMP BULB - REMOVAL, ASH . . 8L-71
RECEIVER LAMP UNIT - INSTALLATION,
ASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-72
RECEIVER LAMP UNIT - REMOVAL, ASH . . 8L-72
RECIRC DOOR - INSTALLATION . . . . . . . . . 24-37
RECIRC DOOR - REMOVAL . . . . . . . . . . . . . 24-37
RECIRCULATION DOOR ACTUATOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 24-26
RECIRCULATION DOOR ACTUATOR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-26
RECLINER - FRONT - INSTALLATION,
SEAT BACK . . . . . . . . . . . . . . . . . . . . . . . . 23-166
RECLINER - FRONT - REMOVAL, SEAT
BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-166
RECOMMENDATIONS - STANDARD
PROCEDURE, HOISTING . . . . . . . . . . . . . . . . . 0-4
RECOVERY - STANDARD PROCEDURE,
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . 24-41
RECOVERY PRESS CONTAINER -
DESCRIPTION, COOLANT . . . . . . . . . . . . . . . 7-19
RECOVERY PRESS CONTAINER -
OPERATION, COOLANT . . . . . . . . . . . . . . . . . 7-19
REFACING - STANDARD PROCEDURE . . 9-26,9-34
REFERENCES - DESCRIPTION, TORQUE . . Intro.-7
REFILLING COOLING SYSTEM 3.7L
ENGINE - STANDARD PROCEDURE. . . . . . . . 7-12
REFRIGERANT - DESCRIPTION . . . . . . . . . . 24-53
REFRIGERANT - OPERATION . . . . . . . . . . . . 24-53
REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS - CAUTION . . . . . . . . . . . . . 24-40
REFRIGERANT LINE - DESCRIPTION . . . . . . 24-38
REFRIGERANT OIL - DESCRIPTION . . . . . . 24-53
REFRIGERANT OIL - OPERATION . . . . . . . . 24-54
REFRIGERANT OIL LEVEL - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 24-54
REFRIGERANT RECOVERY - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 24-41
REFRIGERANT SYSTEM CHARGE -
REFRIGERANT SYSTEM EVACUATE -
REFRIGERANT SYSTEM SERVICE
EQUIPMENT - STANDARD PROCEDURE . . . 24-40
REFRIGERANT SYSTEM SERVICE PORT -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 24-2
REFRIGERANT SYSTEM SERVICE PORT -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2
REGULATOR - DESCRIPTION, FUEL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
REGULATOR - DESCRIPTION, VOLTAGE . . . 8F-31
REGULATOR - ELECTRIC -
INSTALLATION, WINDOW . . . . . . . 23-126,23-134
REGULATOR - ELECTRIC - REMOVAL,
WINDOW . . . . . . . . . . . . . . . . . . . . 23-126,23-134
REGULATOR - INSTALLATION, FUEL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
REGULATOR - MANUAL - INSTALLATION,
WINDOW . . . . . . . . . . . . . . . . . . . . 23-126,23-133
REGULATOR - MANUAL - REMOVAL,
WINDOW . . . . . . . . . . . . . . . . . . . . 23-126,23-133
REGULATOR - OPERATION, FUEL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
REGULATOR - OPERATION, VOLTAGE . . . . . 8F-31
REGULATOR - REMOVAL, FUEL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-14
REINFORCEMENT - INSTALLATION,
GRILLE OPENING . . . . . . . . . . . . . . . . . . . 23-142
REINFORCEMENT - REMOVAL, GRILLE
OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-142
RELAY - DESCRIPTION . . . . . . . . . . . . . 8W-97-13
RELAY - DESCRIPTION, A/C
RELAY - DESCRIPTION, AMPLIFIER
CHOKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-3
RELAY - DESCRIPTION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20
RELAY - DESCRIPTION, CLUTCH SWITCH
OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
RELAY - DESCRIPTION, DAYTIME
RUNNING LAMP . . . . . . . . . . . . . . . . . . . . . 8L-20
RELAY - DESCRIPTION, DOOR LOCK . . . . . . 8N-6
RELAY - DESCRIPTION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-22
RELAY - DESCRIPTION, FUEL PUMP . . . . . 14-34
RELAY - DESCRIPTION, HEADLAMP
HIGH BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
RELAY - DESCRIPTION, HEADLAMP LOW
BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
RELAY - DESCRIPTION, PARK LAMP . . . . . 8L-54
RELAY - DESCRIPTION, REAR FOG LAMP . 8L-56
RELAY - DESCRIPTION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-6
RELAY - DESCRIPTION, STARTER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-41
RELAY - DESCRIPTION, TRAILER TOW . . . . 8L-61
RELAY - DESCRIPTION, TRANSMISSION
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 21-168
RELAY - DESCRIPTION, WIPER
HIGH/LOW. . . . . . . . . . . . . . . . . . . . . . . . . . 8R-23
RELAY - DESCRIPTION, WIPER ON/OFF . . . 8R-25
RELAY - DIAGNOSIS AND TESTING . . . 8W-97-13
RELAY - DIAGNOSIS AND TESTING,
AMPLIFIER CHOKE . . . . . . . . . . . . . . . . . . . . 8A-4
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . 24-21
DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . 8N-6
FRONT FOG LAMP . . . . . . . . . . . . . . . . . . . . 8L-23
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 14-34
HEADLAMP HIGH BEAM . . . . . . . . . . . . . . . 8L-34
HEADLAMP LOW BEAM . . . . . . . . . . . . . . . 8L-40
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3
PARK LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-55
REAR FOG LAMP . . . . . . . . . . . . . . . . . . . . . 8L-57
REAR WINDOW DEFOGGER . . . . . . . . . . . . . 8G-6
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-42
TRAILER TOW . . . . . . . . . . . . . . . . . . . . . . . 8L-62
WIPER HIGH/LOW . . . . . . . . . . . . . . . . . . . 8R-24
WIPER ON/OFF . . . . . . . . . . . . . . . . . . . . . . 8R-26
RELAY - INSTALLATION . . . . . . . . . . . . 8W-97-14
RELAY - INSTALLATION, A/C
RELAY - INSTALLATION, AMPLIFIER
CHOKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
RELAY - INSTALLATION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
RELAY - INSTALLATION, CLUTCH
SWITCH OVERRIDE. . . . . . . . . . . . . . . . . . . . 6-10
RELAY - INSTALLATION, DAYTIME
RUNNING LAMP . . . . . . . . . . . . . . . . . . . . . 8L-21
RELAY - INSTALLATION, DOOR LOCK . . . . . 8N-7
RELAY - INSTALLATION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-24
RELAY - INSTALLATION, FUEL PUMP . . . . . 14-34
RELAY - INSTALLATION, HEADLAMP
HIGH BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 8L-35
RELAY - INSTALLATION, HEADLAMP
LOW BEAM . . . . . . . . . . . . . . . . . . . . . . . . . 8L-41
RELAY - INSTALLATION, HORN . . . . . . . . . . 8H-3
RELAY - INSTALLATION, PARK LAMP . . . . . 8L-56
RELAY - INSTALLATION, REAR FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-58
RELAY - INSTALLATION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-7
RELAY - INSTALLATION, STARTER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-43
RELAY - INSTALLATION, TRAILER TOW . . . 8L-64
RELAY - INSTALLATION, WIPER
HIGH/LOW. . . . . . . . . . . . . . . . . . . . . . . . . . 8R-24
RELAY - INSTALLATION, WIPER ON/OFF . . 8R-26
RELAY - OPERATION . . . . . . . . . . . . . . . 8W-97-13
RELAY - OPERATION, A/C COMPRESSOR
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-15
RELAY - OPERATION, AMPLIFIER CHOKE . . . 8A-3
RELAY - OPERATION, BLOWER MOTOR . . . 24-20
RELAY - OPERATION, CLUTCH SWITCH
OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
RELAY - OPERATION, DAYTIME
RUNNING LAMP . . . . . . . . . . . . . . . . . . . . . 8L-20
RELAY - OPERATION, DOOR LOCK . . . . . . . . 8N-6
KJ INDEX 21
RELAY - OPERATION, FRONT FOG LAMP . . 8L-22
RELAY - OPERATION, FUEL PUMP . . . . . . . 14-34
RELAY - OPERATION, HEADLAMP HIGH
BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-33
RELAY - OPERATION, HEADLAMP LOW
BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-39
RELAY - OPERATION, PARK LAMP . . . . . . . 8L-54
RELAY - OPERATION, REAR FOG LAMP . . . 8L-57
RELAY - OPERATION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-6
RELAY - OPERATION, STARTER MOTOR . . . 8F-42
RELAY - OPERATION, TRAILER TOW . . . . . 8L-62
RELAY - OPERATION, TRANSMISSION
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 21-168
RELAY - OPERATION, WIPER HIGH/LOW . . 8R-23
RELAY - OPERATION, WIPER ON/OFF . . . . 8R-25
RELAY - REMOVAL . . . . . . . . . . . . . . . . 8W-97-14
RELAY - REMOVAL, A/C COMPRESSOR
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
RELAY - REMOVAL, AMPLIFIER CHOKE . . . . 8A-4
RELAY - REMOVAL, BLOWER MOTOR . . . . 24-21
RELAY - REMOVAL, CLUTCH SWITCH
OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
RELAY - REMOVAL, DAYTIME RUNNING
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
RELAY - REMOVAL, DOOR LOCK . . . . . . . . . 8N-6
RELAY - REMOVAL, FRONT FOG LAMP . . . 8L-24
RELAY - REMOVAL, FUEL PUMP . . . . . . . . 14-34
RELAY - REMOVAL, HEADLAMP HIGH
BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-34
RELAY - REMOVAL, HEADLAMP LOW
BEAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-40
RELAY - REMOVAL, HORN . . . . . . . . . . . . . . 8H-3
RELAY - REMOVAL, PARK LAMP . . . . . . . . 8L-55
RELAY - REMOVAL, REAR FOG LAMP . . . . 8L-58
RELAY - REMOVAL, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-7
RELAY - REMOVAL, STARTER MOTOR . . . . 8F-43
RELAY - REMOVAL, TRAILER TOW . . . . . . . 8L-63
RELAY - REMOVAL, WIPER HIGH/LOW . . . 8R-24
RELAY - REMOVAL, WIPER ON/OFF . . . . . . 8R-26
RELAYS - DIAGNOSIS AND TESTING,
ASD AND FUEL PUMP . . . . . . . . . . . . . . . . . . 8I-4
RELEASE - STANDARD PROCEDURE,
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . 14-4
RELEASE BEARING - INSTALLATION,
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
RELEASE BEARING - REMOVAL, CLUTCH . . . 6-6
RELEASE CABLE - INSTALLATION, LATCH . 23-120
RELEASE CABLE - REMOVAL, LATCH . . . . 23-120
RELEASE HANDLE - INSTALLATION,
LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-120
RELEASE HANDLE - REMOVAL, LATCH . . 23-120
RELEASE SWITCH - DIAGNOSIS AND
TESTING, FLIP-UP GLASS . . . . . . . . . . . . . . 8N-5
RELIEF VALVE - DESCRIPTION, HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
RELIEF VALVE - OPERATION, HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
REMOTE KEYLESS ENTRY MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8N-7
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-7
REMOTE KEYLESS ENTRY
TRANSMITTER - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-8
TRANSMITTER - SPECIFICATIONS . . . . . . . . 8N-9
REMOTE SWITCHES - DESCRIPTION . . . . . 8A-11
REMOTE SWITCHES - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-12
REMOTE SWITCHES - INSTALLATION . . . . . 8A-13
REMOTE SWITCHES - OPERATION . . . . . . . 8A-12
REMOTE SWITCHES - REMOVAL . . . . . . . . 8A-13
REPAIR - DESCRIPTION, THREADED
HOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-4
REPAIR - STANDARD PROCEDURE,
ALUMINUM THREAD. . . . . . . . . . . . . . . . . . 21-81
REPAIR - STANDARD PROCEDURE,
REAR GLASS HEATING GRID . . . . . . . . . . . . 8G-4
REPAIR DAMAGED OR WORN THREADS
- STANDARD PROCEDURE . . . . . . . . . . . . . . . 9-9
REPAIRING LEAKS - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
REPEATER LAMP BULB - INSTALLATION . . 8L-60
REPEATER LAMP BULB - REMOVAL . . . . . . 8L-60
REPEATER LAMP UNIT - INSTALLATION . . 8L-61
REPEATER LAMP UNIT - REMOVAL . . . . . . 8L-60
REQUIREMENTS - DESCRIPTION,
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 24-1
RESERVOIR - DESCRIPTION, VACUUM . . . . 8P-7
RESERVOIR - DESCRIPTION, WASHER . . . 8R-21
RESERVOIR - DIAGNOSIS AND TESTING,
VACUUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-7
RESERVOIR - INSTALLATION, FLUID . . . . . . 5-26
RESERVOIR - INSTALLATION, VACUUM . . . . 8P-8
RESERVOIR - INSTALLATION, WASHER . . . 8R-22
RESERVOIR - OPERATION, VACUUM . . . . . . 8P-7
RESERVOIR - OPERATION, WASHER . . . . . 8R-21
RESERVOIR - REMOVAL, FLUID . . . . . . . . . . 5-26
RESERVOIR - REMOVAL, VACUUM . . . . . . . . 8P-7
RESERVOIR - REMOVAL, WASHER . . . . . . 8R-21
RESISTANCE, 2.4L - IGNITION COIL . . . . . . . 8I-2
RESISTANCE, 2.4L - SPARK PLUG CABLE . . . 8I-3
RESISTANCE, 3.7L V-6 - IGNITION COIL . . . . 8I-3
RESISTOR - DESCRIPTION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
RESISTOR - DIAGNOSIS AND TESTING,
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . 24-22
RESISTOR - INSTALLATION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
RESISTOR - OPERATION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
RESISTOR - REMOVAL, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
RESTRAINT DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER A
SUPPLEMENTAL . . . . . . . . . . . . . . . . . . . . . . 8O-6
RESTRAINT SYSTEM - DIAGNOSIS AND
TESTING, SUPPLEMENTAL . . . . . . . . . . . . . . 8O-6
RESTRAINT SYSTEM - WARNING . . . . . . . . 8O-5
RESTRAINTS - DESCRIPTION . . . . . . . . . . . . 8O-2
RESTRAINTS - OPERATION . . . . . . . . . . . . . 8O-4
RESTRAINTS - STANDARD PROCEDURE,
HANDLING NON-DEPLOYED
SUPPLEMENTAL . . . . . . . . . . . . . . . . . . . . . . 8O-6
RETAINER/BULKHEAD - ASSEMBLY, 4C . . 21-123
RETAINER/BULKHEAD - DISASSEMBLY,
4C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-122
RETRACTOR - INSTALLATION, FRONT
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-24
RETRACTOR - INSTALLATION, REAR
CENTER SEAT BELT . . . . . . . . . . . . . . . . . . 8O-33
RETRACTOR - INSTALLATION, REAR
OUTBOARD SEAT BELT . . . . . . . . . . . . . . . . 8O-34
RETRACTOR - REMOVAL, FRONT SEAT
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
RETRACTOR - REMOVAL, REAR CENTER
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-32
RETRACTOR - REMOVAL, REAR
OUTBOARD SEAT BELT . . . . . . . . . . . . . . . . 8O-33
RETURN - DESCRIPTION, SENSOR . . . . . . . 8E-14
RETURN HOSE (GEAR TO THE COOLER)
- INSTALLATION . . . . . . . . . . . . . . . . . . . . . 19-22
RETURN HOSE (GEAR TO THE COOLER)
- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 19-21
RETURN HOSE (RESERVOIR TO THE
COOLER) - INSTALLATION . . . . . . . . . . . . . 19-22
RETURN HOSE (RESERVOIR TO THE
COOLER) - REMOVAL . . . . . . . . . . . . . . . . . 19-21
REVERSE FLUSHING - STANDARD
PROCEDURE, COOLING SYSTEM . . . . . . . . . 7-12
RFE TRANSMISSION, SPECIAL TOOLS . . . 21-120
RHD - INSTALLATION . . . . . . . . . . . . . . . 8W-97-6
RHD - REMOVAL . . . . . . . . . . . . . . . . . . . 8W-97-5
RIGHT POWER SEAT SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8N-19
DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-20
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
RIGHT SIDE - INSTALLATION . . . . . . . . 2-12,2-15
RIGHT SIDE - REMOVAL . . . . . . . . . . . . 2-11,2-14
RING - INSTALLATION, PINION
GEAR/RING GEAR/TONE . . . . . . . . . . . 3-112,3-82
RING - REMOVAL, PINION GEAR/RING
GEAR/TONE . . . . . . . . . . . . . . . . . . . . . 3-110,3-79
RING FITTING - STANDARD
PROCEDURE, PISTON . . . . . . . . . . . . . . . . . . 9-52
RISER - INSTALLATION, MANUAL SEAT . . 23-168
RISER - REMOVAL, MANUAL SEAT . . . . . . 23-167
RKE TRANSMITTER BATTERIES -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8N-8
RKE TRANSMITTER CUSTOMER
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8N-8
RKE TRANSMITTER PROGRAMING -
STANDARD PROCEDURE . . . . . . . . . . . . . . . 8N-9
ROAD TEST - DIAGNOSIS AND TESTING . . . 8P-2
ROAD TESTING - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-78
ROCKER ARM - DESCRIPTION . . . . . . . 9-29,9-37
ROCKER ARM - INSTALLATION . . . . . . . . . . 9-37
ROCKER ARM - REMOVAL . . . . . . . . . . . . . . 9-37
ROD - DESCRIPTION, PISTON &
CONNECTING. . . . . . . . . . . . . . . . . . . . . . . . . 9-49
ROD BEARING - FITTING - STANDARD
PROCEDURE, CONNECTING . . . . . . . . . . . . . 9-40
ROD BEARING, FITTING - CONNECTING . . . . 9-49
ROD END - INSTALLATION, TIE . . . . . . . . . 19-16
ROD END - REMOVAL, TIE . . . . . . . . . . . . . 19-16
ROD END REMOVAL TOOL, SPECIAL
TOOLS - OUTER TIE . . . . . . . . . . . . . . . . . . 19-15
ROTATION - STANDARD PROCEDURE,
TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2
ROTOR - DIAGNOSIS AND TESTING,
DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
ROTOR - STANDARD PROCEDURE, DISC
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
ROTORS - INSTALLATION . . . . . . . . . . . . . . . 5-19
ROTORS - REMOVAL . . . . . . . . . . . . . . . . . . 5-19
ROUTING 3.7L ENGINE - DESCRIPTION,
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 7-2
RUN CHANNEL - INSTALLATION, GLASS . 23-123,
23-130
RUN CHANNEL - REMOVAL, GLASS . . . . 23-123,
23-130
RUNNING LAMP RELAY - DESCRIPTION,
DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
RUNNING LAMP RELAY - INSTALLATION,
DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
RUNNING LAMP RELAY - OPERATION,
DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-20
RUNNING LAMP RELAY - REMOVAL,
DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-21
RUNOUT - DIAGNOSIS AND TESTING,
TIRES AND WHEEL . . . . . . . . . . . . . . . . . . . . 22-1
SAFETY CERTIFICATION LABEL -
DESCRIPTION, VEHICLE . . . . . . . . . . . . . . Intro.-9
SAFETY PRECAUTIONS AND WARNINGS,
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
SAFETY PRECAUTIONS, WARNING -
WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . 23-173
SANDING/BUFFING & POLISHING -
DESCRIPTION, FINESSE . . . . . . . . . . . . . . 23-163
SCHEDULES - DESCRIPTION,
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 0-4
SCHEMATICS AND DIAGRAMS -
HYDRAULIC SCHEMATICS. . . . . . . . . . . . . 21-100
SCHEMATICS, SCHEMATICS AND
DIAGRAMS - HYDRAULIC . . . . . . . . . . . . . 21-100
SCUFF PLATE - INSTALLATION, DOOR
SILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-157
SCUFF PLATE - INSTALLATION, REAR
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-160
SCUFF PLATE - REMOVAL, DOOR SILL . . . 23-157
SCUFF PLATE - REMOVAL, REAR DOOR . . 23-160
SEAL - FRONT - INSTALLATION,
CRANKSHAFT OIL . . . . . . . . . . . . . . . . . . . . . 9-47
SEAL - FRONT - REMOVAL,
CRANKSHAFT OIL . . . . . . . . . . . . . . . . . . . . . 9-46
SEAL - INSTALLATION, ADAPTER
HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . 21-124
SEAL - INSTALLATION, A-PILLAR . . . . . . . 23-185
SEAL - INSTALLATION, COWL/PLENUM . . 23-187
SEAL - INSTALLATION, COWL/PLENUM
WINDOW BAFFLE . . . . . . . . . . . . . . . . . . . 23-187
SEAL - INSTALLATION, FRONT OUTPUT
SHAFT . . . . . . . . . . . . . . . . . . . . . . 21-208,21-246
SEAL - INSTALLATION, GLASS PANEL . . . 23-178
SEAL - INSTALLATION, OIL PUMP
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
SEAL - INSTALLATION, PINION . . 3-103,3-39,3-68
22 INDEX KJ
SEAL - INSTALLATION, REAR OUTPUT
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-212
SEAL - NV1500 - INSTALLATION,
SEAL - NV1500 - REMOVAL, EXTENSION
HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-32
SEAL - NV3550 - INSTALLATION,
SEAL - NV3550 - REMOVAL, EXTENSION
HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-74
SEAL - REAR - INSTALLATION,
CRANKSHAFT OIL . . . . . . . . . . . . . . . . . . . . . 9-48
SEAL - REAR - REMOVAL, CRANKSHAFT
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
SEAL - REMOVAL, ADAPTER HOUSING . . 21-124
SEAL - REMOVAL, A-PILLAR . . . . . . . . . . . 23-185
SEAL - REMOVAL, COWL/PLENUM . . . . . . 23-187
SEAL - REMOVAL, COWL/PLENUM
WINDOW BAFFLE . . . . . . . . . . . . . . . . . . . 23-187
SEAL - REMOVAL, FRONT OUTPUT
SHAFT . . . . . . . . . . . . . . . . . . . . . . 21-208,21-246
SEAL - REMOVAL, GLASS PANEL . . . . . . . 23-178
SEAL - REMOVAL, OIL PUMP FRONT . . . . 21-152
SEAL - REMOVAL, PINION . . . . . 3-102,3-38,3-68
SEAL - REMOVAL, REAR OUTPUT SHAFT . 21-210
SEAL AREA LEAKS - DIAGNOSIS AND
TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . . 9-61
SEALER LOCATIONS - SPECIFICATIONS . . . 23-87
SEALS - DESCRIPTION, VALVE GUIDE . 9-29,9-38
SEALS - INSTALLATION, AXLE SHAFT . . . . 3-102,
3-38
SEALS - REMOVAL, AXLE SHAFT . . . . 3-101,3-37
SEAT - FRONT - INSTALLATION . . . . . . . . 23-165
SEAT - FRONT - REMOVAL . . . . . . . . . . . . 23-165
SEAT - REAR - INSTALLATION . . . . . . . . . 23-168
SEAT - REAR - REMOVAL . . . . . . . . . . . . . 23-168
SEAT BACK - FRONT - INSTALLATION . . . 23-166
SEAT BACK - FRONT - REMOVAL . . . . . . . 23-166
SEAT BACK - REAR - INSTALLATION . . . . 23-168
SEAT BACK - REAR - REMOVAL . . . . . . . . 23-168
SEAT BACK COVER - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT BACK COVER - FRONT - REMOVAL . 23-166
SEAT BACK COVER - REAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-169
SEAT BACK COVER - REAR - REMOVAL . . 23-169
SEAT BACK CUSHION - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT BACK CUSHION - FRONT -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT BACK CUSHION - REAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-170
SEAT BACK CUSHION - REAR -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
SEAT BACK FRAME - REAR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-171
SEAT BACK FRAME - REAR - REMOVAL . . 23-171
SEAT BACK LATCH / LOCK -
INSTALLATION, FOLDING REAR . . . . . . . . 23-170
SEAT BACK LATCH / LOCK - REMOVAL,
FOLDING REAR . . . . . . . . . . . . . . . . . . . . . 23-170
SEAT BACK LATCH STRIKER -
SEAT BACK LATCH STRIKER - REMOVAL,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
SEAT BACK RECLINER - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-166
SEAT BACK RECLINER - FRONT -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-166
SEAT BELT & RETRACTOR -
INSTALLATION, FRONT . . . . . . . . . . . . . . . . 8O-24
INSTALLATION, REAR CENTER . . . . . . . . . . 8O-33
INSTALLATION, REAR OUTBOARD . . . . . . . 8O-34
SEAT BELT & RETRACTOR - REMOVAL,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-23
REAR CENTER. . . . . . . . . . . . . . . . . . . . . . . 8O-32
REAR OUTBOARD. . . . . . . . . . . . . . . . . . . . 8O-33
SEAT BELT BUCKLE - INSTALLATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-26
SEAT BELT BUCKLE - INSTALLATION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-35
SEAT BELT BUCKLE - REMOVAL, FRONT . . 8O-25
SEAT BELT BUCKLE - REMOVAL, REAR . . . 8O-34
SEAT BELT SWITCH - DESCRIPTION . . . . . 8O-35
SEAT BELT SWITCH - OPERATION . . . . . . . 8O-36
SEAT BELT TENSIONER - DESCRIPTION . . . 8O-36
SEAT BELT TENSIONER - OPERATION . . . . 8O-36
SEAT BELT TURNING LOOP ADJ USTER -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-38
SEAT BELT TURNING LOOP ADJ USTER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-37
SEAT CUSHION - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT CUSHION - FRONT - REMOVAL . . . . 23-167
SEAT CUSHION - REAR - INSTALLATION . 23-171
SEAT CUSHION - REAR - REMOVAL . . . . . 23-171
SEAT CUSHION COVER - FRONT -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT CUSHION COVER - FRONT -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT CUSHION SIDE SHIELDS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT CUSHION SIDE SHIELDS -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SEAT ELEMENT - DESCRIPTION, HEATED . 8G-13
SEAT ELEMENT - DIAGNOSIS AND
TESTING, HEATED. . . . . . . . . . . . . . . . . . . . 8G-13
SEAT ELEMENT - OPERATION, HEATED . . . 8G-13
SEAT HEATER SWITCH - DESCRIPTION,
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-11
SEAT HEATER SWITCH - DESCRIPTION,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8G-14
SEAT HEATER SWITCH - INSTALLATION,
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
SEAT HEATER SWITCH - INSTALLATION,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8G-15
SEAT HEATER SWITCH - OPERATION,
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-12
SEAT HEATER SWITCH - OPERATION,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8G-14
SEAT HEATER SWITCH - REMOVAL,
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
SEAT HEATER SWITCH - REMOVAL,
PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8G-15
SEAT MODULE - DESCRIPTION, HEATED . . 8E-21
SEAT MODULE - DIAGNOSIS AND
TESTING, HEATED . . . . . . . . . . . . . . . . . . . . 8E-22
SEAT MODULE - INSTALLATION, HEATED . . 8E-24
SEAT MODULE - OPERATION, HEATED . . . . 8E-21
SEAT MODULE - REMOVAL, HEATED . . . . . 8E-24
SEAT RISER - INSTALLATION, MANUAL . . 23-168
SEAT RISER - REMOVAL, MANUAL . . . . . . 23-167
SEAT SENSOR - DIAGNOSIS AND
TESTING, HEATED. . . . . . . . . . . . . . . . . . . . 8G-14
SEAT SWITCH - DESCRIPTION, LEFT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-16
SEAT SWITCH - DESCRIPTION, RIGHT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
SEAT SWITCH - DIAGNOSIS AND
TESTING, HEATED . . . . . . . . . . . . . . 8G-12,8G-14
TESTING, LEFT POWER . . . . . . . . . . . . . . . 8N-17
TESTING, RIGHT POWER . . . . . . . . . . . . . . 8N-19
SEAT SWITCH - INSTALLATION, LEFT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-18
SEAT SWITCH - INSTALLATION, RIGHT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
SEAT SWITCH - OPERATION, LEFT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-17
SEAT SWITCH - OPERATION, RIGHT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
SEAT SWITCH - REMOVAL, LEFT POWER . 8N-18
SEAT SWITCH - REMOVAL, RIGHT
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
SEAT SYSTEM - DESCRIPTION, HEATED . . 8G-10
SEAT SYSTEM - DIAGNOSIS AND
TESTING, HEATED. . . . . . . . . . . . . . . . . . . . 8G-11
SEAT SYSTEM - OPERATION, HEATED . . . . 8G-10
SEAT TRACK - DESCRIPTION . . . . . . . . . . . 8N-15
SEAT TRACK - DIAGNOSIS AND TESTING . 8N-16
SEAT TRACK - INSTALLATION . . . . . . . . . . 23-168
SEAT TRACK - INSTALLATION . . . . . . . . . . 8N-16
SEAT TRACK - OPERATION . . . . . . . . . . . . . 8N-15
SEAT TRACK - REMOVAL . . . . . . . . . . . . . 23-168
SEAT TRACK - REMOVAL . . . . . . . . . . . . . . 8N-16
SEATBELT INDICATOR - DESCRIPTION . . . . 8J -27
SEATBELT INDICATOR - OPERATION . . . . . . 8J -28
SEATS - DESCRIPTION, INTAKE/
EXHAUST VALVES . . . . . . . . . . . . . . . . . . . . . 9-26
SEATS - DESCRIPTION, POWER . . . . . . . . . 8N-14
SEATS - DIAGNOSIS AND TESTING,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-15
SEATS - INSTALLATION, INTAKE/
EXHAUST VALVES . . . . . . . . . . . . . . . . . 9-28,9-36
SEATS - OPERATION, POWER . . . . . . . . . . 8N-15
SEATS - REMOVAL, INTAKE/EXHAUST
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . 9-27,9-35
SECTION IDENTIFICATION AND
INFORMATION - DESCRIPTION. . . . . . . . 8W-01-6
SECURITY - DESCRIPTION, VEHICLE
THEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-1
SECURITY - OPERATION, VEHICLE THEFT . . 8Q-3
SECURITY INDICATOR - DESCRIPTION . . . . 8J -28
SECURITY INDICATOR - OPERATION . . . . . 8J -28
SECURITY SYSTEM - DIAGNOSIS AND
TESTING, VEHICLE THEFT . . . . . . . . . . . . . . 8Q-6
SENDING UNIT - DIAGNOSIS AND
TESTING, FUEL LEVEL . . . . . . . . . . . . . . . . . 14-9
SENDING UNIT / SENSOR -
DESCRIPTION, FUEL LEVEL . . . . . . . . . . . . . 14-9
SENDING UNIT / SENSOR -
INSTALLATION, FUEL LEVEL . . . . . . . . . . . . 14-10
SENDING UNIT / SENSOR - OPERATION,
FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
SENDING UNIT / SENSOR - REMOVAL,
FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
SENSE - DESCRIPTION, IGNITION
CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-13
SENSE - OPERATION, IGNITION CIRCUIT . . 8E-15
SENSE - PCM INPUT - OPERATION, ASD . . . 8I-4
SENSITIVE DEVICES - STANDARD
PROCEDURE, ELECTROSTATIC
DISCHARGE (ESD) . . . . . . . . . . . . . . . . . 8W-01-8
SENSOR - DESCRIPTION, AMBIENT
TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-9
SENSOR - DESCRIPTION, BATTERY
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8F-24
SENSOR - DESCRIPTION, CRANKSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-30
SENSOR - DESCRIPTION, ENGINE
COOLANT TEMPERATURE . . . . . . . . . . . . . . . 7-19
SENSOR - DESCRIPTION, FRONT
IMPACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-21
SENSOR - DESCRIPTION, FUEL LEVEL
SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . 14-9
SENSOR - DESCRIPTION, INPUT SPEED . 21-143
SENSOR - DESCRIPTION, INTAKE AIR
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-36
SENSOR - DESCRIPTION, KNOCK . . . . . . . . 8I-11
SENSOR - DESCRIPTION, LINE
PRESSURE (LP) . . . . . . . . . . . . . . . . . . . . 21-144
SENSOR - DESCRIPTION, MAP . . . . . . . . . . 14-38
SENSOR - DESCRIPTION, OUTPUT
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
SENSOR - DESCRIPTION, OXYGEN . . . . . . . 14-40
SENSOR - DESCRIPTION, POSITION . . . . 21-209,
21-247
SENSOR - DESCRIPTION, THROTTLE
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
SENSOR - DESCRIPTION,
TRANSMISSION RANGE . . . . . . . . . . . . . . 21-168
SENSOR - DESCRIPTION,
TRANSMISSION TEMPERATURE . . . . . . . . 21-170
SENSOR - DIAGNOSIS AND TESTING,
AMBIENT TEMPERATURE. . . . . . . . . . . . . . . 8M-9
SENSOR - DIAGNOSIS AND TESTING,
HEATED SEAT . . . . . . . . . . . . . . . . . . . . . . . 8G-14
SENSOR - INSTALLATION, BATTERY
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8F-24
SENSOR - INSTALLATION, CRANKSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-32
SENSOR - INSTALLATION, ENGINE
SENSOR - INSTALLATION, FRONT
IMPACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8O-22
SENSOR - INSTALLATION, FRONT
WHEEL SPEED. . . . . . . . . . . . . . . . . . . . . . . . 5-34
SENSOR - INSTALLATION, FUEL LEVEL
SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . 14-10
SENSOR - INSTALLATION, INPUT SPEED . 21-143
SENSOR - INSTALLATION, INTAKE AIR
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-38
SENSOR - INSTALLATION, KNOCK . . . . . . . . 8I-12
SENSOR - INSTALLATION, LINE
PRESSURE (LP) . . . . . . . . . . . . . . . . . . . . 21-144
SENSOR - INSTALLATION, MAP . . . . . . . . . 14-40
SENSOR - INSTALLATION, OUTPUT
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
KJ INDEX 23
SENSOR - INSTALLATION, OXYGEN . . . . . . 14-43
SENSOR - INSTALLATION, POSITION . . . . 21-210,
21-247
SENSOR - INSTALLATION, REAR WHEEL
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
SENSOR - INSTALLATION, THROTTLE
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-48
SENSOR - OPERATION, AMBIENT TEMP . . . 8M-9
SENSOR - OPERATION, BATTERY
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8F-24
SENSOR - OPERATION, CRANKSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
SENSOR - OPERATION, ENGINE
SENSOR - OPERATION, FRONT IMPACT . . . 8O-21
SENSOR - OPERATION, FUEL LEVEL
SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . 14-9
SENSOR - OPERATION, INPUT SPEED . . . 21-143
SENSOR - OPERATION, INTAKE AIR
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-36
SENSOR - OPERATION, KNOCK . . . . . . . . . . 8I-11
SENSOR - OPERATION, LINE PRESSURE
(LP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-144
SENSOR - OPERATION, MAP . . . . . . . . . . . 14-38
SENSOR - OPERATION, OUTPUT SPEED . . 21-152
SENSOR - OPERATION, OXYGEN . . . . . . . . 14-40
SENSOR - OPERATION, POSITION . . . . . . 21-209,
21-247
SENSOR - OPERATION, THROTTLE
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
SENSOR - OPERATION, TRANSMISSION
RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-168
SENSOR - OPERATION, TRANSMISSION
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . 21-170
SENSOR - REMOVAL, BATTERY
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 8F-24
SENSOR - REMOVAL, CRANKSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
SENSOR - REMOVAL, ENGINE COOLANT
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . 7-20
SENSOR - REMOVAL, FRONT IMPACT . . . . 8O-22
SENSOR - REMOVAL, FRONT WHEEL
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
SENSOR - REMOVAL, FUEL LEVEL
SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . 14-9
SENSOR - REMOVAL, INPUT SPEED . . . . . 21-143
SENSOR - REMOVAL, INTAKE AIR
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-37
SENSOR - REMOVAL, KNOCK . . . . . . . . . . . 8I-12
SENSOR - REMOVAL, LINE PRESSURE
(LP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-144
SENSOR - REMOVAL, MAP . . . . . . . . . . . . . 14-39
SENSOR - REMOVAL, OUTPUT SPEED . . . 21-152
SENSOR - REMOVAL, OXYGEN . . . . . . . . . . 14-41
SENSOR - REMOVAL, POSITION . . 21-210,21-247
SENSOR - REMOVAL, REAR WHEEL
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
SENSOR - REMOVAL, THROTTLE
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
SENSOR CIRCUIT - DIAGNOSIS AND
TESTING, AMBIENT TEMPERATURE. . . . . . . 8M-9
SENSOR RETURN - DESCRIPTION . . . . . . . 8E-14
SENSOR/SWITCH - DESCRIPTION, OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
SENSOR/SWITCH - INSTALLATION, OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
SENSOR/SWITCH - OPERATION, OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
SENSOR/SWITCH - REMOVAL, OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
SENTRY KEY IMMOBILIZER MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8E-15
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8E-18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-17
SENTRY KEY TRANSPONDER
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-8
SERPENTINE DRIVE BELT - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 7-15
SERVO - DESCRIPTION . . . . . . . . . . . . . . . . . 8P-4
SERVO - INSTALLATION . . . . . . . . . . . . . . . . 8P-5
SERVO - OPERATION . . . . . . . . . . . . . . . . . . 8P-4
SERVO - REMOVAL . . . . . . . . . . . . . . . . . . . . 8P-4
SETTING TRANSMITTER CODES -
PROCEDURE, TESTING FOR A SHORT
TO GROUND ON FUSES POWERING . . . 8W-01-9
SHAFT - CAUTION, HALF . . . . . . . . . . . . . . . . 3-10
SHAFT - DIAGNOSIS AND TESTING,
HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
SHAFT - DIAGNOSIS AND TESTING,
PROPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SHAFT - FRONT - INSTALLATION,
PROPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SHAFT - FRONT - REMOVAL,
PROPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SHAFT - INSTALLATION, BALANCE . . . . . . . . 9-74
SHAFT - INSTALLATION, HALF . . . . . . . . . . . 3-11
SHAFT - INSTALLATION, IDLER . . . . . . . . . . 9-77
SHAFT - INSTALLATION, INTERMEDIATE . . 19-11
SHAFT - REAR - INSTALLATION,
PROPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
SHAFT - REAR - REMOVAL, PROPELLER . . . . 3-7
SHAFT - REMOVAL, BALANCE . . . . . . . . . . . 9-74
SHAFT - REMOVAL, HALF . . . . . . . . . . . . . . . 3-10
SHAFT - REMOVAL, IDLER . . . . . . . . . . . . . . 9-77
SHAFT - REMOVAL, INTERMEDIATE . . . . . . 19-11
SHAFT ANGLE - STANDARD
PROCEDURES, PROPELLER . . . . . . . . . . . . . . 3-3
SHAFT SEAL - INSTALLATION, FRONT
OUTPUT. . . . . . . . . . . . . . . . . . . . . 21-208,21-246
SHAFT SEAL - INSTALLATION, REAR
OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-212
SHAFT SEAL - REMOVAL, FRONT
OUTPUT. . . . . . . . . . . . . . . . . . . . . 21-208,21-246
SHAFT SEAL - REMOVAL, REAR OUTPUT . 21-210
SHAFT SEALS - INSTALLATION, AXLE . . . . 3-102,
3-38
SHAFT SEALS - REMOVAL, AXLE . . . . 3-101,3-37
SHAFT, SPECIFICATIONS - HALF . . . . . . . . . . 3-11
SHAFT, SPECIFICATIONS - PROPELLER . . . . . 3-6
SHAFTS - INSTALLATION, AXLE . 3-101,3-37,3-65
SHAFTS - REMOVAL, AXLE . . . . . 3-101,3-37,3-65
SHIELD - INSTALLATION, FRONT
WHEELHOUSE SPLASH. . . . . . . . . . . . . . . 23-143
SHIELD - INSTALLATION, REAR
SHIELD - REMOVAL, FRONT
SHIELD - REMOVAL, REAR
SHIELDS - DESCRIPTION, HEAT . . . . . . . . . . 11-4
SHIELDS - INSTALLATION, SEAT
CUSHION SIDE . . . . . . . . . . . . . . . . . . . . . 23-167
SHIELDS - REMOVAL, SEAT CUSHION
SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SHIFT BEZEL - INSTALLATION . . . . . . . . . 23-158
SHIFT BEZEL - REMOVAL . . . . . . . . . . . . . 23-158
SHIFT BOOT - INSTALLATION, 4WD
FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
SHIFT BOOT - REMOVAL, 4WD FLOOR . . . 23-156
SHIFT INTERLOCK SYSTEM -
DESCRIPTION, BRAKE TRANSMISSION . . 21-124
SHIFT INTERLOCK SYSTEM - DIAGNOSIS
AND TESTING, BRAKE TRANSMISSION . . 21-125
SHIFT INTERLOCK SYSTEM -
OPERATION, BRAKE TRANSMISSION . . . . 21-125
SHIFT LEVER - INSTALLATION . . . 21-214,21-249
SHIFT LEVER - REMOVAL . . . . . . . 21-213,21-248
SHIFT MECHANISM - DESCRIPTION . . . . . 21-160
SHIFT MECHANISM - INSTALLATION . . . . 21-160
SHIFT MECHANISM - OPERATION . . . . . . 21-160
SHIFT MECHANISM - REMOVAL . . . . . . . . 21-160
SHOCK - INSTALLATION . . . . . . . . . . . . . . . . 2-18
SHOCK - REMOVAL . . . . . . . . . . . . . . . . . . . . 2-18
SHOES - INSTALLATION, DRUM BRAKE . . . . 5-11
SHOES - REMOVAL, DRUM BRAKE . . . . . . . 5-11
SHORT TO GROUND - STANDARD
PROCEDURE, TESTING FOR A . . . . . . . . 8W-01-9
SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS -
FOR A . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-9
SIDE - INSTALLATION, LEFT . . . . . . . . . 2-12,2-15
SIDE - INSTALLATION, RIGHT . . . . . . . . 2-12,2-15
SIDE - REMOVAL, LEFT . . . . . . . . . . . . . 2-11,2-15
SIDE - REMOVAL, RIGHT . . . . . . . . . . . 2-11,2-14
SIDE BEZEL - INSTALLATION,
INSTRUMENT PANEL PASSENGER . . . . . . 23-154
SIDE BEZEL - REMOVAL, INSTRUMENT
PANEL PASSENGER. . . . . . . . . . . . . . . . . . 23-154
SIDE BEZELS - INSTALLATION,
INSTRUMENT PANEL DRIVER . . . . . . . . . . 23-154
SIDE BEZELS - REMOVAL, INSTRUMENT
PANEL DRIVER . . . . . . . . . . . . . . . . . . . . . 23-153
SIDE CURTAIN AIRBAG - DESCRIPTION . . . 8O-38
SIDE CURTAIN AIRBAG - INSTALLATION . . 8O-41
SIDE CURTAIN AIRBAG - OPERATION . . . . 8O-39
SIDE CURTAIN AIRBAG - REMOVAL . . . . . . 8O-40
SIDE IMPACT AIRBAG CONTROL
MODULE - DESCRIPTION . . . . . . . . . . . . . . 8O-43
MODULE - INSTALLATION . . . . . . . . . . . . . 8O-45
MODULE - OPERATION. . . . . . . . . . . . . . . . 8O-43
MODULE - REMOVAL . . . . . . . . . . . . . . . . . 8O-44
SIDE MOLDINGS - INSTALLATION, BODY . 23-140
SIDE MOLDINGS - REMOVAL, BODY . . . . 23-140
SIDE RAIL WEATHERSTRIP/RETAINER -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 23-186
SIDE RAIL WEATHERSTRIP/RETAINER -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
SIDE SHIELDS - INSTALLATION, SEAT
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SIDE SHIELDS - REMOVAL, SEAT
CUSHION . . . . . . . . . . . . . . . . . . . . . . . . . . 23-167
SIDE VIEW MIRROR - INSTALLATION . . . . 23-145
SIDE VIEW MIRROR - REMOVAL . . . . . . . 23-145
SIDEVIEW MIRROR - REMOVAL . . . . . . . . . . 8N-13
SIGNAL INDICATOR - DESCRIPTION,
TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -34
SIGNAL INDICATOR - OPERATION, TURN . . 8J -34
SILL SCUFF PLATE - INSTALLATION,
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-157
SILL SCUFF PLATE - REMOVAL, DOOR . . . 23-157
SINGLE CARDAN UNIVERSAL J OINTS -
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
SINGLE CARDAN UNIVERSAL J OINTS -
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
SIREN - DESCRIPTION . . . . . . . . . . . . . . . . 8Q-16
SIREN - INSTALLATION . . . . . . . . . . . . . . . 8Q-17
SIREN - OPERATION . . . . . . . . . . . . . . . . . . 8Q-17
SIREN - REMOVAL . . . . . . . . . . . . . . . . . . . 8Q-17
SKID PLATE - INSTALLATION, FRONT . . . . . . 13-6
SKID PLATE - INSTALLATION, FUEL
TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
SKID PLATE - INSTALLATION, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
SKID PLATE - REMOVAL, FRONT . . . . . . . . . 13-6
SKID PLATE - REMOVAL, FUEL TANK . . . . . . 13-9
SKID PLATE - REMOVAL, TRANSFER
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
SKIS INDICATOR - DESCRIPTION . . . . . . . . 8J -31
SKIS INDICATOR - OPERATION . . . . . . . . . . 8J -31
SKIS INITIALIZATION - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-8
SLEEVE - INSTALLATION, HEADREST . . . . 23-164
SLEEVE - REMOVAL, HEADREST . . . . . . . 23-164
SOLENOID - DESCRIPTION, EVAP/PURGE . 25-27
SOLENOID - INSTALLATION, EVAP/
PURGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
SOLENOID - OPERATION, EVAP/PURGE . . . 25-27
SOLENOID - REMOVAL, EVAP/PURGE . . . . . 25-27
SOLENOID SWITCH VALVE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-161
SOLENOID SWITCH VALVE - OPERATION . 21-161
SOLENOIDS - DESCRIPTION . . . . . . . . . . . 21-161
SOLENOIDS - OPERATION . . . . . . . . . . . . . 21-162
SOLENOID/TRS ASSEMBLY -
DESCRIPTION, TRANSMISSION . . . . . . . . 21-169
INSTALLATION, TRANSMISSION . . . . . . . . 21-170
OPERATION, TRANSMISSION . . . . . . . . . . 21-169
SOLENOID/TRS ASSEMBLY - REMOVAL,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-170
SPACER - INSTALLATION, COLLAPSIBLE . . . 3-70
SPACER - REMOVAL, COLLAPSIBLE . . . . . . . 3-70
SPARE TIRE - INSTALLATION . . . . . . . . . . . . 22-9
SPARE TIRE - REMOVAL . . . . . . . . . . . . . . . . 22-8
SPARE TIRE &TEMPORARY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 22-6
SPARK PLUG - CLEANING SPARK
PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-15
SPARK PLUG - DESCRIPTION . . . . . . . . . . . 8I-12
SPARK PLUG - INSTALLATION . . . . . . . . . . . 8I-15
24 INDEX KJ
SPARK PLUG - OPERATION . . . . . . . . . . . . . 8I-12
SPARK PLUG - REMOVAL . . . . . . . . . . . . . . 8I-15
SPARK PLUG CABLE RESISTANCE, 2.4L . . . . 8I-3
SPARK PLUG CONDITIONS - DIAGNOSIS
AND TESTING. . . . . . . . . . . . . . . . . . . . . . . . 8I-13
SPARK PLUGS, SPARK PLUG -
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-15
SPARK PLUGS, SPECIFICATIONS . . . . . . . . . . 8I-3
SPEAKER - DESCRIPTION . . . . . . . . . . . . . . 8A-13
SPEAKER - INSTALLATION . . . . . . . . . . . . . 8A-15
SPEAKER - OPERATION . . . . . . . . . . . . . . . 8A-14
SPEAKER - REMOVAL . . . . . . . . . . . . . . . . . 8A-14
SPECIAL TOOLS - 3.7L ENGINE . . . . . . . . . . 9-15
SPECIAL TOOLS - 8 1/4 AXLE . . . . . . . . . . . 3-98
SPECIAL TOOLS - BASE BRAKES . . . . . . . . . . 5-7
SPECIAL TOOLS - BODY . . . . . . . . . . . . . . . . 23-5
SPECIAL TOOLS - COOLING . . . . . . . . . . . . . 7-14
SPECIAL TOOLS - FRONT AXLE . . . . . . . . . . 3-34
SPECIAL TOOLS - FRONT SUSPENSION . . . . . 2-8
SPECIAL TOOLS - FUEL SYSTEM . . . . . . . . . 14-6
SPECIAL TOOLS - OUTER TIE ROD END
REMOVAL TOOL . . . . . . . . . . . . . . . . . . . . . 19-15
SPECIAL TOOLS - POWER
DISTRIBUTION SYSTEMS . . . . . . . . . . . . 8W-97-2
SPECIAL TOOLS - POWER STEERING
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
SPECIAL TOOLS - REAR AXLE . . . . . . . . . . . 3-63
SPECIAL TOOLS - RFE TRANSMISSION. . . . 21-120
SPECIAL TOOLS - STEERING COLUMN . . . . 19-8
SPECIAL TOOLS - WIRING/TERMINAL . 8W-01-10
SPECIAL TOOLS, BATTERY SYSTEM . . . . . . . 8F-7
SPECIFICATIONS, BATTERY SYSTEM . . . . . . 8F-6
SPECIFICATIONS, BRAKES - ABS . . . . . . . . . 5-33
SPECIFICATIONS, CHARGE CAPACITY . . . . . 24-42
SPECIFICATIONS, CLUTCH . . . . . . . . . . . . . . . 6-5
SPECIFICATIONS, DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
SPECIFICATIONS, FLUID CAPACITIES . . . . . . . 0-4
SPECIFICATIONS, FRAME DIMENSIONS . . . . 13-3
SPECIFICATIONS, FRONT AXLE . . . . . . . . . . . 3-33
SPECIFICATIONS, GAP AND FLUSH . . . . . 23-116
SPECIFICATIONS, IGNITION TIMING . . . . . . . 8I-2
SPECIFICATIONS, LAMPS/LIGHTING -
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-15
SPECIFICATIONS, LAMPS/LIGHTING -
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-71
SPECIFICATIONS, NV1500 . . . . . . . . . . . . . . 21-30
SPECIFICATIONS, OPENING DIMENSIONS . 23-111
SPECIFICATIONS, PAINT CODES . . . . . . . . 23-162
SPECIFICATIONS, REAR AXLE . . . . . . . . . . . . 3-62
SPECIFICATIONS, REMOTE KEYLESS
ENTRY TRANSMITTER . . . . . . . . . . . . . . . . . 8N-9
SPECIFICATIONS, SEALER LOCATIONS . . . . 23-87
SPECIFICATIONS, SPECIFICATIONS . . . . . . . 24-10
SPECIFICATIONS, STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
SPECIFICATIONS, TORQUE . . . . . . . . . . . . . . 13-6
SPECIFICATIONS, WELD AND
STRUCTURAL ADHESIVE LOCATIONS . . . . . . 23-9
SPEED CONTROL - DESCRIPTION . . . . . . . . 8P-1
SPEED CONTROL - OPERATION . . . . . . . . . . 8P-1
SPEED CONTROL - TORQUE . . . . . . . . . . . . . 8P-2
SPEED SENSOR - DESCRIPTION, INPUT . 21-143
SPEED SENSOR - DESCRIPTION,
OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
SPEED SENSOR - INSTALLATION, FRONT
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
SPEED SENSOR - INSTALLATION, INPUT . 21-143
SPEED SENSOR - INSTALLATION,
OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-152
SPEED SENSOR - INSTALLATION, REAR
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
SPEED SENSOR - OPERATION, INPUT . . . 21-143
SPEED SENSOR - OPERATION, OUTPUT . . 21-152
SPEED SENSOR - REMOVAL, FRONT
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
SPEED SENSOR - REMOVAL, INPUT . . . . . 21-143
SPEED SENSOR - REMOVAL, OUTPUT . . . 21-152
SPEED SENSOR - REMOVAL, REAR
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
SPEEDOMETER - DESCRIPTION . . . . . . . . . 8J -32
SPEEDOMETER - OPERATION . . . . . . . . . . . 8J -32
SPLASH SHIELD - INSTALLATION,
FRONT WHEELHOUSE . . . . . . . . . . . . . . . . 23-143
SPLASH SHIELD - INSTALLATION, REAR
WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . 23-144
SPLASH SHIELD - REMOVAL, FRONT
WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . 23-143
SPLASH SHIELD - REMOVAL, REAR
WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . 23-144
SPLICE INFORMATION - DESCRIPTION,
CONNECTOR, GROUND. . . . . . . . . . . . . . 8W-01-7
SPLICING - STANDARD PROCEDURE,
WIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-14
SPRING - INSTALLATION . . . . . . . . . . . 2-13,2-18
SPRING - REMOVAL . . . . . . . . . . . . . . . 2-13,2-18
SPRINGS - DESCRIPTION, VALVE . . . . . 9-29,9-38
SPRINGS - INSTALLATION, VALVE . . . . 9-29,9-38
SPRINGS - REMOVAL, VALVE . . . . . . . . 9-29,9-38
STABILIZER BAR - INSTALLATION . . . . 2-14,2-19
STABILIZER BAR - REMOVAL . . . . . . . . 2-14,2-19
STABILIZER BAR BUSHINGS -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 2-9
STABILIZER BAR BUSHINGS - REMOVAL . . . . 2-9
STABILIZER LINK - INSTALLATION . . . . . . . . 2-14
STABILIZER LINK - REMOVAL . . . . . . . . . . . . 2-14
STAKING - STANDARD PROCEDURE,
HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
STARTER MOTOR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-39
STARTER MOTOR - INSTALLATION . . . . . . . 8F-41
STARTER MOTOR - REMOVAL . . . . . . . . . . 8F-39
STARTER MOTOR, GAS POWERED . . . . . . . 8F-39
STARTER MOTOR RELAY - DESCRIPTION . 8F-41
STARTER MOTOR RELAY -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8F-43
STARTER MOTOR RELAY - OPERATION. . . . . 8F-42
STARTER MOTOR RELAY - REMOVAL . . . . . 8F-43
STARTER RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-42
STARTING PROCEDURE - STANDARD
PROCEDURE, J UMP . . . . . . . . . . . . . . . . . . . . 0-5
STARTING SYSTEM - DESCRIPTION . . . . . . 8F-32
STARTING SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-33
STARTING SYSTEM - INSPECTION . . . . . . . 8F-37
STARTING SYSTEM - OPERATION . . . . . . . . 8F-32
STATE DISPLAY TEST MODE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 25-2
STEERING - DESCRIPTION . . . . . . . . . . . . . . 19-1
STEERING - OPERATION . . . . . . . . . . . . . . . . 19-1
STEERING COLUMN, SPECIAL TOOLS . . . . . 19-8
STEERING FLOW AND PRESSURE -
DIAGNOSIS AND TESTING, POWER . . . . . . . 19-3
STEERING LINKAGE - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 19-16
STEERING PRESSURE SWITCH -
DESCRIPTION, POWER . . . . . . . . . . . . . . . . 19-22
INSTALLATION, POWER . . . . . . . . . . . . . . . 19-22
OPERATION, POWER . . . . . . . . . . . . . . . . . . 19-22
REMOVAL, POWER . . . . . . . . . . . . . . . . . . . 19-22
STEERING PUMP - INITIAL OPERATION -
STANDARD PROCEDURE, POWER . . . . . . . 19-18
STEERING PUMP, SPECIAL TOOLS -
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
STEERING SYSTEM - DIAGNOSIS AND
TESTING, POWER . . . . . . . . . . . . . . . . . . . . . 19-1
STEERING SYSTEM - DIAGNOSIS AND
TESTING, SUSPENSION . . . . . . . . . . . . . . . . . 2-1
STEERING WHEEL - INSTALLATION . . . . . . 19-12
STEERING WHEEL - REMOVAL . . . . . . . . . . 19-12
STOP LAMP BULB - INSTALLATION,
CENTER HIGH MOUNTED . . . . . . . . . . . . . . 8L-19
STOP LAMP BULB - REMOVAL, CENTER
HIGH MOUNTED . . . . . . . . . . . . . . . . . . . . . 8L-18
STOP LAMP UNIT - INSTALLATION,
CENTER HIGH MOUNTED . . . . . . . . . . . . . . 8L-19
STOP LAMP UNIT - REMOVAL, CENTER
HIGH MOUNTED . . . . . . . . . . . . . . . . . . . . . 8L-19
STRAP - DESCRIPTION, RADIO NOISE
SUPPRESSION GROUND. . . . . . . . . . . . . . . . 8A-9
STRAP - INSTALLATION, CHECK . 23-121,23-128,
23-135
STRAP - INSTALLATION, RADIO NOISE
SUPPRESSION GROUND. . . . . . . . . . . . . . . 8A-11
STRAP - OPERATION, RADIO NOISE
STRAP - REMOVAL, CHECK . . . . . 23-121,23-128,
23-135
STRAP - REMOVAL, RADIO NOISE
STRIKER - INSTALLATION, GLOVE BOX
LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-149
STRIKER - INSTALLATION, HOOD AJ AR
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-14
STRIKER - INSTALLATION, LATCH . . . . . . 23-124,
23-132,23-137
STRIKER - INSTALLATION, REAR SEAT
BACK LATCH . . . . . . . . . . . . . . . . . . . . . . . 23-171
STRIKER - REMOVAL, GLOVE BOX
LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-148
STRIKER - REMOVAL, HOOD AJ AR
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
STRIKER - REMOVAL, LATCH . . . 23-124,23-132,
23-137
STRIKER - REMOVAL, REAR SEAT BACK
LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-170
STRUCTURAL ADHESIVE LOCATIONS -
SPECIFICATIONS, WELD . . . . . . . . . . . . . . . . 23-9
STRUCTURAL COVER - DESCRIPTION . . . . . 9-55
STRUCTURAL COVER - INSTALLATION . . . . . 9-55
STRUCTURAL COVER - OPERATION . . . . . . . 9-55
STRUCTURAL COVER - REMOVAL . . . . . . . . 9-55
STUDS - INSTALLATION . . . . . . . . . . . . . . . 22-11
STUDS - REMOVAL . . . . . . . . . . . . . . . . . . . 22-11
SUCTION LINE - INSTALLATION, A/C . . . . . 24-49
SUCTION LINE - REMOVAL, A/C . . . . . . . . . 24-48
SUN VISOR - INSTALLATION . . . . . . . . . . 23-160
SUN VISOR - REMOVAL . . . . . . . . . . . . . . 23-160
SUN VISOR SUPPORT - INSTALLATION . . 23-160
SUN VISOR SUPPORT - REMOVAL . . . . . . 23-160
SUNROOF - DESCRIPTION . . . . . . . . . . . . 23-175
SUNROOF GLASS PANEL ADJ USTMENT,
ADJ USTMENTS . . . . . . . . . . . . . . . . . . . . . 23-178
SUNSHADE - INSTALLATION . . . . . . . . . . . 23-179
SUNSHADE - REMOVAL . . . . . . . . . . . . . . 23-179
SUPPLEMENTAL RESTRAINT
PROCEDURE, SERVICE AFTER A . . . . . . . . . 8O-6
SUPPLEMENTAL RESTRAINT SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8O-6
SUPPLEMENTAL RESTRAINTS -
STANDARD PROCEDURE, HANDLING
NON-DEPLOYED . . . . . . . . . . . . . . . . . . . . . . 8O-6
SUPPLIES - DESCRIPTION, 5 VOLT . . . . . . 8E-13
SUPPLIES - OPERATION, 5 VOLT . . . . . . . . 8E-15
SUPPORT - INSTALLATION, REAR
FASCIA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
SUPPORT - INSTALLATION, SUN VISOR . . 23-160
SUPPORT - REMOVAL, REAR FASCIA . . . . . . 13-3
SUPPORT - REMOVAL, SUN VISOR . . . . . 23-160
SUPPORT BRACKET - INSTALLATION,
REARVIEW MIRROR . . . . . . . . . . . . . . . . . 23-161
SUPPORT CYLINDER - INSTALLATION . . . 23-120
SUPPORT CYLINDER - INSTALLATION,
FLIP-UP GLASS . . . . . . . . . . . . . . . . . . . . . 23-139
SUPPORT CYLINDER - REMOVAL . . . . . . . 23-120
SUPPORT CYLINDER - REMOVAL,
FLIP-UP GLASS . . . . . . . . . . . . . . . . . . . . . 23-139
SUPPRESSION GROUND STRAP -
DESCRIPTION, RADIO NOISE . . . . . . . . . . . . 8A-9
INSTALLATION, RADIO NOISE. . . . . . . . . . . 8A-11
OPERATION, RADIO NOISE . . . . . . . . . . . . . 8A-10
REMOVAL, RADIO NOISE . . . . . . . . . . . . . . 8A-10
SURFACE PREPARATION - STANDARD
PROCEDURE, ENGINE GASKET . . . . . . . . . . . . 9-9
SUSPENSION - DIAGNOSIS AND
TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . . 2-17
SUSPENSION AND STEERING SYSTEM -
BALL J OINT - DESCRIPTION, UPPER . . . . . . 2-20
BALL J OINT - OPERATION, UPPER . . . . . . . . 2-20
SUSPENSION, SPECIAL TOOLS - FRONT . . . . 2-8
SWING GATE - INSTALLATION . . . . . . . . . 23-138
SWING GATE - REMOVAL . . . . . . . . . . . . . 23-138
SWING GATE BELTLINE WEATHERSTRIP
- INSTALLATION . . . . . . . . . . . . . . . . . . . . 23-186
- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 23-186
SWING GATE OPENING WEATHERSTRIP
- INSTALLATION . . . . . . . . . . . . . . . . . . . . 23-186
- REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 23-186
SWITCH - DESCRIPTION . . . . . . . . . . . . . . . . 8P-5
SWITCH - DESCRIPTION, A/C HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-17
KJ INDEX 25
SWITCH - DESCRIPTION, A/C LOW
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
SWITCH - DESCRIPTION, BACKUP LAMP . . 8L-15
SWITCH - DESCRIPTION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
SWITCH - DESCRIPTION, BRAKE LAMP . . . 8L-16
SWITCH - DESCRIPTION, CLUTCH
PEDAL POSITION . . . . . . . . . . . . . . . . . . . . . 6-11
SWITCH - DESCRIPTION, CONTROL . . . . . 23-184
SWITCH - DESCRIPTION, DOOR AJ AR . . . . 8L-77
SWITCH - DESCRIPTION, DOOR
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . . 8Q-9
SWITCH - DESCRIPTION, DRIVER SEAT
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-11
SWITCH - DESCRIPTION, FLIP-UP
GLASS AJ AR . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
SWITCH - DESCRIPTION, FRONT
WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . 8R-16
SWITCH - DESCRIPTION, HAZARD . . . . . . . 8L-29
SWITCH - DESCRIPTION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-37
SWITCH - DESCRIPTION, HOOD AJ AR . . . . 8Q-11
SWITCH - DESCRIPTION, HORN . . . . . . . . . . 8H-4
SWITCH - DESCRIPTION, IGNITION . . . . . . . 19-8
SWITCH - DESCRIPTION, KEY-IN
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-10
SWITCH - DESCRIPTION, LEFT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-16
SWITCH - DESCRIPTION, MULTI-
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-46
SWITCH - DESCRIPTION, OVERDRIVE. . . . . 21-153
SWITCH - DESCRIPTION, PASSENGER
SEAT HEATER . . . . . . . . . . . . . . . . . . . . . . . 8G-14
SWITCH - DESCRIPTION, POWER
STEERING PRESSURE. . . . . . . . . . . . . . . . . 19-22
SWITCH - DESCRIPTION, REAR
SWITCH - DESCRIPTION, REAR
WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . 8R-43
SWITCH - DESCRIPTION, RIGHT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
SWITCH - DESCRIPTION, SEAT BELT . . . . . 8O-35
SWITCH - DESCRIPTION, TAILGATE
AJ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-82
SWITCH - DESCRIPTION, TAILGATE
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . . 8N-9
SWITCH - DESCRIPTION, WASHER
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
SWITCH - DIAGNOSIS AND TESTING,
A/C HIGH PRESSURE . . . . . . . . . . . . . . . . . 24-18
A/C LOW PRESSURE. . . . . . . . . . . . . . . . . . 24-19
BACKUP LAMP . . . . . . . . . . . . . . . . . . . . . . 8L-15
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . 24-23
BRAKE LAMP . . . . . . . . . . . . . . . . . . . . . . . 8L-17
CLUTCH PEDAL POSITION . . . . . . . . . . . . . . 6-11
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 23-184
DOOR CYLINDER LOCK . . . . . . . . . . . . . . . 8Q-10
DOOR LOCK/UNLOCK . . . . . . . . . . . . . . . . . . 8N-4
FLIP-UP GLASS RELEASE. . . . . . . . . . . . . . . 8N-5
HEADLAMP LEVELING. . . . . . . . . . . . . . . . . 8L-37
HEATED SEAT . . . . . . . . . . . . . . . . . . 8G-12,8G-14
HOOD AJ AR . . . . . . . . . . . . . . . . . . . . . . . . 8Q-12
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-4
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-8
KEY-IN IGNITION . . . . . . . . . . . . . . . . . . . . . 19-10
LEFT POWER SEAT . . . . . . . . . . . . . . . . . . . 8N-17
MULTI-FUNCTION . . . . . . . . . . . . . . . . . . . . 8L-50
POWER MIRROR . . . . . . . . . . . . . . . . . . . . 8N-12
REAR WINDOW DEFOGGER . . . . . . . . . . . . . 8G-8
RIGHT POWER SEAT. . . . . . . . . . . . . . . . . . 8N-19
TAILGATE CYLINDER LOCK. . . . . . . . . . . . . . 8N-9
WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-22
SWITCH - INSTALLATION . . . . . . . . . . . . . . . 8P-6
SWITCH - INSTALLATION, A/C HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
SWITCH - INSTALLATION, A/C LOW
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
SWITCH - INSTALLATION, BLOWER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
SWITCH - INSTALLATION, BRAKE LAMP . . 8L-18
SWITCH - INSTALLATION, CARGO LAMP . . 8L-74
SWITCH - INSTALLATION, CONTROL . . . . 23-184
SWITCH - INSTALLATION, DOOR
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . 8Q-10
SWITCH - INSTALLATION, DOOR LOCK /
UNLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5
SWITCH - INSTALLATION, DRIVER SEAT
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
SWITCH - INSTALLATION, HAZARD . . . . . . 8L-30
SWITCH - INSTALLATION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
SWITCH - INSTALLATION, HOOD AJ AR . . . 8Q-12
SWITCH - INSTALLATION, LEFT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-18
SWITCH - INSTALLATION, MULTI-
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-53
SWITCH - INSTALLATION, PASSENGER
SEAT HEATER. . . . . . . . . . . . . . . . . . . . . . . . . 8G-15
SWITCH - INSTALLATION, POWER
MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-13
SWITCH - INSTALLATION, POWER
SWITCH - INSTALLATION, READING
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-80
SWITCH - INSTALLATION, RIGHT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
SWITCH - INSTALLATION, TAILGATE
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . 8N-10
SWITCH - INSTALLATION, WASHER
FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 8R-18
SWITCH - INSTALLATION, WINDOW . . . . . 8N-23
SWITCH - OPERATION . . . . . . . . . . . . . . . . . 8P-5
SWITCH - OPERATION, A/C HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
SWITCH - OPERATION, A/C LOW
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
SWITCH - OPERATION, BACKUP LAMP . . . 8L-15
SWITCH - OPERATION, BLOWER MOTOR . . 24-23
SWITCH - OPERATION, BRAKE LAMP . . . . . 8L-16
SWITCH - OPERATION, CLUTCH PEDAL
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
SWITCH - OPERATION, CONTROL . . . . . . . 23-184
SWITCH - OPERATION, DOOR AJ AR . . . . . . 8L-77
SWITCH - OPERATION, DOOR CYLINDER
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
SWITCH - OPERATION, DRIVER SEAT
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-12
SWITCH - OPERATION, FLIP-UP GLASS
AJ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-77
SWITCH - OPERATION, FRONT
WIPER/WASHER . . . . . . . . . . . . . . . . . . . . . 8R-16
SWITCH - OPERATION, HAZARD . . . . . . . . . 8L-29
SWITCH - OPERATION, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-37
SWITCH - OPERATION, HOOD AJ AR . . . . . 8Q-12
SWITCH - OPERATION, LEFT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-17
SWITCH - OPERATION, MULTI-FUNCTION . 8L-48
SWITCH - OPERATION, OVERDRIVE . . . . . 21-153
SWITCH - OPERATION, PASSENGER
SEAT HEATER . . . . . . . . . . . . . . . . . . . . . . . 8G-14
SWITCH - OPERATION, POWER
SWITCH - OPERATION, REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-8
SWITCH - OPERATION, REAR WIPER/
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
SWITCH - OPERATION, RIGHT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-19
SWITCH - OPERATION, SEAT BELT . . . . . . . 8O-36
SWITCH - OPERATION, TAILGATE AJ AR . . . 8L-82
SWITCH - OPERATION, TAILGATE
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . . 8N-9
SWITCH - OPERATION, WASHER FLUID
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
SWITCH - REMOVAL . . . . . . . . . . . . . . . . . . . 8P-6
SWITCH - REMOVAL, A/C HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
SWITCH - REMOVAL, A/C LOW
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
SWITCH - REMOVAL, BLOWER MOTOR . . . 24-23
SWITCH - REMOVAL, BRAKE LAMP . . . . . . 8L-17
SWITCH - REMOVAL, CARGO LAMP . . . . . . 8L-73
SWITCH - REMOVAL, CONTROL . . . . . . . . 23-184
SWITCH - REMOVAL, DOOR CYLINDER
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-10
SWITCH - REMOVAL, DOOR LOCK /
UNLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-4
SWITCH - REMOVAL, DRIVER SEAT
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-13
SWITCH - REMOVAL, HAZARD . . . . . . . . . . 8L-30
SWITCH - REMOVAL, HEADLAMP
LEVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-38
SWITCH - REMOVAL, HOOD AJ AR . . . . . . . 8Q-12
SWITCH - REMOVAL, LEFT POWER SEAT . 8N-18
SWITCH - REMOVAL, MULTI-FUNCTION . . . 8L-53
SWITCH - REMOVAL, PASSENGER SEAT
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-15
SWITCH - REMOVAL, POWER MIRROR . . . 8N-13
SWITCH - REMOVAL, POWER STEERING
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 19-22
SWITCH - REMOVAL, READING LAMP . . . . 8L-80
SWITCH - REMOVAL, RIGHT POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-20
SWITCH - REMOVAL, TAILGATE
CYLINDER LOCK . . . . . . . . . . . . . . . . . . . . . 8N-10
SWITCH - REMOVAL, WASHER FLUID
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
SWITCH - REMOVAL, WINDOW . . . . . . . . . 8N-23
SWITCH BRACKET - INSTALLATION,
HOOD AJ AR . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
SWITCH BRACKET - REMOVAL, HOOD
AJ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
SWITCH INSTALLATION, INSTALLATION -
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-9
SWITCH OVERRIDE RELAY -
DESCRIPTION, CLUTCH. . . . . . . . . . . . . . . . . 6-10
INSTALLATION, CLUTCH . . . . . . . . . . . . . . . . 6-10
OPERATION, CLUTCH . . . . . . . . . . . . . . . . . . 6-10
SWITCH OVERRIDE RELAY - REMOVAL,
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
SWITCH REMOVAL, REMOVAL -
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-9
SWITCH STRIKER - INSTALLATION,
HOOD AJ AR . . . . . . . . . . . . . . . . . . . . . . . . 8Q-14
SWITCH STRIKER - REMOVAL, HOOD
AJ AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-13
SWITCH VALVE - DESCRIPTION,
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . 21-161
SWITCH VALVE - OPERATION, SOLENOID . 21-161
SWITCHES - DESCRIPTION, REMOTE . . . . . 8A-11
SWITCHES - DIAGNOSIS AND TESTING,
REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-12
SWITCHES - INSTALLATION, REMOTE . . . . 8A-13
SWITCHES - OPERATION, REMOTE . . . . . . 8A-12
SWITCHES - REMOVAL, REMOTE . . . . . . . . 8A-13
SYMBOLS - DESCRIPTION,
INTERNATIONAL . . . . . . . . . . . . . . . . . . . . Intro.-4
SYMBOLS - DESCRIPTION,
INTERNATIONAL . . . . . . . . . . . . . . . . . . . . . . . 0-1
TABLE, SPECIFICATIONS - A/C
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 24-9
TACHOMETER - DESCRIPTION . . . . . . . . . . 8J -33
TACHOMETER - OPERATION . . . . . . . . . . . . 8J -33
TAILGATE AJ AR SWITCH - DESCRIPTION . . 8L-82
TAILGATE AJ AR SWITCH - OPERATION . . . 8L-82
TAILGATE CYLINDER LOCK SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8N-9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8N-10
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . 8N-9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-10
TANK - DESCRIPTION, FUEL . . . . . . . . . . . . 14-24
TANK - INSTALLATION, FUEL . . . . . . . . . . . 14-27
TANK - OPERATION, FUEL . . . . . . . . . . . . . . 14-24
26 INDEX KJ
TANK - REMOVAL, FUEL . . . . . . . . . . . . . . . 14-25
TANK CHECK VALVE - DESCRIPTION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
TANK CHECK VALVE - INSTALLATION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
TANK CHECK VALVE - OPERATION, FUEL . . 14-28
TANK CHECK VALVE - REMOVAL, FUEL . . . 14-28
TANK SKID PLATE - INSTALLATION,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
TANK SKID PLATE - REMOVAL, FUEL . . . . . . 13-9
TASK MANAGER - DESCRIPTION . . . . . . . . 25-17
TASK MANAGER - OPERATION . . . . . . . . . . 25-21
TCM QUICK LEARN - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 8E-21
TEMP INDICATOR - DESCRIPTION,
TRANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -33
TEMP INDICATOR - OPERATION, TRANS . . 8J -34
TEMP SENSOR - DESCRIPTION,
AMBIENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-9
TEMP SENSOR - OPERATION, AMBIENT . . . 8M-9
TEMPERATURE GAUGE - DESCRIPTION,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -18
TEMPERATURE GAUGE - OPERATION,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -18
TEMPERATURE SENSOR - DESCRIPTION,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 7-19
INTAKE AIR . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-170
TEMPERATURE SENSOR - DIAGNOSIS
AND TESTING, AMBIENT . . . . . . . . . . . . . . . 8M-9
TEMPERATURE SENSOR -
INSTALLATION, BATTERY . . . . . . . . . . . . . . 8F-24
INSTALLATION, ENGINE COOLANT . . . . . . . . 7-21
INSTALLATION, INTAKE AIR . . . . . . . . . . . . 14-38
TEMPERATURE SENSOR - OPERATION,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 7-20
INTAKE AIR . . . . . . . . . . . . . . . . . . . . . . . . . 14-36
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-170
TEMPERATURE SENSOR - REMOVAL,
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-24
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . 7-20
INTAKE AIR . . . . . . . . . . . . . . . . . . . . . . . . . 14-37
TEMPERATURE SENSOR CIRCUIT -
DIAGNOSIS AND TESTING, AMBIENT . . . . . 8M-9
TENSIONER - DESCRIPTION, SEAT BELT . . 8O-36
TENSIONER - OPERATION, SEAT BELT . . . . 8O-36
TERMINAL - INSTALLATION . . . . . . . . . 8W-01-14
TERMINAL - REMOVAL . . . . . . . . . . . . . 8W-01-14
TEST - DIAGNOSIS AND TESTING, FUEL
PRESSURE LEAK DOWN . . . . . . . . . . . . . . . . 14-3
PUMP AMPERAGE. . . . . . . . . . . . . . . . . . . . 14-16
PUMP CAPACITY . . . . . . . . . . . . . . . . . . . . . 14-15
PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . 14-15
TEST - DIAGNOSIS AND TESTING,
HYDRAULIC PRESSURE . . . . . . . . . . . . . . . 21-79
TEST - DIAGNOSIS AND TESTING, ROAD . . . 8P-2
TEST - STANDARD PROCEDURE,
BUILT-IN INDICATOR . . . . . . . . . . . . . . . . . . 8F-10
HYDROMETER . . . . . . . . . . . . . . . . . . . . . . . 8F-11
IGNITION-OFF DRAW. . . . . . . . . . . . . . . . . . 8F-14
TEST - STANDARD PROCEDURE, LOAD . . . 8F-12
OPEN-CIRCUIT VOLTAGE . . . . . . . . . . . . . . . 8F-12
VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . 8O-8
TEST MODE - DESCRIPTION, CIRCUIT
ACTUATION . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
TEST MODE - DESCRIPTION, STATE
DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
TESTER - STANDARD PROCEDURE,
USING MIDTRONICS ELECTRICAL . . . . . . . 8F-15
TETHER ANCHOR - DESCRIPTION, CHILD . 8O-13
TETHER ANCHOR - OPERATION, CHILD . . . 8O-13
THEFT SECURITY - DESCRIPTION,
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-1
THEFT SECURITY - OPERATION, VEHICLE . . 8Q-3
THEFT SECURITY SYSTEM - DIAGNOSIS
AND TESTING, VEHICLE . . . . . . . . . . . . . . . . 8Q-6
THERMAL GUARD - DESCRIPTION . . . . . . . 8F-20
THERMAL GUARD - INSTALLATION . . . . . . 8F-20
THERMAL GUARD - OPERATION . . . . . . . . . 8F-20
THERMAL GUARD - REMOVAL . . . . . . . . . . 8F-20
THERMOSTAT - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
THERMOSTAT - OPERATION, ENGINE
COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
THREAD REPAIR - STANDARD
PROCEDURE, ALUMINUM . . . . . . . . . . . . . . 21-81
THREADED HOLE REPAIR -
THREADS - STANDARD PROCEDURE,
REPAIR DAMAGED OR WORN . . . . . . . . . . . . 9-9
THROTTLE BODY - DESCRIPTION . . . . . . . . 14-43
THROTTLE BODY - INSTALLATION . . . . . . . 14-44
THROTTLE BODY - OPERATION . . . . . . . . . 14-43
THROTTLE BODY - REMOVAL . . . . . . . . . . . 14-43
THROTTLE CONTROL CABLE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-46
THROTTLE CONTROL CABLE - REMOVAL . . 14-45
THROTTLE POSITION SENSOR -
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 14-47
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14-48
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
TIE ROD END - INSTALLATION . . . . . . . . . . 19-16
TIE ROD END - REMOVAL . . . . . . . . . . . . . . 19-16
TIE ROD END REMOVAL TOOL, SPECIAL
TOOLS - OUTER . . . . . . . . . . . . . . . . . . . . . 19-15
TIME INDICATOR - DESCRIPTION, FULL . . . 8J -29
TIME INDICATOR - DESCRIPTION, PART . . 8J -29
TIME INDICATOR - OPERATION, FULL . . . . 8J -30
TIME INDICATOR - OPERATION, PART . . . . 8J -29
TIMING - DESCRIPTION, VALVE . . . . . . . . . . 9-71
TIMING - OPERATION, VALVE . . . . . . . . . . . . 9-71
TIMING - SPECIFICATIONS, IGNITION . . . . . . 8I-2
TIMING BELT / CHAIN COVER(S) -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 9-76
TIMING BELT / CHAIN COVER(S) -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
TIMING CHAIN WEAR, STANDARD
PROCEDURE - MEASURING . . . . . . . . . . . . . 9-71
TIRE - INSTALLATION, SPARE . . . . . . . . . . . 22-9
TIRE - REMOVAL, SPARE . . . . . . . . . . . . . . . 22-8
TIRE INFLATION - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
TIRE NOISE OR VIBRATION - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 22-8
TIRE ROTATION - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-2
TIRE &TEMPORARY - DESCRIPTION,
SPARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6
TIRE WEAR PATTERNS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 22-8
TIRES - DESCRIPTION . . . . . . . . . . . . . . . . . 22-6
TIRES - DESCRIPTION, RADIAL-PLY . . . . . . . 22-6
TIRES - DESCRIPTION, REPLACEMENT . . . . 22-7
TIRES AND WHEEL RUNOUT -
TO GROUND - STANDARD PROCEDURE,
TESTING FOR A SHORT . . . . . . . . . . . . . 8W-01-9
TO GROUND ON FUSES POWERING
PROCEDURE, TESTING FOR A SHORT . . 8W-01-9
TO USE WIRING DIAGRAMS -
DESCRIPTION, HOW. . . . . . . . . . . . . . . . 8W-01-1
TOE ADJ USTMENT - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
TOE ADJ USTMENT - STANDARD
PROCEDURE, CAMBER, CASTER . . . . . . . . . . 2-5
TOOL, SPECIAL TOOLS - OUTER TIE
ROD END REMOVAL . . . . . . . . . . . . . . . . . . 19-15
TOOLS - 3.7L ENGINE, SPECIAL . . . . . . . . . . 9-15
TOOLS - 8 1/4 AXLE, SPECIAL . . . . . . . . . . . 3-98
TOOLS - BASE BRAKES, SPECIAL . . . . . . . . . 5-7
TOOLS - BODY, SPECIAL . . . . . . . . . . . . . . . . 23-5
TOOLS - COOLING, SPECIAL . . . . . . . . . . . . . 7-14
TOOLS - FRONT AXLE, SPECIAL . . . . . . . . . . 3-34
TOOLS - FRONT SUSPENSION, SPECIAL . . . . 2-8
TOOLS - FUEL SYSTEM, SPECIAL . . . . . . . . 14-6
TOOLS - OUTER TIE ROD END REMOVAL
TOOL, SPECIAL . . . . . . . . . . . . . . . . . . . . . . 19-15
TOOLS - POWER DISTRIBUTION
SYSTEMS, SPECIAL . . . . . . . . . . . . . . . . 8W-97-2
TOOLS - POWER STEERING PUMP,
SPECIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
TOOLS - REAR AXLE, SPECIAL . . . . . . . . . . . 3-63
TOOLS - RFE TRANSMISSION, SPECIAL . . 21-120
TOOLS - STEERING COLUMN, SPECIAL . . . . 19-8
TOOLS - WIRING/TERMINAL, SPECIAL . 8W-01-10
TOOLS, BATTERY SYSTEM - SPECIAL . . . . . 8F-7
TOOLS, SPECIFICATIONS - SPECIAL . . . . 3-12,3-6
TOOLS, SPECIFICATIONS - SPECIAL . . . . . . 8F-24
TOP COVER - INSTALLATION,
TOP COVER - REMOVAL, INSTRUMENT
PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-152
TORQUE - SPECIFICATIONS . . . . . . . . . . . . . 13-6
TORQUE CHART, SPECIFICATIONS . . 19-15,19-19,
19-8
TORQUE CHART, SPECIFICATIONS . . . . . 2-17,2-8
TORQUE CONVERTER - DESCRIPTION . . . 21-162
TORQUE CONVERTER - INSTALLATION . . . 21-167
TORQUE CONVERTER - OPERATION . . . . . 21-166
TORQUE CONVERTER - REMOVAL . . . . . . 21-167
TORQUE, EXCEPT DIESEL . . . . . . . . . . . . . . 8F-23
TORQUE, GAS POWERED . . . . . . . . . . . . . . 8F-38
TORQUE, IGNITION SYSTEM . . . . . . . . . . . . . 8I-3
TORQUE REFERENCES - DESCRIPTION . . Intro.-7
TORQUE, SPECIFICATIONS . . . . . . . . . . . . . . . 5-7
TORQUE, SPECIFICATIONS . . . . . . . . . . . . . . 7-13
TORQUE, SPECIFICATIONS . . . . . . . . . . . . . 25-26
TORQUE, SPEED CONTROL . . . . . . . . . . . . . 8P-2
TOUCH-UP - DESCRIPTION, PAINT . . . . . . 23-163
TOW CONNECTOR - INSTALLATION,
TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-61
TOW CONNECTOR - REMOVAL, TRAILER . . 8L-61
TOW HOOK - INSTALLATION, FRONT . . . . . . 13-8
TOW HOOK - INSTALLATION, REAR . . . . . . . 13-8
TOW HOOK - REMOVAL, FRONT . . . . . . . . . . 13-8
TOW HOOK - REMOVAL, REAR . . . . . . . . . . . 13-8
TOW RELAY - DESCRIPTION, TRAILER . . . . 8L-61
TOW RELAY - DIAGNOSIS AND TESTING,
TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-62
TOW RELAY - INSTALLATION, TRAILER . . . 8L-64
TOW RELAY - OPERATION, TRAILER . . . . . 8L-62
TOW RELAY - REMOVAL, TRAILER . . . . . . . 8L-63
TOW WIRING - DESCRIPTION, TRAILER . . 8L-64
TOWING - STANDARD PROCEDURE . . . . . . . . 0-6
TRACK - DESCRIPTION, SEAT . . . . . . . . . . 8N-15
TRACK - DIAGNOSIS AND TESTING,
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-16
TRACK - INSTALLATION, SEAT . . . . . . . . . 23-168
TRACK - INSTALLATION, SEAT . . . . . . . . . . 8N-16
TRACK - OPERATION, SEAT . . . . . . . . . . . . 8N-15
TRACK - REMOVAL, SEAT . . . . . . . . . . . . . 23-168
TRACK - REMOVAL, SEAT . . . . . . . . . . . . . . 8N-16
TRAC-LOK - ASSEMBLY, DIFFERENTIAL . . . 3-109,
3-77
TRAC-LOK - CLEANING, DIFFERENTIAL . . . 3-109,
3-77
TRAC-LOK - DISASSEMBLY,
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . 3-107,3-75
TRAC-LOK - INSPECTION, DIFFERENTIAL . 3-109,
3-77
TRAC-LOK - DIAGNOSIS AND TESTING . . 3-106,
3-74
TRAILER HITCH - INSTALLATION . . . . . . . . . 13-9
TRAILER HITCH - REMOVAL . . . . . . . . . . . . . 13-9
TRAILER TOW CONNECTOR -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 8L-61
TRAILER TOW CONNECTOR - REMOVAL . . 8L-61
TRAILER TOW RELAY - DESCRIPTION . . . . 8L-61
TRAILER TOW RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-62
TRAILER TOW RELAY - INSTALLATION . . . 8L-64
TRAILER TOW RELAY - OPERATION . . . . . . 8L-62
TRAILER TOW RELAY - REMOVAL . . . . . . . 8L-63
TRAILER TOW WIRING - DESCRIPTION . . . 8L-64
TRANS COOLER - DESCRIPTION . . . . . . . . . 7-32
TRANS TEMP INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -33
TRANS TEMP INDICATOR - OPERATION . . . 8J -34
KJ INDEX 27
TRANSCEIVER MODULE - DESCRIPTION,
INTRUSION . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-14
TRANSCEIVER MODULE -
INSTALLATION, INTRUSION . . . . . . . . . . . . 8Q-16
TRANSCEIVER MODULE - OPERATION,
INTRUSION . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-15
TRANSCEIVER MODULE - REMOVAL,
INTRUSION . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-15
TRANSFER CASE - NV231 - ASSEMBLY . . 21-194
TRANSFER CASE - NV231 - CLEANING . . 21-190
TRANSFER CASE - NV231 -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-178
TRANSFER CASE - NV231 - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-180
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-182
TRANSFER CASE - NV231 - INSPECTION . 21-190
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-205
TRANSFER CASE - NV231 - OPERATION . 21-179
TRANSFER CASE - NV231 - REMOVAL . . . 21-181
TRANSFER CASE - NV242 - ASSEMBLY . . 21-230
TRANSFER CASE - NV242 - CLEANING . . 21-227
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-215
TRANSFER CASE - NV242 - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . 21-216
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-218
TRANSFER CASE - NV242 - INSPECTION . 21-228
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 21-243
TRANSFER CASE - NV242 - OPERATION . 21-215
TRANSFER CASE - NV242 - REMOVAL . . . 21-217
TRANSFER CASE, NV231 . . . . . . . . . . . . . 21-206
TRANSFER CASE, NV242 . . . . . . . . . . . . . 21-244
TRANSFER CASE SKID PLATE -
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 13-7
TRANSFER CASE SKID PLATE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
TRANSFER CASE, SPECIFICATIONS -
NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-244
TRANSMISSION - 45RFE -
DESCRIPTION, AUTOMATIC. . . . . . . . . . . . . 21-76
TRANSMISSION - 45RFE - OPERATION,
AUTOMATIC. . . . . . . . . . . . . . . . . . . . . . . . . 21-77
TRANSMISSION - DESCRIPTION,
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
TRANSMISSION - DIAGNOSIS AND
TESTING, AUTOMATIC. . . . . . . . . . . . . . . . . 21-77
TRANSMISSION - DIAGNOSIS AND
TESTING, MANUAL . . . . . . . . . . . . . . . 21-2,21-33
TRANSMISSION CLUTCH OPERATION -
DIAGNOSIS AND TESTING, AIR
CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-80
TRANSMISSION CONTROL MODULE -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8E-18
TRANSMISSION CONTROL MODULE -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8E-18
TRANSMISSION CONTROL RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-168
TRANSMISSION CONTROL RELAY -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-168
TRANSMISSION FILL - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 21-128
TRANSMISSION FLUID - DESCRIPTION,
AUTOMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
TRANSMISSION FLUID - OPERATION,
AUTOMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
TRANSMISSION RANGE INDICATOR
ILLUMINATION BULB - INSTALLATION . . . . 8L-83
ILLUMINATION BULB - REMOVAL. . . . . . . . 8L-82
TRANSMISSION RANGE SENSOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-168
TRANSMISSION RANGE SENSOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-168
TRANSMISSION SHIFT INTERLOCK
SYSTEM - DESCRIPTION, BRAKE . . . . . . . 21-124
SYSTEM - DIAGNOSIS AND TESTING,
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-125
SYSTEM - OPERATION, BRAKE. . . . . . . . . 21-125
TRANSMISSION SOLENOID/TRS
ASSEMBLY - DESCRIPTION. . . . . . . . . . . . 21-169
ASSEMBLY - INSTALLATION . . . . . . . . . . . 21-170
ASSEMBLY - OPERATION . . . . . . . . . . . . . 21-169
ASSEMBLY - REMOVAL . . . . . . . . . . . . . . . 21-170
TRANSMISSION, SPECIAL TOOLS - RFE . . 21-120
TRANSMISSION, SPECIFICATIONS . . . . . . 21-119
TRANSMISSION TEMPERATURE SENSOR
- DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 21-170
TRANSMISSION TEMPERATURE SENSOR
- OPERATION. . . . . . . . . . . . . . . . . . . . . . . 21-170
TRANSMITTER - DESCRIPTION,
UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . 8M-8
TESTING, REMOTE KEYLESS ENTRY . . . . . . 8N-8
TESTING, UNIVERSAL . . . . . . . . . . . . . . . . . 8M-8
TRANSMITTER - OPERATION,
UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . 8M-8
TRANSMITTER - SPECIFICATIONS,
REMOTE KEYLESS ENTRY . . . . . . . . . . . . . . 8N-9
TRANSMITTER BATTERIES - STANDARD
PROCEDURE, RKE. . . . . . . . . . . . . . . . . . . . . 8N-8
TRANSMITTER CODES - STANDARD
PROCEDURE, ERASING . . . . . . . . . . . . . . . . 8M-8
TRANSMITTER CODES - STANDARD
PROCEDURE, SETTING. . . . . . . . . . . . . . . . . 8M-9
TRANSMITTER CUSTOMER
PROCEDURE, RKE. . . . . . . . . . . . . . . . . . . . . 8N-8
TRANSMITTER PROGRAMING -
STANDARD PROCEDURE, RKE . . . . . . . . . . . 8N-9
TRANSPONDER KEY - DESCRIPTION . . . . . 8Q-18
TRANSPONDER KEY - OPERATION . . . . . . . 8Q-18
TRANSPONDER PROGRAMMING -
STANDARD PROCEDURE, SENTRY KEY . . . . 8Q-8
TRAY - DESCRIPTION, BATTERY . . . . . . . . . 8F-21
TRAY - INSTALLATION, BATTERY . . . . . . . . 8F-21
TRAY - OPERATION, BATTERY . . . . . . . . . . 8F-21
TRAY - REMOVAL, BATTERY . . . . . . . . . . . . 8F-21
TREAD WEAR INDICATORS - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . 22-8
TRIM - INSTALLATION, B-PILLAR
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-157
TRIM - INSTALLATION, B-PILLAR UPPER . 23-158
TRIM - REMOVAL, B-PILLAR LOWER . . . . 23-157
TRIM - REMOVAL, B-PILLAR UPPER . . . . 23-157
TRIM AND GRAB HANDLE -
INSTALLATION, A-PILLAR . . . . . . . . . . . . . 23-156
TRIM AND GRAB HANDLE - REMOVAL,
A-PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-156
TRIM COVER - INSTALLATION, COWL . . . 23-157
TRIM COVER - REMOVAL, COWL . . . . . . . 23-157
TRIM LACE - INSTALLATION, OPENING . . 23-180
TRIM LACE - REMOVAL, OPENING . . . . . . 23-180
TRIM PANEL - INSTALLATION . . . 23-126,23-132,
23-138
TRIM PANEL - INSTALLATION, QUARTER . 23-159
TRIM PANEL - REMOVAL . 23-125,23-132,23-138
TRIM PANEL - REMOVAL, QUARTER . . . . 23-159
TRIP DEFINITION - DESCRIPTION . . . . . . . . 25-19
TROUBLE CODES - DESCRIPTION,
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . 25-2
TUBE - DESCRIPTION, A/C ORIFICE . . . . . . 24-50
TUBE - INSTALLATION, A/C ORIFICE . . . . . . 24-50
TUBE - INSTALLATION, DRAIN . . . . . . . . . 23-181
TUBE - OPERATION, A/C ORIFICE . . . . . . . . 24-50
TUBE - REMOVAL, A/C ORIFICE . . . . . . . . . 24-50
TUBE - REMOVAL, DRAIN . . . . . . . . . . . . . 23-180
TURN SIGNAL INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -34
TURN SIGNAL INDICATOR - OPERATION . . 8J -34
TURNING LOOP ADJ USTER -
INSTALLATION, SEAT BELT . . . . . . . . . . . . . 8O-38
TURNING LOOP ADJ USTER - REMOVAL,
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-37
UNIT - ADJ USTMENT, FRONT FOG LAMP . . 8L-25
UNIT - ADJ USTMENT, HEADLAMP . . . . . . . 8L-42
UNIT - DIAGNOSIS AND TESTING, FUEL
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . . 14-9
UNIT - INSTALLATION, ASH RECEIVER
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-72
UNIT - INSTALLATION, CARGO LAMP . . . . . 8L-74
UNIT - INSTALLATION, CENTER HIGH
UNIT - INSTALLATION, COURTESY LAMP . . 8L-77
UNIT - INSTALLATION, FRONT FOG
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-25
UNIT - INSTALLATION, FRONT LAMP . . . . . 8L-28
UNIT - INSTALLATION, HEADLAMP . . . . . . . 8L-42
UNIT - INSTALLATION, LICENSE PLATE
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-46
UNIT - INSTALLATION, READING LAMP . . . 8L-81
UNIT - INSTALLATION, REAR LAMP . . . . . . 8L-60
UNIT - INSTALLATION, REPEATER LAMP . . 8L-61
UNIT - REMOVAL, ASH RECEIVER LAMP . . 8L-72
UNIT - REMOVAL, CARGO LAMP . . . . . . . . 8L-74
UNIT - REMOVAL, CENTER HIGH
UNIT - REMOVAL, COURTESY LAMP . . . . . 8L-76
UNIT - REMOVAL, FRONT FOG LAMP . . . . . 8L-25
UNIT - REMOVAL, FRONT LAMP . . . . . . . . . 8L-27
UNIT - REMOVAL, HEADLAMP . . . . . . . . . . 8L-41
UNIT - REMOVAL, LICENSE PLATE LAMP . . 8L-45
UNIT - REMOVAL, READING LAMP . . . . . . . 8L-81
UNIT - REMOVAL, REAR LAMP . . . . . . . . . . 8L-59
UNIT - REMOVAL, REPEATER LAMP . . . . . . 8L-60
UNIT / SENSOR - DESCRIPTION, FUEL
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . . 14-9
UNIT / SENSOR - INSTALLATION, FUEL
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . 14-10
UNIT / SENSOR - OPERATION, FUEL
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . . 14-9
UNIT / SENSOR - REMOVAL, FUEL
LEVEL SENDING . . . . . . . . . . . . . . . . . . . . . . 14-9
UNIVERSAL J OINTS - ASSEMBLY,
SINGLE CARDAN. . . . . . . . . . . . . . . . . . . . . . . 3-9
UNIVERSAL J OINTS - DISASSEMBLY,
SINGLE CARDAN. . . . . . . . . . . . . . . . . . . . . . . 3-8
UNIVERSAL TRANSMITTER -
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . 8M-8
UNIVERSAL TRANSMITTER - DIAGNOSIS
AND TESTING. . . . . . . . . . . . . . . . . . . . . . . . 8M-8
UNIVERSAL TRANSMITTER - OPERATION . . 8M-8
UNLOCK SWITCH - INSTALLATION,
DOOR LOCK . . . . . . . . . . . . . . . . . . . . . . . . . 8N-5
UNLOCK SWITCH - REMOVAL, DOOR
LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-4
UPPER BALL J OINT - INSTALLATION . . . . . . 2-20
UPPER BALL J OINT - REMOVAL . . . . . . . . . . 2-20
UPPER CONTROL ARM - INSTALLATION . . . 2-21
UPPER CONTROL ARM - REMOVAL . . . . . . . 2-20
UPPER SUSPENSION ARM, BUSHINGS,
AND BALL J OINT - DESCRIPTION. . . . . . . . . 2-20
UPPER SUSPENSION ARM, BUSHINGS,
AND BALL J OINT - OPERATION . . . . . . . . . . 2-20
UPPER TRIM - INSTALLATION, B-PILLAR . 23-158
UPPER TRIM - REMOVAL, B-PILLAR . . . . 23-157
USE WIRING DIAGRAMS -
DESCRIPTION, HOW TO . . . . . . . . . . . . . 8W-01-1
USING MIDTRONICS ELECTRICAL
TESTER - STANDARD PROCEDURE. . . . . . . 8F-15
V-6 - ENGINE FIRING ORDER, 3.7L . . . . . . . . 8I-2
V-6 - IGNITION COIL RESISTANCE, 3.7L . . . . 8I-3
VACUUM CHECK VALVE - DESCRIPTION . . 24-28
VACUUM CHECK VALVE - INSTALLATION . . 24-28
VACUUM CHECK VALVE - OPERATION . . . . 24-28
VACUUM CHECK VALVE - REMOVAL . . . . . . 24-28
VACUUM LINES - DESCRIPTION . . . . . . . . . 25-33
VACUUM RESERVOIR - DESCRIPTION . . . . . 8P-7
VACUUM RESERVOIR - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-7
VACUUM RESERVOIR - INSTALLATION . . . . 8P-8
VACUUM RESERVOIR - OPERATION . . . . . . . 8P-7
VACUUM RESERVOIR - REMOVAL . . . . . . . . 8P-7
VACUUM SYSTEM - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-6
VALUE - DESCRIPTION, LOAD . . . . . . . . . . 25-20
VALVE - DESCRIPTION, FLOW
MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . 14-6
VALVE - DESCRIPTION, FRONT CHECK . . . . 8R-8
VALVE - DESCRIPTION, FUEL TANK
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
VALVE - DESCRIPTION, HIGH PRESSURE
RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
VALVE - DESCRIPTION, PCV . . . . . . . . . . . . 25-29
VALVE - DESCRIPTION, REAR CHECK . . . . 8R-34
VALVE - DESCRIPTION, SOLENOID
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-161
VALVE - DESCRIPTION, VACUUM CHECK . . 24-28
VALVE - DIAGNOSIS AND TESTING, PCV . . 25-31
VALVE - DIAGNOSIS AND TESTING,
PROPORTIONING . . . . . . . . . . . . . . . . . . . . . 5-20
28 INDEX KJ
VALVE - INSTALLATION, FLOW
MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . 14-7
VALVE - INSTALLATION, FRONT CHECK . . . . 8R-9
VALVE - INSTALLATION, FUEL TANK
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
VALVE - INSTALLATION, PCV . . . . . . . . . . . 25-32
VALVE - INSTALLATION, REAR CHECK . . . . 8R-35
VALVE - INSTALLATION, VACUUM CHECK . 24-28
VALVE - OPERATION, FLOW
MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . 14-6
VALVE - OPERATION, FRONT CHECK . . . . . . 8R-9
VALVE - OPERATION, FUEL TANK CHECK . . 14-28
VALVE - OPERATION, HIGH PRESSURE
RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
VALVE - OPERATION, PCV . . . . . . . . . . . . . . 25-31
VALVE - OPERATION, REAR CHECK . . . . . . 8R-34
VALVE - OPERATION, SOLENOID SWITCH . 21-161
VALVE - OPERATION, VACUUM CHECK . . . . 24-28
VALVE - REMOVAL, FLOW
MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . 14-6
VALVE - REMOVAL, FRONT CHECK . . . . . . . 8R-9
VALVE - REMOVAL, FUEL TANK CHECK . . . 14-28
VALVE - REMOVAL, PCV . . . . . . . . . . . . . . . 25-32
VALVE - REMOVAL, REAR CHECK . . . . . . . 8R-34
VALVE - REMOVAL, VACUUM CHECK . . . . . 24-28
VALVE BODY - ASSEMBLY . . . . . . . . . . . . 21-176
VALVE BODY - CLEANING . . . . . . . . . . . . . 21-175
VALVE BODY - DESCRIPTION. . . . . . . . . . . . 21-171
VALVE BODY - DISASSEMBLY . . . . . . . . . . 21-173
VALVE BODY - INSPECTION . . . . . . . . . . . 21-175
VALVE BODY - INSTALLATION . . . . . . . . . . 21-177
VALVE BODY - OPERATION . . . . . . . . . . . . 21-171
VALVE BODY - REMOVAL . . . . . . . . . . . . . 21-172
VALVE GUIDE SEALS - DESCRIPTION . . 9-29,9-38
VALVE GUIDES - DESCRIPTION . . . . . . 9-19,9-30
VALVE SPRINGS - DESCRIPTION . . . . . 9-29,9-38
VALVE SPRINGS - INSTALLATION . . . . . 9-29,9-38
VALVE SPRINGS - REMOVAL . . . . . . . . 9-29,9-38
VALVE TIMING - DESCRIPTION . . . . . . . . . . . 9-71
VALVE TIMING - OPERATION . . . . . . . . . . . . 9-71
VALVES & SEATS - DESCRIPTION,
INTAKE/EXHAUST . . . . . . . . . . . . . . . . . . . . . 9-26
VALVES & SEATS - INSTALLATION,
INTAKE/EXHAUST . . . . . . . . . . . . . . . . . 9-28,9-36
VALVES & SEATS - REMOVAL,
INTAKE/EXHAUST . . . . . . . . . . . . . . . . . 9-27,9-35
VANITY LAMP BULB - INSTALLATION . . . . . 8L-84
VANITY LAMP BULB - REMOVAL . . . . . . . . 8L-83
VAPOR CANISTER - DESCRIPTION . . . . . . . 25-33
VAPOR CANISTER - INSTALLATION . . . . . . 25-33
VAPOR CANISTER - OPERATION . . . . . . . . . 25-33
VAPOR CANISTER - REMOVAL . . . . . . . . . . 25-33
VARIATION ADJ USTMENT - STANDARD
PROCEDURE, COMPASS . . . . . . . . . . . . . . . 8M-3
VEHICLE EMISSION CONTROL
INFORMATION (VECI) LABEL -
VEHICLE IDENTIFICATION NUMBER -
VEHICLE SAFETY CERTIFICATION LABEL
- DESCRIPTION. . . . . . . . . . . . . . . . . . . . . Intro.-9
VEHICLE THEFT SECURITY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8Q-1
VEHICLE THEFT SECURITY - OPERATION . . 8Q-3
VEHICLE THEFT SECURITY SYSTEM -
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8Q-6
VERIFICATION TEST - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 8O-8
VIBRATION - DIAGNOSIS AND TESTING,
TIRE NOISE OR . . . . . . . . . . . . . . . . . . . . . . . 22-8
VIBRATION DAMPER - INSTALLATION . . . . . 9-55
VIBRATION DAMPER - REMOVAL . . . . . . . . . 9-54
VIEW MIRROR - INSTALLATION, SIDE . . . 23-145
VIEW MIRROR - REMOVAL, REAR . . . . . . 23-161
VIEW MIRROR - REMOVAL, SIDE . . . . . . . 23-145
VISCOUS - CLEANING, RADIATOR - FAN . . . 7-29
VISCOUS - DESCRIPTION, RADIATOR -
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
VISCOUS - INSPECTION, RADIATOR -
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
VISCOUS - INSTALLATION, RADIATOR -
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
VISCOUS - OPERATION, RADIATOR -
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
VISCOUS - REMOVAL, RADIATOR - FAN . . . . 7-28
VISCOUS FAN DRIVE - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
VISOR - INSTALLATION, SUN . . . . . . . . . . 23-160
VISOR - REMOVAL, SUN . . . . . . . . . . . . . . 23-160
VISOR SUPPORT - INSTALLATION, SUN . . 23-160
VISOR SUPPORT - REMOVAL, SUN . . . . . 23-160
VOLT SUPPLIES - DESCRIPTION, 5 . . . . . . 8E-13
VOLT SUPPLIES - OPERATION, 5 . . . . . . . . 8E-15
VOLTAGE DROP - STANDARD
PROCEDURE, TESTING FOR A . . . . . . . 8W-01-10
VOLTAGE POTENTIAL - STANDARD
PROCEDURE, TESTING OF . . . . . . . . . . . 8W-01-9
VOLTAGE REGULATOR - DESCRIPTION . . . . 8F-31
VOLTAGE REGULATOR - OPERATION . . . . . 8F-31
VOLTAGE TEST - STANDARD
PROCEDURE, OPEN-CIRCUIT . . . . . . . . . . . 8F-12
VOLUME CHECK - STANDARD
PROCEDURE, OIL PUMP . . . . . . . . . . . . . . 21-148
WAIT-TO-START INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -35
WAIT-TO-START INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -35
WARNING - INSTALLATION . . . . . . . . . . . . 23-173
WARNING - REMOVAL . . . . . . . . . . . . . . . 23-173
WARNING - SAFETY PRECAUTIONS AND
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
WARNING - SERVICE WARNINGS . . . . . . . . 24-39
WARNING - WINDSHIELD SAFETY
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . 23-173
WARNING, BRAKES - BASE . . . . . . . . . . . . . . 5-2
WARNING, CLUTCH . . . . . . . . . . . . . . . . . . . . . 6-2
WARNING, FRONT . . . . . . . . . . . . . . . . . . . . . . 2-7
WARNING, REAR . . . . . . . . . . . . . . . . . . . . . . 2-16
WARNING, RESTRAINT SYSTEM . . . . . . . . . 8O-5
WARNING SYSTEM - DESCRIPTION,
CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-1
WARNING SYSTEM - DIAGNOSIS AND
TESTING, CHIME. . . . . . . . . . . . . . . . . . . . . . 8B-6
WARNING SYSTEM - OPERATION,
CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-2
WARNINGS, GENERAL . . . . . . . . . . . . . . 8W-01-7
WARNINGS, WARNING - SAFETY
PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . 23-1
WARNINGS, WARNING - SERVICE . . . . . . . 24-39
WASHER FLUID INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -35
DIAGNOSIS AND TESTING. . . . . . . . . . . . . . 8J -36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -36
WASHER FLUID LEVEL SWITCH -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8R-18
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-17
WASHER HOSES/TUBES - DESCRIPTION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-10
WASHER HOSES/TUBES - DESCRIPTION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-35
WASHER HOSES/TUBES - OPERATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-10
WASHER HOSES/TUBES - OPERATION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-36
WASHER NOZZLE - DESCRIPTION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-11
WASHER NOZZLE - DESCRIPTION, REAR . 8R-36
WASHER NOZZLE - INSTALLATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-11
WASHER NOZZLE - INSTALLATION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-37
WASHER NOZZLE - OPERATION, FRONT . . 8R-11
WASHER NOZZLE - OPERATION, REAR . . . 8R-36
WASHER NOZZLE - REMOVAL, FRONT . . . . 8R-11
WASHER NOZZLE - REMOVAL, REAR . . . . 8R-36
WASHER PUMP/MOTOR - DESCRIPTION . . 8R-18
WASHER PUMP/MOTOR - INSTALLATION . 8R-20
WASHER PUMP/MOTOR - OPERATION . . . 8R-19
WASHER PUMP/MOTOR - REMOVAL . . . . . 8R-19
WASHER RESERVOIR - DESCRIPTION . . . . 8R-21
WASHER RESERVOIR - INSTALLATION . . . 8R-22
WASHER RESERVOIR - OPERATION . . . . . . 8R-21
WASHER RESERVOIR - REMOVAL . . . . . . . 8R-21
WASHER SYSTEM - CLEANING, FRONT
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-7
WASHER SYSTEM - CLEANING, REAR
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-32
WASHER SYSTEM - DIAGNOSIS AND
TESTING, FRONT WIPER . . . . . . . . . . . . . . . 8R-6
WASHER SYSTEM - DIAGNOSIS AND
TESTING, REAR WIPER . . . . . . . . . . . . . . . 8R-30
WASHER SYSTEM - INSPECTION, FRONT
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-7
WASHER SYSTEM - INSPECTION, REAR
WIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-33
WATER DRAINAGE AND WIND NOISE
DIAGNOSIS, DIAGNOSIS AND TESTING . . 23-176
WATER LEAKS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2
WATER PUMP - DESCRIPTION . . . . . . . . . . . 7-29
WATER PUMP - OPERATION . . . . . . . . . . . . . 7-30
WATERDAM - INSTALLATION . . . . 23-126,23-133
WATERDAM - REMOVAL . . . . . . . . 23-126,23-133
WATER-IN-FUEL INDICATOR -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8J -37
WATER-IN-FUEL INDICATOR -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8J -37
WEAR INDICATORS - DIAGNOSIS AND
TESTING, TREAD. . . . . . . . . . . . . . . . . . . . . . 22-8
WEAR PATTERNS - DIAGNOSIS AND
TESTING, TIRE . . . . . . . . . . . . . . . . . . . . . . . 22-8
WEAR, STANDARD PROCEDURE -
MEASURING TIMING CHAIN . . . . . . . . . . . . . 9-71
WEATHERSTRIP - INSTALLATION, COWL . 23-185
WEATHERSTRIP - INSTALLATION, DOOR
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP - INSTALLATION, DOOR
PRIMARY . . . . . . . . . . . . . . . . . . . . . . . . . . 23-185
WEATHERSTRIP - INSTALLATION,
SWING GATE BELTLINE. . . . . . . . . . . . . . . 23-186
WEATHERSTRIP - INSTALLATION,
SWING GATE OPENING . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP - REMOVAL, COWL . . . . . 23-185
WEATHERSTRIP - REMOVAL, DOOR
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP - REMOVAL, DOOR
PRIMARY . . . . . . . . . . . . . . . . . . . . . . . . . . 23-185
WEATHERSTRIP - REMOVAL, SWING
GATE BELTLINE . . . . . . . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP - REMOVAL, SWING
GATE OPENING . . . . . . . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP/RETAINER -
INSTALLATION, SIDE RAIL . . . . . . . . . . . . 23-186
WEATHERSTRIP/RETAINER -
INSTALLATION, WINDSHIELD A-PILLAR . . 23-187
WEATHERSTRIP/RETAINER - REMOVAL,
SIDE RAIL . . . . . . . . . . . . . . . . . . . . . . . . . 23-186
WEATHERSTRIP/RETAINER - REMOVAL,
WINDSHIELD A-PILLAR. . . . . . . . . . . . . . . 23-186
WELD AND STRUCTURAL ADHESIVE
LOCATIONS - SPECIFICATIONS . . . . . . . . . . . 23-9
WHEEL - INSTALLATION, STEERING . . . . . . 19-12
WHEEL - REMOVAL, STEERING . . . . . . . . . 19-12
WHEEL ALIGNMENT - DESCRIPTION . . . . . . . 2-3
WHEEL ALIGNMENT - OPERATION . . . . . . . . . 2-3
WHEEL BALANCING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 22-4
WHEEL CYLINDERS - ASSEMBLY . . . . . . . . . 5-29
WHEEL CYLINDERS - CLEANING . . . . . . . . . 5-28
WHEEL CYLINDERS - DISASSEMBLY . . . . . . 5-28
WHEEL CYLINDERS - INSPECTION . . . . . . . . 5-29
WHEEL CYLINDERS - INSTALLATION . . . . . . 5-29
WHEEL CYLINDERS - REMOVAL . . . . . . . . . . 5-28
WHEEL MOUNTING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 22-10
WHEEL OPENING FLARE MOLDINGS -
REMOVAL, FRONT . . . . . . . . . . . . . . . . . . . 23-145
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 23-145
WHEEL REPLACEMENT - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 22-10
WHEEL RUNOUT - DIAGNOSIS AND
TESTING, TIRES . . . . . . . . . . . . . . . . . . . . . . 22-1
WHEEL SPEED SENSOR -
INSTALLATION, FRONT . . . . . . . . . . . . . . . . . 5-34
WHEEL SPEED SENSOR -
INSTALLATION, REAR . . . . . . . . . . . . . . . . . . 5-35
WHEEL SPEED SENSOR - REMOVAL,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
WHEEL SPEED SENSOR - REMOVAL,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
WHEELHOUSE SPLASH SHIELD -
KJ INDEX 29
REMOVAL, FRONT . . . . . . . . . . . . . . . . . . . 23-143
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . 23-144
WHEELS - DESCRIPTION . . . . . . . . . . . . . . . 22-9
WHEELS - DIAGNOSIS AND TESTING . . . . . 22-10
WIND DEFLECTOR - INSTALLATION . . . . . 23-180
WIND DEFLECTOR - REMOVAL . . . . . . . . . 23-180
WIND NOISE - DIAGNOSIS AND TESTING . . 23-3
WIND NOISE DIAGNOSIS, DIAGNOSIS
AND TESTING - WATER DRAINAGE . . . . . 23-176
WINDOW - INSTALLATION, QUARTER . . . 23-172
WINDOW - REMOVAL, QUARTER . . . . . . . 23-172
WINDOW BAFFLE SEAL - INSTALLATION,
COWL/PLENUM . . . . . . . . . . . . . . . . . . . . . 23-187
WINDOW BAFFLE SEAL - REMOVAL,
COWL/PLENUM . . . . . . . . . . . . . . . . . . . . . 23-187
WINDOW DEFOGGER - DESCRIPTION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
WINDOW DEFOGGER - OPERATION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-3
WINDOW DEFOGGER FUNCTION -
DIAGNOSIS AND TESTING, REAR HVAC
CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . 8G-9
WINDOW DEFOGGER GRID -
DESCRIPTION, REAR . . . . . . . . . . . . . . . . . . 8G-5
WINDOW DEFOGGER GRID - DIAGNOSIS
AND TESTING, REAR . . . . . . . . . . . . . . . . . . 8G-5
WINDOW DEFOGGER GRID -
OPERATION, REAR. . . . . . . . . . . . . . . . . . . . . . 8G-5
WINDOW DEFOGGER RELAY -
DIAGNOSIS AND TESTING, REAR. . . . . . . . . 8G-6
INSTALLATION, REAR . . . . . . . . . . . . . . . . . . 8G-7
OPERATION, REAR . . . . . . . . . . . . . . . . . . . . 8G-6
REMOVAL, REAR . . . . . . . . . . . . . . . . . . . . . 8G-7
WINDOW DEFOGGER SWITCH -
OPERATION, REAR . . . . . . . . . . . . . . . . . . . . 8G-8
WINDOW DEFOGGER SYSTEM -
WINDOW MOTOR - REMOVAL . . . . . . . . . . 8N-22
WINDOW REGULATOR - ELECTRIC -
INSTALLATION. . . . . . . . . . . . . . . . 23-126,23-134
WINDOW REGULATOR - ELECTRIC -
REMOVAL . . . . . . . . . . . . . . . . . . . 23-126,23-134
WINDOW REGULATOR - MANUAL -
INSTALLATION. . . . . . . . . . . . . . . . 23-126,23-133
WINDOW REGULATOR - MANUAL -
REMOVAL . . . . . . . . . . . . . . . . . . . 23-126,23-133
WINDOW SWITCH - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-22
WINDOW SWITCH - INSTALLATION . . . . . . 8N-23
WINDOW SWITCH - REMOVAL . . . . . . . . . . 8N-23
WINDOWS - DESCRIPTION, POWER . . . . . 8N-21
WINDOWS - DIAGNOSIS AND TESTING,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-21
WINDOWS - OPERATION, POWER . . . . . . . 8N-21
WINDSHIELD A-PILLAR WEATHERSTRIP/
RETAINER - INSTALLATION. . . . . . . . . . . . 23-187
RETAINER - REMOVAL . . . . . . . . . . . . . . . 23-186
WINDSHIELD SAFETY PRECAUTIONS,
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . 23-173
WIPER & WASHER SYSTEM -
CLEANING, FRONT . . . . . . . . . . . . . . . . . . . . 8R-7
CLEANING, REAR . . . . . . . . . . . . . . . . . . . . 8R-32
DIAGNOSIS AND TESTING, FRONT. . . . . . . . 8R-6
DIAGNOSIS AND TESTING, REAR. . . . . . . . 8R-30
INSPECTION, FRONT. . . . . . . . . . . . . . . . . . . 8R-7
INSPECTION, REAR. . . . . . . . . . . . . . . . . . . 8R-33
WIPER ARM - DESCRIPTION, FRONT . . . . . 8R-12
WIPER ARM - DESCRIPTION, REAR . . . . . . 8R-37
WIPER ARM - INSTALLATION, FRONT . . . . 8R-13
WIPER ARM - INSTALLATION, REAR . . . . . 8R-38
WIPER ARM - OPERATION, FRONT . . . . . . 8R-12
WIPER ARM - OPERATION, REAR . . . . . . . 8R-38
WIPER ARM - REMOVAL, FRONT . . . . . . . . 8R-12
WIPER ARM - REMOVAL, REAR . . . . . . . . . 8R-38
WIPER ARM PARK RAMP -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8R-43
WIPER ARM PARK RAMP - REMOVAL . . . . 8R-43
WIPER BLADE - DESCRIPTION, FRONT . . . 8R-13
WIPER BLADE - DESCRIPTION, REAR . . . . 8R-39
WIPER BLADE - INSTALLATION, FRONT . . . 8R-14
WIPER BLADE - INSTALLATION, REAR . . . . 8R-40
WIPER BLADE - OPERATION, FRONT . . . . . 8R-14
WIPER BLADE - OPERATION, REAR . . . . . . 8R-39
WIPER BLADE - REMOVAL, FRONT . . . . . . 8R-14
WIPER BLADE - REMOVAL, REAR . . . . . . . 8R-40
WIPER HIGH/LOW RELAY -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8R-23
WIPER HIGH/LOW RELAY - DIAGNOSIS
AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 8R-24
WIPER HIGH/LOW RELAY -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8R-24
WIPER HIGH/LOW RELAY - OPERATION . . 8R-23
WIPER HIGH/LOW RELAY - REMOVAL . . . . 8R-24
WIPER MODULE - DESCRIPTION, FRONT . 8R-15
WIPER MODULE - INSTALLATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-16
WIPER MODULE - OPERATION, FRONT . . . 8R-15
WIPER MODULE - REMOVAL, FRONT . . . . 8R-16
WIPER MOTOR - DESCRIPTION, REAR . . . 8R-41
WIPER MOTOR - INSTALLATION, REAR . . . 8R-42
WIPER MOTOR - OPERATION, REAR . . . . . 8R-41
WIPER MOTOR - REMOVAL, REAR . . . . . . 8R-42
WIPER ON/OFF RELAY - DESCRIPTION . . . 8R-25
WIPER ON/OFF RELAY - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-26
WIPER ON/OFF RELAY - INSTALLATION . . . 8R-26
WIPER ON/OFF RELAY - OPERATION . . . . . 8R-25
WIPER ON/OFF RELAY - REMOVAL . . . . . . 8R-26
WIPERS/WASHERS - DESCRIPTION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-2
WIPERS/WASHERS - DESCRIPTION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-27
WIPERS/WASHERS - OPERATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-4
WIPERS/WASHERS - OPERATION, REAR . . 8R-29
WIPER/WASHER SWITCH -
DESCRIPTION, FRONT . . . . . . . . . . . . . . . . 8R-16
WIPER/WASHER SWITCH -
DESCRIPTION, REAR . . . . . . . . . . . . . . . . . 8R-43
WIPER/WASHER SWITCH - OPERATION,
FRONT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-16
WIPER/WASHER SWITCH - OPERATION,
REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-43
WIRE SPLICING - STANDARD
PROCEDURE . . . . . . . . . . . . . . . . . . . . . 8W-01-14
WIRING - DESCRIPTION, TRAILER TOW . . 8L-64
WIRING DIAGRAMS - DESCRIPTION,
HOW TO USE . . . . . . . . . . . . . . . . . . . . . 8W-01-1
WIRING HARNESS - DIAGNOSIS AND
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-7
WIRING/TERMINAL, SPECIAL TOOLS . . 8W-01-10
WORN THREADS - STANDARD
PROCEDURE, REPAIR DAMAGED OR . . . . . . . 9-9
30 INDEX KJ
LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION INTERNATIONAL SYMBOLS . . 1
FLUID TYPES
DESCRIPTION
DESCRIPTION - FLUID TYPES . . . . . . . . . . . . 1
DESCRIPTION - AXLE . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - MANUAL TRANSMISSION . . . 2
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - TRANSFER CASE - NV231 . . 3
DESCRIPTION - TRANSFER CASE - NV242 . . 3
DESCRIPTION - ENGINE COOLANT . . . . . . . . 3
OPERATION - AUTOMATIC TRANSMISSION
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 4
FLUID FILL/CHECK LOCATIONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE SCHEDULES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HOISTING
STANDARD PROCEDURE - HOISTING
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 5
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 6
TOWING
STANDARD PROCEDURE - TOWING . . . . . . . . . 6
INTERNATIONAL SYMBOLS
DESCRIPTION INTERNATIONAL SYMBOLS
Dai ml erChrysl er Corporati on uses i nternati onal
symbol s to i denti fy engi ne compartment l ubri cant
and fl ui d i nspecti on and fi l l l ocati ons (Fi g. 1).
FLUID TYPES
DESCRIPTION
DESCRIPTION - FLUID TYPES
When servi ce i s requi red, Dai ml erChrysl er Corpo-
rati on recommends that onl y Mopar brand parts,
l ubri cants and chemi cal s be used. Mopar provi des
the best engi neered products for servi ci ng
Dai ml erChrysl er Corporati on vehi cl es.
Onl y l ubri cants beari ng desi gnati ons defi ned by
the fol l owi ng organi zati on shoul d be used to servi ce a
Chrysl er Corporati on vehi cl e.
Soci ety of Automoti ve Engi neers (SAE)
Ameri can Petrol eum I nsti tute (API ) (Fi g. 2)
Nati onal Lubri cati ng Grease I nsti tute (NLGI )
(Fi g. 3)
SAE VISCOSITY RATING
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . These are speci fi ed wi th a dual
SAE vi scosi ty grade whi ch i ndi cates the col d-to-hot
temperature vi scosi ty range. Exampl e SAE 5W-30 =
mul ti grade engi ne oi l .
Dai ml erChrysl er Corporati on onl y recommends
mul ti grade engi ne oi l s.
Fig. 1 International Symbols
KJ LUBRICATION & MAINTENANCE 0 - 1
API QUALITY CLASSIFICATION
Thi s symbol (Fi g. 2) on the front of an oi l contai ner
means that the oi l has been certi fi ed by the Ameri -
can Petrol eum I nsti tute (API ) to meet al l the l ubri -
cati on requi rements speci fi ed by Dai ml erChrysl er
Corporati on.
GEAR LUBRICANTS
SAE rati ngs al so appl y to mul ti grade gear l ubri -
cants. I n addi ti on, API cl assi fi cati on defi nes the
l ubri cants usage. Such as API GL-5 and SAE 75W-
90.
LUBRICANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 3) on the l abel . At the bottom NLGI
symbol i s the usage and qual i ty i denti fi cati on l etters.
Wheel beari ng l ubri cant i s i denti fi ed by the l etter
G. Chassi s l ubri cant i s i denti fi ed by the l atter L.
The l etter fol l owi ng the usage l etter i ndi cates the
qual i ty of the l ubri cant. The fol l owi ng symbol s i ndi -
cate the hi ghest qual i ty.
SPECIALIZED LUBRICANTS AND OILS
Some mai ntenance or repai r procedures may
requi re the use of speci al i zed l ubri cants or oi l s. Con-
sul t the appropri ate secti ons i n thi s manual for the
correct appl i cati on of these l ubri cants.
DESCRIPTION - AXLE
A mul ti -purpose, hypoi d gear l ubri cant whi ch con-
forms to MI L-L-2105C and API GL 5 qual i ty speci fi -
cati ons shoul d be used. Mopar Hypoi d Gear
Lubri cants conforms to these speci fi cati ons.
FRONT AXLE
Lubri cant for 186FI A (Model 30) axl e i s SAE
75W-140 SYNTHETI C.
REAR AXLE
Lubri cant for 198RBI (Model 35) axl e i s SAE
75W-140 SYNTHETI C.
Lubri cant for 8 1/4 axl e i s a thermal l y stabl e
SAE 75W-90. For trai l er tow or heavy duty appl i ca-
ti ons the l ubri cant shoul d be repl aced wi th SAE
75W-140 SYNTHETI C.
NOTE: Trac-lok equipped axles require a friction
modifier be added to the lubricant.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
DESCRIPTION - MANUAL TRANSMISSION
Mopar manual transmi ssi on fl ui d i s the l ubri cant
recommended for the NV1500 and the NV3550 trans-
mi ssi ons.
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to the maintenance schedules in this
group for the recommended maintenance (fluid/filter
change) intervals for this transmission.
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Mopar ATF +4, type 9602, Automati c Transmi s-
si on Fl ui d i s the recommended fl ui d for
Dai ml erChrysl er automati c transmi ssi ons.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopar ATF +4, type 9602, Automati c Transmi s-
si on Fl ui d when new i s red i n col or. The ATF i s dyed
red so i t can be i denti fi ed from other fl ui ds used i n
the vehi cl e such as engi ne oi l or anti freeze. The red
col or i s not permanent and i s not an i ndi cator of fl ui d
condi ti on. As the vehi cl e i s dri ven, the ATF wi l l begi n
to l ook darker i n col or and may eventual l y become
brown. This is normal. ATF+4 al so has a uni que
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION & MAINTENANCE KJ
FLUID TYPES (Continued)
odor that may change wi th age. Consequentl y, odor
and col or cannot be used to i ndi cate the fl ui d condi -
ti on or the need for a fl ui d change.
FLUID ADDITIVES
Dai ml erChrysl er strongl y recommends agai nst the
addi ti on of any fl ui ds to the transmi ssi on, other than
those automati c transmi ssi on fl ui ds l i sted above.
Excepti ons to thi s pol i cy are the use of speci al dyes
to ai d i n detecti ng fl ui d l eaks.
Vari ous speci al addi ti ves and suppl ements exi st
that cl ai m to i mprove shi ft feel and/or qual i ty. These
addi ti ves and others al so cl ai m to i mprove converter
cl utch operati on and i nhi bi t overheati ng, oxi dati on,
varni sh, and sl udge. These cl ai ms have not been sup-
ported to the sati sfacti on of Dai ml erChrysl er and
these addi ti ves must not be used. The use of trans-
mi ssi on seal ers shoul d al so be avoi ded, si nce they
may adversel y affect the i ntegri ty of transmi ssi on
seal s.
DESCRIPTION - TRANSFER CASE - NV231
Recommended l ubri cant for the NV231 transfer
case i s Mopar ATF +4, type 9602, Automati c Trans-
mi ssi on Fl ui d.
DESCRIPTION - TRANSFER CASE - NV242
Recommended l ubri cant for the NV242 transfer
case i s Mopar ATF+4, type 9602 Automati c Trans-
mi ssi on Fl ui d.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n
the cyl i nder head area near the exhaust val ves and
engi ne bl ock. Then cool ant carri es the heat to the
radi ator where the tube/fi n radi ator can transfer the
heat to the ai r.
The use of al umi num cyl i nder bl ocks, cyl i nder
heads, and water pumps requi res speci al corrosi on
protecti on. Mopar Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (MS-9769), or the equi va-
l ent ethyl ene gl ycol base cool ant wi th organi c corro-
si on i nhi bi tors (cal l ed HOAT, for Hybri d Organi c
Addi ti ve Technol ogy) i s recommended. Thi s cool ant
offers the best engi ne cool i ng wi thout corrosi on when
mi xed wi th 50% Ethyl ene Gl ycol and 50% di sti l l ed
water to obtai n a freeze poi nt of -37C (-35F). I f i t
l oses col or or becomes contami nated, drai n, fl ush,
and repl ace wi th fresh properl y mi xed cool ant sol u-
ti on.
CAUTION: Mopar Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon cl i mate and vehi cl e operati ng
condi ti ons. The cool ant performance of vari ous mi x-
tures fol l ows:
Pure Water-Water can absorb more heat than a
mi xture of water and ethyl ene-gl ycol . Thi s i s for pur-
pose of heat transfer onl y. Water al so freezes at a
hi gher temperature and al l ows corrosi on.
100 percent Ethylene-Glycol-The corrosi on
i nhi bi ti ng addi ti ves i n ethyl ene-gl ycol need the pres-
ence of water to di ssol ve. Wi thout water, addi ti ves
form deposi ts i n system. These act as i nsul ati on
causi ng temperature to ri se to as hi gh as 149C
(300F). Thi s temperature i s hot enough to mel t pl as-
ti c and soften sol der. The i ncreased temperature can
resul t i n engi ne detonati on. I n addi ti on, 100 percent
ethyl ene-gl ycol freezes at -22C (-8F).
50/50 Ethylene-Glycol and Water-I s the recom-
mended mi xture, i t provi des protecti on agai nst freez-
i ng to -37C (-34F). The anti freeze concentrati on
must always be a mi ni mum of 44 percent, year-
round i n al l cl i mates. I f percentage i s l ower, engi ne
parts may be eroded by cavi tati on. Maxi mum protec-
ti on agai nst freezi ng i s provi ded wi th a 68 percent
anti freeze concentrati on, whi ch prevents freezi ng
down to -67.7C (-90F). A hi gher percentage wi l l
freeze at a warmer temperature. Al so, a hi gher per-
centage of anti freeze can cause the engi ne to over-
heat because speci fi c heat of anti freeze i s l ower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automati c transmi ssi on fl ui d i s sel ected based
upon several qual i ti es. The fl ui d must provi de a hi gh
l evel of protecti on for the i nternal components by
provi di ng a l ubri cati ng fi l m between adjacent metal
components. The fl ui d must al so be thermal l y stabl e
so that i t can mai ntai n a consi stent vi scosi ty through
a l arge temperature range. I f the vi scosi ty stays con-
stant through the temperature range of operati on,
transmi ssi on operati on and shi ft feel wi l l remai n con-
si stent. Transmi ssi on fl ui d must al so be a good con-
ductor of heat. The fl ui d must absorb heat from the
i nternal transmi ssi on components and transfer that
heat to the transmi ssi on case.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK 18.5 U.S. Gallons (70
Liters)****
ENGINE OIL
Engine Oil - with Filter -
2.4L
2.4L (5.0 qts.)
Engine Oil - with Filter -
3.7L
3.7L (5.0 qts.)
Engine Oil - With Filter -
2.5L Diesel
6.5L (6.9 qts.)
ENGINE COOLANT
Cooling System - 2.4L 9.6L (10.1 qts.)
Cooling System - 3.7L 12.3L (13.0 qts.)
Cooling System - 2.5L
Diesel
12.5L (13.2 qts.)
AUTOMATIC TRANSMISSION
Service Fill - 45RFE 4.73L (10.0 pts)
O-haul Fill - 45RFE 13.33L (28.0 pts)
Dry fill capacity Depending on type and size of
internal cooler, length and inside diameter of cooler
lines, or use of an auxiliary cooler, these figures may
vary. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC/FLUID - STANDARD PROCEDURE)
TRANSFER CASE
NV231 1.4L (2.95 pts.)
NV242 1.6L (3.4 pts.)
MANUAL TRANSMISSION
NV1500 (Approximate dry
fill or fill to bottom edge of
the fill plug hole.)
2.28L (2.41 qts.)
NV3550 (Approximate dry
fill or fill to bottom edge of
fill plug hole.)
2.28L (2.41 qts.)
FRONT AXLE
186 FIA (Model 30) 1.24L (41.9 fl. oz.)
REAR AXLE
198 RBI (Model 35) 1.78L (60.2 fl. oz.)*
8 1/4 2.08L (4.4 pts.)*
* When equipped with Trac-lok, include 4.0 ounces of
Friction Modifier.
****Nominal refill capacities are shown. A variation
may be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fl ui d check/fi l l poi nt l ocati ons are l ocated i n
each appl i cabl e servi ce manual secti on.
MAINTENANCE SCHEDULES
DESCRIPTION
Mai ntenance Schedul e I nformati on not i ncl uded i n
thi s secti on, i s l ocated i n the appropri ate Owners
Manual .
HOISTING
STANDARD PROCEDURE - HOISTING
RECOMMENDATIONS
Refer to the Owners Manual for emergency vehi cl e
l i fti ng procedures.
When properl y posi ti oned, a fl oor jack can be used
to l i ft a Jeep vehi cl e (Fi g. 4). Support the vehi cl e i n
the rai sed posi ti on wi th jack stands at the front and
rear ends of the frame rai l s.
CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:
A body si de si l l .
A steeri ng l i nkage component.
A dri ve shaft.
The engi ne or transmi ssi on oi l pan.
The fuel tank.
A front suspensi on arm.
Transfer case.
NOTE: Use the correct sub-frame rail or frame rail
lifting locations only.
HOIST
Refer to the Owners Manual for emergency vehi cl e
l i fti ng procedures.
A vehi cl e can be l i fted wi th:
A si ngl e-post, frame-contact hoi st.
A twi n-post, chassi s hoi st.
A ramp-type, dri ve-on hoi st.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
Fig. 4 Correct Vehicle Lifting Locations
1 - Frame Contact Lift (Single Post)
Chassis Lift (Non-Axle Dual Post)
Outboard Lift (Dual Post)
Floor Jack
2 - Floor Jack
J UMP STARTING
STANDARD PROCEDURE - JUMP STARTING
PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS.
DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
DO NOT JUMP START WHEN BATTERY INDI-
CATOR DOT IS YELLOW OR BRIGHT COLOR. BAT-
TERY CAN EXPLODE.
DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCHING OF BATTERY CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW DISABLED VEHICLES
BATTERY TO EXCEED 16 VOLTS. PERSONAL
INJURY OR DAMAGE TO ELECTRICAL SYSTEM
CAN RESULT.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
Generator dri ve bel t condi ti on and tensi on.
Fuel fumes or l eakage, correct i f necessary.
Frozen battery.
Yel l ow or bri ght col or test i ndi cator, i f equi pped.
Low battery fl ui d l evel .
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster
source, turn off al l accessori es, pl ace gear sel ector i n
park or neutral , set park brake or equi val ent and
operate engi ne at 1200 rpm.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake or equi val ent. Turn
OFF al l accessori es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t (Fi g.
5). Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to battery posi ti ve (+) termi nal . Connect
BLACK jumper cabl e cl amp to the engi ne as cl ose to
the ground cabl e connecti on as possi bl e (Fi g. 5).
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
When usi ng a Booster vehi cl e, di sconnect
BLACK cabl e cl amp from battery negati ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal .
Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
TOWING
STANDARD PROCEDURE - TOWING
A vehi cl e equi pped wi th SAE approved wheel l i ft-
type towi ng equi pment can be used to tow Jeep vehi -
cl es. When towi ng a 4WD vehi cl e usi ng a wheel -l i ft
Fig. 5 Jumper Cable Clamp Connections
1 - BOOSTER BATTERY
2 - NEGATIVE JUMPER CABLE
3 - ENGINE GROUND
4 - DO NOT ALLOW VEHICLES TO TOUCH
5 - BATTERY NEGATIVE CABLE
6 - DISCHARGED BATTERY
7 - POSITIVE JUMPER CABLE
towi ng devi ce, use tow dol l i es under the opposi te end
of the vehi cl e. A vehi cl e wi th fl atbed devi ce can al so
be used to transport a di sabl ed vehi cl e (Fi g. 6).
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:
Secure l oose and protrudi ng parts.
Al ways use a safety chai n system that i s i nde-
pendent of the l i fti ng and towi ng equi pment.
Do not al l ow towi ng equi pment to contact the
di sabl ed vehi cl es fuel tank.
Do not al l ow anyone under the di sabl ed vehi cl e
whi l e i t i s l i fted by the towi ng devi ce.
Do not al l ow passengers to ri de i n a vehi cl e
bei ng towed.
Al ways observe state and l ocal l aws regardi ng
towi ng regul ati ons.
Do not tow a vehi cl e i n a manner that coul d
jeopardi ze the safety of the operator, pedestri ans or
other motori sts.
Do not attach tow chai ns, T-hooks, or J-hooks to
a bumper, steeri ng l i nkage, dri ve shafts or a non-re-
i nforced frame hol e.
Do not tow a heavi l y l oaded vehi cl e. Use a fl at-
bed devi ce to transport a l oaded vehi cl e.
TWO-WHEEL-DRIVE VEHICLE TOWING
Dai ml erChrysl er Corporati on recommends that a
vehi cl e be towed wi th the rear end l i fted, whenever
possi bl e.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
WARNING: ENSURE VEHICLE IS ON A LEVEL SUR-
FACE OR THE WHEELS ARE BLOCKED TO PRE-
VENT VEHICLE FROM ROLLING.
TWO WHEEL DRIVE TOWING-REAR END LIFTED
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
2WD vehi cl es can be towed wi th the front wheel s
on the surface for extended di stances at speeds not
exceedi ng 48 km/h (30 mph).
(1) Attach wheel l i ft devi ce to rear wheel s.
(2) Pl ace the transmi ssi on i n neutral .
(3) Rai se vehi cl e to towi ng posi ti on.
(4) Attach safety chai ns. Route chai ns so not to
i nterfere wi th tai l pi pe when vehi cl e i s l i fted.
(5) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
(6) Secure steeri ng wheel i n strai ght ahead posi -
ti on wi th a cl amp devi ce desi gned for towi ng.
(7) Pl ace transmi ssi on i n park.
TWO WHEEL DRIVE TOWING-FRONT END LIFTED
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
(3) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(4) Attach wheel l i ft devi ce to front wheel s and
rai se vehi cl e to towi ng posi ti on.
(5) Attach the safety chai ns.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Dai ml erChrysl er Corporati on recommends that a
4WD vehi cl e be transported on a fl at-bed devi ce. A
Wheel -l i ft devi ce can be used provi ded the trailing
wheels are off the ground and positioned in
tow dollies.
Fig. 6 Tow Vehicles With Approved Equipment
TOWING (Continued)
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION.
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
FOUR WHEEL DRIVE TOWINGREAR END LIFTED
(1) Attach wheel l i ft devi ce to front wheel s.
(3) Rai se the front of the vehi cl e off the ground
and i nstal l tow dol l i es under front wheel s.
(4) Attach wheel l i ft devi ce to rear wheel s and
(5) Attach safety chai ns. Route chai ns so not to
i nterfere wi th tai l pi pe when vehi cl e i s l i fted.
FOUR WHEEL DRIVE TOWINGFRONT END
LIFTED
(3) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(4) Attach wheel l i ft devi ce to front wheel s and
(5) Attach the safety chai ns.
TOWING (Continued)
SUSPENSION
TABLE OF CONTENTS
page page
FRONT
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 1
BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL - CLEVIS BRACKET BUSHING . . . . 2
REMOVAL - UPPER CONTROL ARM
BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION - CLEVIS BRACKET
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION - UPPER CONTROL ARM
BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOWER BALL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR
SPECIAL TOOLS
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . 6
UPPER BALL JOINT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUSHINGS
REMOVAL
REMOVAL - LOWER SUSPENSION ARM
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL - UPPER SUSPENSION ARM
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION
INSTALLATION - LOWER SUSPENSION
ARM BUSHING . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION - UPPER SUSPENSION ARM
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT
SPECIAL TOOLS
FRONT SUSPENSION
BALL JOINT PRESS - C-4212F
Remover C-4150A
REMOVER / INSTALLER FRONT LOWER BALL
JOINT - 8859
KJ SUSPENSION 2s - 1
BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM BUSHING
(1) Remove the l ower control arm (Refer to 2 -
SUSPENSI ON/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the control arm i n a vi se.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
(3) Press the bushi ng out usi ng speci al tool s
8858-5 (Recei ver), 8858-6 (Dri ver) and 8839 wi th the
threaded rod and the beari ng as shown (Fi g. 1)
REMOVAL - CLEVIS BRACKET BUSHING
(1) Remove the cl evi s bracket from the shock
(Refer to 2 - SUSPENSI ON/FRONT/CLEVI S
BRACKET - REMOVAL).
cess.
FRONT LOWER CONTROL ARM & CLEVIS
BUSHING REMOVER/INSTALLER - 8858
REAR LOWER CONTROL ARM BUSHING
REMOVER/INSTALLER - 8862
FRONT LOWER CONTROL BUSHING REMOVER/
INSTALLER - 8830
Fig. 1 LOWER CONTROL ARM BUSHING -
REMOVAL
1 - 8858-5 RECEIVER
2 - 8858-6 DRIVER
3 - 8839 THREADED ROD
2s - 2 SUSPENSION KJ
FRONT (Continued)
(2) Press the bushi ng out usi ng speci al tool s
8858-1 (recei ver), 8858-3 (dri ver) and 8839 wi th the
threaded rod 8839 and the beari ng as shown (Fi g. 2)
REMOVAL - UPPER CONTROL ARM BUSHINGS
(1) Remove the upper control arm (Refer to 2 -
SUSPENSI ON/FRONT/UPPER CONTROL ARM -
REMOVAL).
(2) Secure the control arm i n a vi se.
cess.
(3) I nstal l bushi ng remover tool s 8830-3, 8830-2
and 88304 wi th the threaded rod 8838 and the bear-
i ng as shown (Fi g. 3)
(4) Press out the bushi ng.
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
BUSHING
cess.
(1) I nstal l the new l ower control arm bushi ngs i nto
the l ower control arm usi ng tool s 8858-5 (dri ver),
8858-6 (recei ver) and the beari ng wi th the threaded
rod 8839 (Fi g. 4) maki ng sure to properl y ori ent the
bushi ng i n the control .
Fig. 2 CLEVIS BRACKET BUSHING
2 - 8858-1 RECEIVER
3 - 8858-3 DRIVER
Fig. 3 UPPER CONTROL ARM BUSHING REMOVAL
1 - 8830-3
2 - 8830-2
3 - 8830-4
4 - 8838
Fig. 4 LOWER CONTROL ARM BUSHING -
INSTALLATION
1 - 8858-5 DRIVER
2 - 8858-6 RECEIVER
BUSHINGS (Continued)
(2) Remove the control arm from the vi se.
(3) I nstal l the l ower control arm (Refer to 2 - SUS-
PENSI ON/FRONT/LOWER CONTROL ARM -
I NSTALLATI ON).
(4) Reset the vehi cl e ri de hei ght (Refer to 2 - SUS-
PENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
(5) Perform a wheel al i gnment (Refer to 2 - SUS-
PROCEDURE).
INSTALLATION - CLEVIS BRACKET BUSHING
cess.
(1) I nstal l the new cl evi s bracket bushi ng i nto the
l ower control arm usi ng tool s 8858-2 (dri ver), 8858-1
(recei ver) and the beari ng wi th the threaded rod
8839 (Fi g. 5) maki ng sure to properl y ori ent the
bushi ng i n the control .
(2) I nstal l the cl evi s bracket (Refer to 2 - SUS-
PENSI ON/FRONT/CLEVI S BRACKET - I NSTALLA-
TI ON).
INSTALLATION - UPPER CONTROL ARM
BUSHINGS
cess.
(1) I nstal l the new upper control arm bushi ngs
i nto the upper control arm usi ng tool s 8830-3, 8830-1
and 8830-2 the beari ng wi th the threaded rod 8838
(Fi g. 6) maki ng sure to properl y ori ent the bushi ng i n
the control arm.
(2) Remove the control arm from the vi se.
(3) I nstal l the upper control arm (Refer to 2 - SUS-
PENSI ON/FRONT/UPPER CONTROL ARM -
I NSTALLATI ON).
(4) Reset the vehi cl e ri de hei ght (Refer to 2 - SUS-
PROCEDURE).
PROCEDURE).
Fig. 5 CLEVIS BRACKET BUSHING
1 - 8858-2 DRIVER
2 - 8858-1 RECEIVER
Fig. 6 UPPER CONTROL ARM BUSHING -
INSTALLATION
1 - 8830-3
2 - 8830-1
3 - BUSHING
4 - 8830-2
5 - 8838
LOWER BALL J OINT
REMOVAL
(1) Remove the ti re and wheel assembl y.
(2) Remove the brake cal i per and rotor (Refer to 5
- BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
REMOVAL).
(3) Di sconnect the ti e rod from the steeri ng
knuckl e (Refer to 19 - STEERI NG/LI NKAGE/TI E
ROD END - REMOVAL).
(4) Remove the steeri ng knuckl e (Refer to 2 - SUS-
PENSI ON/FRONT/KNUCKLE - REMOVAL).
(5) Move the hal fshaft to the si de and support the
hal fshaft out of the way (I f Equi pped).
cess.
(6) Secure the steeri ng knuckl e i n a vi se.
(7) Press the bal l joi nt from the steeri ng knuckl e
usi ng speci al tool s C-4212F (PRESS), 8859-2
(RECEI VER) and 8859-1 (DRI VER) (Fi g. 7).
INSTALLATION
cess.
(1) I nstal l the bal l joi nt i nto the steeri ng knuckl e
and press i n usi ng speci al tool s C-4212F (press),
8859-3 (dri ver) and 6761 (recei ver) (Fi g. 8).
(2) I nstal l the bal l joi nt boot.
(3) Remove the support for the hal fshaft and
i nstal l i nto posi ti on (I f Equi pped).
(4) I nstal l the steeri ng knuckl e (Refer to 2 - SUS-
PENSI ON/FRONT/KNUCKLE - I NSTALLATI ON).
(5) I nstal l the ti e rod end i nto the steeri ng knuckl e
(Refer to 19 - STEERI NG/LI NKAGE/TI E ROD END -
I NSTALLATI ON).
(6) I nstal l and ti ghten the hal fshaft nut to 136
Nm (100 ft. l bs.).
(7) I nstal l the brake cal i per and rotor (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
I NSTALLATI ON).
(8) I nstal l the ti re and wheel assembl y (Refer to 22
- TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Check the vehi cl e ri de hei ght (Refer to 2 - SUS-
PROCEDURE).
PROCEDURE).
Fig. 7 LOWER BALL JOINT
1 - 8859-1 DRIVER
2 - C-4212F PRESS
3 - 8859-2 RECEIVER
Fig. 8 LOWER BALL JOINT
1 - 6761 RECEIVER
2 - 8859-3 DRIVER
3 - C-4212F PRESS
REAR
SPECIAL TOOLS
REAR SUSPENSION
UPPER BALL J OINT
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Support the rear axl e wi th a hydraul i c jack.
(3) Remove the bal l joi nt pi nch bol t from the top of
the axl e. (Fi g. 9)
(4) Separate the bal l joi nt arm assembl y from the
di fferenti al housi ng by pryi ng upwards.
(5) Remove the upper suspensi on arm from the
vehi cl e (Refer to 2 - SUSPENSI ON/REAR/UPPER
CONTROL ARM - REMOVAL).
(6) Secure the suspensi on arm i n a vi se.
(7) I nstal l speci al tool s C-4212F (press), 8861-3
(dri ver) and 8861-2 (recei ver) (Fi g. 10)
(8) Press out the ol d bal l joi nt.
INSTALLATION
(1) I nstal l speci al tool s C-4212F (press), 8861-1
(recei ver) and 8861-2 (dri ver) wi th the bal l joi nt i n
pl ace (Fi g. 11).
BALL JOINT PRESS - C-4212F
REMOVER / INSTALLER REAR UPPER BALL JOINT
- 8861
REMOVAL / INSTALLATION REAR UPPER
CONTROL ARM BUSHINGS - 8860
Fig. 9 BALL JOINT PINCH BOLT
1 - UPPER BALL JOINT
2 - PINCH BOLT
Fig. 10 UPPER BALL JOINT - REMOVAL
1 - C-4212F PRESS
2 - 8861-3 DRIVER
3 - 8861-2 RECEIVER
(2) Press the bal l joi nt i n the upper suspensi on
arm.
(3) Remove the upper suspensi on arm from the
vi se.
(4) Rei nstal l the upper suspensi on arm (Refer to 2
- SUSPENSI ON/REAR/UPPER CONTROL ARM -
I NSTALLATI ON).
(5) Rai se the rear axl e wi th a hydraul i c jack to
al i gn the bal l joi nt wi th the di fferenti al housi ng
bracket.
(6) I nsert the bal l joi nt i nto the di fferenti al hous-
i ng bracket.
(7) I nstal l the bal l joi nt pi nch bol t and ti ghten to
95 Nm (70 ft. l bs.). (Fi g. 9).
(8) Remove the supports and l ower the vehi cl e.
BUSHINGS
REMOVAL
REMOVAL - LOWER SUSPENSION ARM
BUSHING
(1) Remove the l ower suspensi on arm (Refer to 2 -
SUSPENSI ON/REAR/LOWER CONTROL ARM -
REMOVAL).
cess.
(3) I nstal l speci al tool s 8862-4 (recei ver), 8862-5
(spacer) and 8862-1 or 8862- 2 (dri ver) wi th the
threaded rod 8839 and the beari ng as shown (Fi g. 12)
REMOVAL - UPPER SUSPENSION ARM
BUSHING
(1) Remove the upper suspensi on arm (Refer to 2 -
SUSPENSI ON/REAR/UPPER CONTROL ARM -
REMOVAL).
cess.
(3) I nstal l speci al tool s 8853-3 (dri ver), 8860-1
(recei ver) and wi th the threaded rod 8838 and the
beari ng as shown (Fi g. 13)
Fig. 11 UPPER BALL JOINT - INSTALLATION
1 - C-4212F PRESS
2 - 8861-1 RECEIVER
3 - 8861-2 DRIVER
Fig. 12 LOWER SUSPENSION ARM BUSHING
REMOVAL
2 - 8862-4 RECEIVER
3 - 8862-5 SPACER
4 - 8862-1 OR 8862-2 DRIVERS
UPPER BALL J OINT (Continued)
INSTALLATION
INSTALLATION - LOWER SUSPENSION ARM
BUSHING
cess.
(1) I nstal l the new l ower suspensi on arm bushi ngs
i nto the l ower suspensi on arm usi ng tool s 8862-3
(dri ver), 8862-4 (recei ver), 8862-5 (spacer) and the
beari ng wi th the threaded rod 8839 (Fi g. 14) maki ng
sure to properl y ori ent the bushi ng i n the suspensi on
arm.
(2) Remove the suspensi on arm from the vi se.
(3) I nstal l the l ower suspensi on arm (Refer to 2 -
SUSPENSI ON/REAR/LOWER CONTROL ARM -
I NSTALLATI ON).
INSTALLATION - UPPER SUSPENSION ARM
BUSHING
cess.
(1) I nstal l the new upper suspensi on arm bushi ngs
i nto the upper suspensi on arm usi ng tool s 8835-3
(recei ver), 8860-2 (dri ver) and the beari ng wi th the
threaded rod 8838 (Fi g. 15) maki ng sure to properl y
ori ent the bushi ng i n the suspensi on arm.
(2) Remove the suspensi on arm from the vi se.
(3) I nstal l the upper suspensi on arm (Refer to 2 -
SUSPENSI ON/REAR/UPPER CONTROL ARM -
I NSTALLATI ON).
Fig. 13 UPPER SUSPENSION ARM BUSHING -
REMOVAL
1 - 8853-3 DRIVER
2 - 8860-1 RECEIVER
Fig. 14 LOWER SUSPENSION ARM BUSHING
INSTALLATION
1 - 8862-3 DRIVER
2 - 8862-5 SPACER
3 - 8862-4 RECEIVER
Fig. 15 UPPER SUSPENSION ARM BUSHING -
INSTALLATION
2 - 8835-3 RECEIVER
3 - 8860-2 DRIVER
DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 1
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT AXLE - 186FIA . . . . . . . . . . . . . . . . . . . . 19
REAR AXLE - 198RBI . . . . . . . . . . . . . . . . . . . . . 49
REAR AXLE - 8 1/4 . . . . . . . . . . . . . . . . . . . . . . . 86
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURES - PROPELLER
SHAFT ANGLE . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 6
PROPELLER SHAFT - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PROPELLER SHAFT - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SINGLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT
VIBRATION
Ti res that are out-of-round, or wheel s that are
unbal anced, wi l l cause a l ow frequency vi brati on.
Brake rotors that are unbal anced wi l l cause a
harsh, l ow frequency vi brati on.
Dri vel i ne vi brati on can al so resul t from l oose or
damaged engi ne mounts.
Propel l er shaft vi brati on i ncreases as the vehi cl e
speed i s i ncreased. A vi brati on that occurs wi thi n a
speci fi c speed range i s not usual l y caused by a pro-
pel l er shaft bei ng unbal anced. Defecti ve joi nts or an
i ncorrect propel l er shaft angl e, are usual l y the cause
of such a vi brati on.
KJ DIFFERENTIAL & DRIVELINE 3 - 1
DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1. Undercoating or other foreign
material on shaft.
1. Clean exterior of shaft and wash
with solvent.
2. Loose U-joint clamp screws. 2. Install new clamps and screws
and tighten to proper torque.
3. Loose or bent U-joint yoke or
excessive runout.
3. Install new yoke.
4. Incorrect driveline angularity. 4. Measure and correct driveline
angles.
5. Worn joint. 5. Install new joint.
6. Propeller shaft damaged or out
of balance.
6. Installl new propeller shaft.
7. Broken rear spring. 7. Install new rear spring.
8. Excessive runout or unbalanced
condition.
8. Re-index propeller shaft, test, and
evaluate.
9. Excessive drive pinion gear shaft
runout.
9. Re-index propeller shaft and
evaluate.
10. Excessive axle yoke deflection. 10. Inspect and replace yoke if
necessary.
11. Excessive transfer case runout. 11. Inspect and repair as necessary.
Joint Noise 1. Loose U-joint clamp screws. 1. Install new clamps and screws
and tighten to proper torque.
2. Lack of lubrication. 2. Replace joints as necessary.
BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180 relative to the yoke may eliminate some
vibrations.
I f propel l er shaft i s suspected of bei ng unbal anced,
i t can be veri fi ed wi th the fol l owi ng procedure:
(1) Rai se the vehi cl e.
(2) Cl ean al l the forei gn materi al from the propel -
l er shaft and the uni versal joi nts.
(3) I nspect the propel l er shaft for mi ssi ng bal ance
wei ghts, broken wel ds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) I nspect the uni versal joi nts to ensure that they
are not worn, are properl y i nstal l ed, and are cor-
rectl y al i gned wi th the shaft.
(5) Check the uni versal joi nt cl amp screws torque.
(6) Remove the wheel s and ti res. I nstal l the wheel
l ug nuts to retai n the brake drums or rotors.
(7) Mark and number the shaft si x i nches from the
yoke end at four posi ti ons 90 apart.
(8) Run and accel erate the vehi cl e unti l vi brati on
occurs. Note the i ntensi ty and speed the vi brati on
occurred. Stop the engi ne.
(9) I nstal l a screw cl amp at posi ti on 1 (Fi g. 1).
Fig. 1 CLAMP AT POSITION 1
1 - CLAMP
2 - SCREWDRIVER
3 - 2 PROPELLER SHAFT KJ
PROPELLER SHAFT (Continued)
(10) Start the engi ne and re-check for vi brati on. I f
there i s l i ttl e or no change i n vi brati on, move the
cl amp to one of the other three posi ti ons. Repeat the
vi brati on test.
(11) I f there i s no di fference i n vi brati on at the
other posi ti ons, the source of the vi brati on may not
be propel l er shaft.
(12) I f the vi brati on decreased, i nstal l a second
cl amp (Fi g. 2) and repeat the test.
(13) I f the addi ti onal cl amp causes an addi ti onal
vi brati on, separate the cl amps (1/4 i nch above and
bel ow the mark). Repeat the vi brati on test (Fi g. 3).
(14) I ncrease di stance between the cl amp screws
and repeat the test unti l the amount of vi brati on i s
at the l owest l evel . Bend the sl ack end of the cl amps
so the screws wi l l not l oosen.
(15) I f the vi brati on remai ns unacceptabl e, appl y
the same steps to the front end of the propel l er shaft.
(16) I nstal l the wheel and ti res. Lower the vehi cl e.
RUNOUT
(1) Remove di rt, rust, pai nt and undercoati ng from
the propel l er shaft surface where the di al i ndi cator
wi l l contact the shaft.
(2) The di al i ndi cator must be i nstal l ed perpendi c-
ul ar to the shaft surface.
(3) Measure runout at the center and ends of the
shaft suffi ci entl y far away from wel d areas to ensure
that the effects of the wel d process wi l l not enter i nto
the measurements.
(4) Refer to Runout Speci fi cati ons chart.
(5) I f the propel l er shaft runout i s out of speci fi ca-
ti on, remove the propel l er shaft, i ndex the shaft 180,
and re-i nstal l the propel l er shaft. Measure shaft
runout agai n.
(6) I f the propel l er shaft runout i s now wi thi n
speci fi cati ons, mark the shaft and yokes for proper
ori entati on.
(7) I f the propel l er shaft runout i s not wi thi n spec-
i fi cati ons, veri fy that the runout of the transmi ssi on/
transfer case and axl e are wi thi n speci fi cati ons.
Correct as necessary and re-measure propel l er shaft
runout.
(8) Repl ace the propel l er shaft i f the runout sti l l
exceeds the l i mi ts.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURES - PROPELLER
SHAFT ANGLE
The procedure appl i es to both the front propel l er
shafts and the rear propel l er shaft. To obtai n the
front (output) angl e on the C/V front propel l er shaft,
the i ncl i nometer i s pl aced on the machi ned ri ng of
the pi ni on fl ange. To obtai n the propel l er shaft angl e
measurement on the C/V front propel l er shaft, the
i ncl i nometer i s pl aced on the propel l er shaft tube.
(1) Rai se and support the vehi cl e at the axl es as
l evel as possi bl e. Al l ow the wheel s and propel l er
shaft to turn.
(2) Remove any external beari ng snap ri ngs from
uni versal joi nt i f equi pped, so the i ncl i nometer base
wi l l si ts fl at.
Fig. 2 TWO CLAMPS AT SAME POSITION
Fig. 3 CLAMPS SEPARATED
1 - INCH
KJ PROPELLER SHAFT 3 - 3
(3) Rotate the shaft unti l transmi ssi on/transfer
case output yoke beari ng cap i s faci ng downward, i f
necessary.
NOTE: Always make measurements from front to
rear.
(4) Pl ace I ncl i nometer on yoke beari ng cap, or the
pi ni on fl ange ri ng, (A) paral l el to the shaft (Fi g. 4).
Center bubbl e i n si ght gl ass and record measure-
ment.
NOTE: This measurement will give you the trans-
mission or Output Yoke Angle (A).
(5) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on yoke beari ng cap, or propel l er shaft
tube on C/V propel l er shaft, paral l el to the shaft (Fi g.
5). Center bubbl e i n si ght gl ass and record measure-
ment. Thi s measurement can al so be taken at the
rear end of the shaft.
NOTE: This measurement will give you the propeller
shaft angle (C).
(6) Subtract smal l er fi gure from l arger (C mi nus
A) to obtai n transmi ssi on output operati ng angl e.
(7) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on pi ni on yoke beari ng cap paral l el to
the shaft (Fi g. 6). Center bubbl e i n si ght gl ass and
record measurement.
NOTE: This measurement will give you the pinion
shaft or input yoke angle (B).
Fig. 4 OUTPUT YOKE ANGLE (A)
1 - SLIP YOKE BEARING CAP
2 - INCLINOMETER
Fig. 5 PROPELLER SHAFT ANGLE (C)
1 - SHAFT YOKE BEARING CAP
2 - INCLINOMETER
Fig. 6 INPUT YOKE ANGLE (B)
1 - PINION YOKE BEARING CAP
2 - INCLINOMETER
(8) Subtract smal l er fi gure from l arger (C mi nus
B) to obtai n axl e I nput Operati ng Angl e.
Refer to rul es gi ven bel ow and the exampl e i n (Fi g.
7) for addi ti onal i nformati on.
Good cancel l ati on of U-joi nt operati ng angl es
(wi thi n 1).
Operati ng angl es l ess than 3.
Operati ng angl es l ess than 10 for doubl e cardan
U-joi nt.
At l east 1/2 of one degree conti nuous operati ng
(propel l er shaft) angl e.
Fig. 7 U-JOINT ANGLE EXAMPLE
1 - 4.9Angle (C)
2 - 3.2Angle (B)
3 - Input Yoke
4 - 3.0Angle (A)
5 - Output Yoke
SPECIFICATIONS
PROPELLER SHAFT
TORQUE SPECIFICATIONS
DESCRIPTION Nm Ft. Lbs. In. Lbs.
Front Shaft - Companion
Flange Bolts
30 22 -
Rear Shaft - Yoke Nuts 18 13 -
SPECIAL TOOLS
PROPELLER SHAFT - FRONT
REMOVAL
(1) Shi ft transmi ssi on and transfer case i nto Neu-
tral .
(3) Mark compani on fl anges and C/V joi nts at the
front and rear of the propel l er shaft for i nstal l ati on
reference.
(4) Remove bol ts from the front and rear C/V
joi nts.
(5) Push propel l er shaft forward to cl ear transfer
case compani on fl ange (Fi g. 8).
(6) Remove the shaft from the front axl e compan-
i on fl ange.
(7) Ti l t the front of the shaft down and pul l shaft
forward and remove from the vehi cl e.
INSTALLATION
(1) I nstal l propel l er shaft between compani on
fl anges.
(2) Al i gn marks on the compani on fl anges wi th the
marks on the C/V joi nts.
(3) I nstal l front C/V joi nt bol ts and ti ghten to 30
Nm (22 ft. l bs.).
(4) I nstal l rear C/V joi nt bol ts and ti ghten to 30
Nm (22 ft. l bs.).
(5) Lower vehi cl e.
Inclinometer 7663
Fig. 8 TRANSFER CASE COMPANION FLANGE
1 - FLANGE BOLT
2 - COMPANION FLANGE
PROPELLER SHAFT - REAR
REMOVAL
(1) Shi ft the transmi ssi on/transfer case i nto Neu-
tral .
(2) Rai se and support vehi cl e.
(3) Mark a reference l i ne across the pi ni on yoke
and propel l er shaft for i nstal l ati on.
(4) Remove U-joi nt strap bol ts at the pi ni on shaft
yoke.
(5) Pry open cl amp hol di ng the dust boot to propel -
l er shaft yoke (Fi g. 9), i f equi pped.
(6) Sl i de sl i p yoke off of the transmi ssi on/transfer
case output shaft and remove the propel l er shaft
(Fi g. 10).
INSTALLATION
(1) Sl i de sl i p yoke on the transmi ssi on/transfer
case output shaft.
(2) Al i gn reference marks on the pi ni on yoke and
propel l er shaft.
(3) I nstal l U-joi nt straps and ti ghten strap bol ts to
18 Nm (13 ft. l bs.).
(4) Ti ghten dust boot cl amp i f equi pped wi th
Cl amp C-4975A (Fi g. 11).
(5) Remove support and l ower the vehi cl e.
Fig. 9 DUST BOOT CLAMP
1 - SLINGER
2 - BOOT
3 - AWL
4 - TRANSFER CASE
Fig. 10 REAR PROPELLER SHAFT
1 - CLAMP
2 - YOKE
3 - PROPELLER SHAFT
4 - AXLE YOKE
5 - CLAMP
6 - OUTPUT SHAFT
7 - BOOT
Fig. 11 CRIMPING BOOT CLAMP
1 - CLAMP TOOL
2 - SLINGER
3 - BOOT
4 - CLAMPS
SINGLE CARDAN UNIVERSAL
J OINTS
DISASSEMBLY
NOTE: Individual components of cardan universal
joints are not serviceable. If worn or leaking, they
must be replaced as an assembly.
(1) Remove the propel l er shaft.
(2) Tap the outsi de of the beari ng cap assembl y
wi th a dri ft to l oosen snap ri ng.
(3) Remove snap ri ngs from both si des of yoke
(Fi g. 12).
(4) Set the yoke i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the yoke.
(5) Posi ti on the yoke wi th the grease fi tti ng, i f
equi pped, poi nti ng up.
(6) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and press the cap through the yoke to
rel ease the l ower beari ng cap (Fi g. 13).
(7) I f the beari ng cap wi l l not pul l out of the yoke
by hand after pressi ng, tap the yoke ear near the
beari ng cap to di sl odge the cap.
(8) To remove the opposi te beari ng cap, turn the
yoke over and strai ghten the cross i n the open hol e.
Then, careful l y press the end of the cross unti l the
remai ni ng beari ng cap can be removed (Fi g. 14).
CAUTION: If the cross or bearing cap are not straight
during installation, the bearing cap will score the walls
of the yoke bore and damage can occur.
Fig. 12 REMOVE SNAP RING
1 - SNAP RING
Fig. 13 PRESS OUT BEARING
1 - PRESS
2 - SOCKET
Fig. 14 PRESS OUT REMAINING BEARING
1 - CROSS
2 - BEARING CAP
ASSEMBLY
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores.
(2) Posi ti on the cross i n the yoke wi th i ts l ube fi t-
ti ng, i f equi pped, poi nti ng up (Fi g. 15).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 16). Keep the
needl e beari ngs upri ght i n the beari ng cap.
(4) Press the beari ng cap i nto the yoke bore
enough to cl ear snap ri ng groove.
(5) I nstal l a snap ri ng.
(6) Repeat Step 3 and Step 4 to i nstal l the oppo-
si te beari ng cap.
NOTE: If the joint is stiff or binding, strike the yoke
with a soft hammer to seat the needle bearings.
(7) Add grease to l ube fi tti ng, i f equi pped.
(8) I nstal l the propel l er shaft.
Fig. 15 CROSS IN YOKE
1 - CROSS
2 - YOKE
Fig. 16 INSTALL BEARING ON TRUNNION
1 - BEARING CAP
2 - TRUNNION
SINGLE CARDAN UNIVERSAL J OINTS (Continued)
HALF SHAFT
TABLE OF CONTENTS
page page
HALF SHAFT
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - HALF SHAFT . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 12
CV JOINT/BOOT-OUTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
CV JOINT/BOOT-INNER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
HALF SHAFT
CAUTION
CAUTION:: Never grasp half shaft assembly by the
boots. This may cause the boot to pucker or crease
and reduce the service life of the boot.
Avoid over angulating or stroking the C/V joints
when handling the half shaft.
Half shafts exposed to battery acid, transmission
fluid, brake fluid, differential fluid or gasoline may
cause the boots to deteriorate.
DIAGNOSIS AND TESTING - HALF SHAFT
Check for grease at the i nboard and outboard C/V
joi nt. Thi s i s a si gn of boot or boot cl amp damage.
NOISE AND/OR VIBRATION IN TURNS
A cl i cki ng noi se or a vi brati on i n turns coul d be
caused by a damaged outer C/V or i nner tri pod joi nt
seal boot or seal boot cl amps. Thi s wi l l resul t i n the
l oss/contami nati on of the joi nt grease, resul ti ng i n
i nadequate l ubri cati on of the joi nt. Noi se coul d al so
be caused by another component of the vehi cl e com-
i ng i n contact wi th the hal f shafts.
CLUNKING NOISE DURING ACCELERATION
Thi s noi se may be a resul t of a damaged or worn
C/V joi nt. A torn boot or l oose/mi ssi ng cl amp on the
i nner/outer joi nt whi ch has al l owed the grease to be
l ost wi l l damage the C/V joi nt.
SHUDDER OR VIBRATION DURING ACCELERATION
Thi s probl em coul d be a resul t of a worn/damaged
i nner tri pod joi nt or a sti cki ng tri pod joi nt. I mproper
wheel al i gnment may al so cause a shudder or vi brati on.
VIBRATION AT HIGHWAY SPEEDS
Thi s probl em coul d be a resul t of out of bal ance
front ti res or ti re/wheel runout. Forei gn materi al
(mud, etc.) packed on the backsi de of the wheel (s)
wi l l al so cause a vi brati on.
REMOVAL
(2) Remove wheel and ti re assembl y.
(3) Remove hal f shaft hub nut.
(4) Remove stabi l i zer l i nk (Fi g. 1).
Fig. 1 STABILIZER BAR LINK
1 - STABILIZER BAR
2 - STABILIZER BAR LINK
3 - 10 HALF SHAFT KJ
(5) Remove l ower cl evi s bol t (Fi g. 2).
(6) Seperate l ower bal l joi nt from the l ower control
arm (Fi g. 3).
(7) Pul l out on the steeri ng knuckl e and push the
hal f shaft out of the knuckl e.
(8) Wi th a pry bar remove the hal f shaft from the
axl e.
NOTE: The right side has a splined axle shaft that
will stay in the axle.
INSTALLATION
(1) Appl y a l i ght coat of wheel beari ng grease on
the femal e spl i nes of the i nner C/V joi nt.
(2) I nstal l hal f shaft on the axl e shaft spl i ne and
push fi rml y to engage the snap ri ng. Pul l on the hal f
shaft to veri fy snap has engaged.
(3) Cl ean hub beari ng bore and appl y a l i ght coat
of wheel beari ng grease.
(4) Pul l out on the steeri ng knuckl e and push the
hal f shaft through the knuckl e.
(5) I nstal l l ower bal l joi nt i nto the l ower control
arm and ti ghten pi nch bol t.
(6) Al i gn cl evi s wi th knuckl e. I nstal l and ti ghten
l ower cl evi s bol t.
(7) I nstal l stabi l i zer l i nk.
(8) I nstal l hal f shaft hub nut.
(9) I nstal l wheel and ti re assembl y.
(10) Remove support and l ower vehi cl e.
SPECIFICATIONS
HALF SHAFT
Half Shaft Nut 136 100 -
Fig. 3 LOWER CONTROL ARM
1 - FRONT CAM BOLT
2 - OUTER TIE ROD END
3 - LOWER BALL JOINT NUT
4 - LOWER CONTROL ARM
5 - REAR CAM BOLT
Fig. 2 CLEVIS BRACKET
1 - UPPER BOLT
2 - CLEVIS BRACKET
3 - LOWER BOLT
KJ HALF SHAFT 3 - 11
HALF SHAFT (Continued)
SPECIAL TOOLS
CV J OINT/BOOT-OUTER
REMOVAL
(1) Cl amp shaft i n a vi se (wi th soft jaws) and sup-
port C/V joi nt.
(2) Remove cl amps wi th a cut-off wheel or gri nder
(Fi g. 4).
CAUTION: Do not damage C/V housing or half shaft.
(3) Sl i de the boot down the shaft.
(4) Remove l ubri cant to expose the C/V joi nt snap
ri ng.
(5) Spread snap ri ng and sl i de the joi nt off the
shaft (Fi g. 5).
(6) Sl i de boot off the shaft and di scard ol d boot.
(7) Mark al i gnment marks on the i nner race/hub,
beari ng cage and housi ng wi th dabs of pai nt (Fi g. 6).
(8) Cl amp C/V joi nt i n a verti cal posi ti on i n a i n
soft jawed vi se.
(9) Press down one si de of the beari ng cage to gai n
access to the bal l at the opposi te.
NOTE: If joint is tight, use a hammer and brass drift
to loosen the bearing hub. Do not contact the bear-
ing cage with the drift.
CLAMP INSTALLER C-4975A
Fig. 4 BOOT CLAMP LOCATIONS
1 - C/V HOUSING
2 - CLAMP
3 - HALF SHAFT
4 - CLAMP
5 - C/V BOOT
Fig. 5 OUTER C/V JOINT
1 - SNAP RING
2 - SNAP RING GROVE
3 - SNAP RING PLIERS
Fig. 6 BEARING ACCESS
1 - ALIGNMENT MARKS
2 - BEARING HUB
3 - BEARING CAGE
4 - HOUSING
HALF SHAFT (Continued)
(10) Remove bal l from the beari ng cage (Fi g. 7).
(11) Repeat step above unti l al l si x bal l s are
removed from the beari ng cage.
(12) Li ft cage and i nner race upward and out from
the housi ng (Fi g. 8).
(13) Turn i nner race 90 i n the cage and rotate the
i nner race/hub out of the cage (Fi g. 9).
INSTALLATION
NOTE: If C/V joint is worn, replace entire C/V joint
and boot.
(1) Appl y a l i ght coat of grease to the C/V joi nt
components before assembl i ng them.
(2) Al i gn the i nner race, cage and housi ng accord-
i ng to the al i gnment reference marks.
(3) I nsert the i nner race i nto the cage (Fi g. 10) and
rotate race i nto the cage.
Fig. 7 BEARING
1 - HOUSING
2 - INNER RACE/HUB
3 - BEARING CAGE
4 - BALL
Fig. 8 CAGE AND INNER RACE/HUB
1 - HOUSING
2 - INNER RACE
3 - CAGE WINDOW
Fig. 9 INNER RACE/HUB
Fig. 10 INNER RACE/HUB
1 - INNER RACE/HUB
2 - BEARING CAGE
CV J OINT/BOOT-OUTER (Continued)
(4) Rotate the i nner race/hub i n the cage (Fi g. 11).
(5) I nsert cage i nto the housi ng (Fi g. 12). Rotate
the cage 90 i nto the housi ng (Fi g. 13).
(6) Appl y the l ubri cant i ncl uded wi th the repl ace-
ment boot to the bal l races. Spread the l ubri cant
equal l y between al l the races.
(7) Ti l t i nner race/hub and cage and i nstal l the
bal l s (Fi g. 14).
1 - CAGE WINDOWS
2 - SNAP RING
Fig. 12 BEARING CAGE AND HOUSING
1 - OUTER RACE
2 - BEARING CAGE WINDOW
3 - CV JOINT HOUSING
1 - C/V HOUSING
2 - BEARING HUB LARGE COUNTERBORE OUTWARD
3 - BOOT RETAINING SHOULDER
4 - BEARING HUB SMALL COUNTERBORE INWARD
5 - SLINGER
Fig. 14 BALL BEARING
1 - C/V HOUSING
2 - INNER RACE/HUB
3 - BEARING CAGE
4 - BEARING
(8) Pl ace new cl amps onto new boot and sl i de boot
onto the shaft to i ts ori gi nal posi ti on.
(9) Appl y the rest of l ubri cant to the C/V joi nt and
boot.
(10) I nstal l the joi nt onto the shaft. Push the joi nt
onto the shaft unti l the snap ri ng seats i n the groove
(Fi g. 15). Pul l on the joi nt to veri fy the span ri ng has
engaged.
(11) Posi ti on the boot on the joi nt i n i ts ori gi nal
posi ti on. Ensure that the boot i s not twi sted and
remove any excess ai r.
(12) Secure both boot cl amps (Fi g. 16) wi th Cl amp
I nstal l er C-4975A. Pl ace tool on cl amp bri dge and
ti ghten tool unti l the jaws of the tol l are cl osed.
CV J OINT/BOOT-INNER
REMOVAL
(1) Cl amp shaft i n a vi se (wi th soft jaws) and sup-
port C/V joi nt.
(2) Remove cl amps wi th a cut-off wheel or gri nder.
CAUTION: Do not damage C/V housing or half
shaft.
(3) Sl i de the boot down the shaft (Fi g. 17).
Fig. 15 OUTER C/V JOINT
1 - SNAP RING
2 - SHAFT TAPER
3 - SNAP RING GROVE
4 - BEARING HUB
Fig. 16 BOOT CLAMP LOCATIONS
1 - C/V HOUSING
2 - CLAMP
3 - HALF SHAFT
4 - CLAMP
5 - C/V BOOT
Fig. 17 INNER C/V BOOT
1 - HOUSING
2 - BOOT
3 - HOUSING SNAP RING
(4) Remove l ubri cant to expose the C/V housi ng
snap ri ng and remove snap ri ng (Fi g. 18).
(5) Remove beari ngs from the cage (Fi g. 19).
(6) Rotate cage 30 and sl i de cage off the i nner
race and down the shaft.
(7) Remove spread i nner race snap ri ng (Fi g. 20)
and remove race from the shaft.
(8) Remove boot from the shaft and di scard.
(9) Cl ean and i nspect al l components for wear or
damage (Fi g. 21).
Fig. 18 HOUSING SNAP RING
1 - HOUSING
2 - SNAP RING
3 - CAGE/INNER RACE
Fig. 19 C/V BEARINGS
1 - CAGE
2 - INNER RACE
3 - SHAFT
4 - BEARING
Fig. 20 INNER RACE
1 - INNER RACE
2 - PLIERS
3 - SHAFT
4 - SNAP RING ACCESS
Fig. 21 INNER C/V JOINT
1 - HOUSING
2 - CAGE
3 - BEARINGS
5 - INNER RACE SNAP RING
6 - INNER RACE
CV J OINT/BOOT-INNER (Continued)
INSTALLATION
(1) Appl y a coat of grease suppl i ed wi th the joi nt/
boot to the C/V joi nt components before assembl i ng
them.
(2) Pl ace new cl amps on the new boot and sl i de
boot down the shaft.
(3) Sl i de cage onto the shaft (Fi g. 22) wi th the
smal l di ameter end towards the boot.
(4) I nstal l the i nner race onto the shaft (Fi g. 23).
Pul l on the race to veri fy snap ri ng has engaged.
(5) Al i gn cage wi th the i nner race and sl i de over
the race.
(6) Turn the cage 30 to al i gn the cage wi ndows
wi th the race (Fi g. 24).
(7) Appl y grease to the i nner race and beari ngs
and i nstal l the beari ngs.
Fig. 22 BEARING CAGE
1 - SHAFT
2 - CAGE
3 - SMALL DIAMETER
4 - SNAP RING GROOVE
Fig. 23 INNER RACE
1 - INNER RACE
2 - CAGE
3 - SHAFT
Fig. 24 CAGE/INNER RACE
1 - CAGE
2 - INNER RACE
3 - SHAFT
4 - CAGE WINDOW
(8) Appl y grease to the housi ng bore (Fi g. 25) then
i nstal l the beari ng assmbl y i nto the housi ng.
(9) I nstal l the housi ng snap ri ng and veri fy i t i s
seated i n the groove.
(10) Fi l l the housi ng and boot wi th the remai ni ng
grease.
(11) Sl i de the boot onto the C/V housi ng i nto i ts
ori gi nal posi ti on. Ensure boot i s not twi sted and
remove any excess ai r.
(12) Secure both boot cl amps wi th Cl amp I nstal l er
C-4975A. Pl ace tool on cl amp bri dge and ti ghten tool
unti l the jaws of the tool are cl osed.
Fig. 25 C/V COMPONENTS
1 - HOUSING
2 - BEARING ASSEMBLY
4 - HOUSING BORE
FRONT AXLE - 186FIA
TABLE OF CONTENTS
page page
FRONT AXLE - 186FIA
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - AXLE . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS - FRONT AXLE . . . . . . . . . . . 33
SPECIAL TOOLS
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . 34
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 41
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
FRONT AXLE - 186FIA
DESCRIPTION
The 186FI A (Model 30) axl e consi sts of an al umu-
num center secti on wi th an axl e tube extendi ng from
one si de. The tube i s pressed i nto the di fferenti al
housi ng. The i ntegral type housi ng, hypoi d gear
desi gn has the centerl i ne of the pi ni on set bel ow the
centerl i ne of the ri ng gear.
The di fferenti al case i s a one-pi ece desi gn. The di ffer-
enti al pi ni on mate shaft i s retai ned wi th a rol l -pi n. Di f-
ferenti al beari ng prel oad and ri ng gear backl ash i s
adjusted by the use of shi ms (sel ect thi ckness). The
shi ms are l ocated between the di fferenti al beari ng cups
and the axl e housi ng. Pi ni on beari ng prel oad i s set and
mai ntai ned by the use of a col l apsi bl e spacer.
The power i s transferred from the axl e through two
constant vel oci ty (C/V) dri ve shafts to the wheel hubs.
The di fferenti al cover provi des a means for i nspec-
ti on and servi ce wi thout removi ng the axl e from the
vehi cl e. The cover has a vent tube used to rel i eve
i nternal pressure caused by vapori zati on and i nter-
nal expansi on.
OPERATION
The axl e recei ves power from the transfer case through
the front propel l er shaft. The front propel l er shaft i s con-
nected to the pi ni on gear whi ch rotates the di fferenti al
through the gear mesh wi th the ri ng gear bol ted to the
di fferenti al case. The engi ne power i s transmi tted to the
axl e shafts through the pi ni on mate and si de gears. The
si de gears are spl i ned to the axl e shafts.
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 1).
Fig. 1 DIFFERENTIAL-STRAIGHT AHEAD DRIVING
1 - STRAIGHT AHEAD DRIVING
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
KJ FRONT AXLE - 186FIA 3 - 19
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
2). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y:
Check for i nsuffi ci ent l ubri cant.
I ncorrect ri ng gear backl ash.
Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on mate shaft can al so cause a
snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
U-joi nt or by worn si de-gear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by:
Damaged dri ve shaft.
Mi ssi ng dri ve shaft bal ance wei ght(s).
Worn or out of bal ance wheel s.
Loose wheel l ug nuts.
Worn U-joi nt(s).
Loose/broken spri ngs.
Damaged axl e shaft beari ng(s).
Loose pi ni on gear nut.
Excessi ve pi ni on yoke run out.
Bent axl e shaft(s).
Check for l oose or damaged front end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rear end
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
Fig. 2 DIFFERENTIAL-ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
3 - 20 FRONT AXLE - 186FIA KJ
FRONT AXLE - 186FIA (Continued)
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged) can be caused by:
Hi gh engi ne i dl e speed.
Transmi ssi on shi ft operati on.
Loose engi ne/transmi ssi on/transfer case mounts.
Worn U-joi nts.
Loose spri ng mounts.
Loose pi ni on gear nut and yoke.
Excessi ve ri ng gear backl ash.
Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
(2) Remove wheel and ti re assembl i es.
(3) Remove hal f shaft hub nuts.
(4) Remove l ower control arms. Refer to 2 suspen-
si on for procedure.
(5) Remove hal f shafts.
(6) Remove ski d pl ate.
(7) Remove di fferenti al drai n pl ug (Fi g. 3) and
drai n fl ui d.
(8) Remove di fferenti al vent hose (Fi g. 4) from
cover.
(9) Remove propel l er shaft from pi ni on fl ange.
(10) Support axl e wi th a l i ft/jack.
(11) Remove bol t from l eft front axl e bracket frame
mount (Fi g. 5).
(12) Remove bol ts from ri ght axl e bracket frame
mounts (Fi g. 6).
(13) Remove bol t from l eft rear axl e bracket frame
mount (Fi g. 7).
(14) Lower axl e from vehi cl e.
(15) Remove brackets from axl e i f necessary.
INSTALLATION
(1) I nstal l l eft rear bracket to axl e and ti ghten to
61 Nm (45 ft. l bs.).
(2) I nstal l ri ght bracket to axl e and ti ghten to 88
Nm (65 ft. l bs.).
(3) I nstal l l eft front bracket to axl e and ti ghten to
61 Nm (45 ft. l bs.).
(4) Rai se axl e up and al i gn brackets wi th frame
mounts.
(5) I nstal l frame mount bol ts and ti ghten to 88
Nm (65 ft. l bs.).
(6) I nstal l propel l er shaft.
(7) I nstal l hal f shafts.
Fig. 3 DRAIN PLUG
1 - LEFT FRONT AXLE BRACKET
2 - DRAIN PLUG
3 - DIFFERENTIAL HOUSING
Fig. 4 DIFFERENTIAL COVER
1 - COVER
2 - VENT TUBE
Fig. 5 LEFT FRONT AXLE BRACKET
1 - LEFT FRONT AXLE BRACKET
2 - BRACKET BOLT
(8) I nstal l l ower control arms, refer to 2 Suspen-
si on for procedures.
(9) I nstal l new hal f shaft hub nuts and ti ghten to
136 Nm (100 ft. l bs.).
(10) I nstal l axl e vent hose.
(11) Fi l l di fferenti al wi th gear l ubri cant.
(12) I nstal l ski d pl ate.
(13) I nstal l wheel and ti re assembl i es.
(15) Check vehi cl e al i gnment.
ADJUSTMENTS
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched onto each gear (Fi g. 8). A pl us
(+) number, mi nus () number or zero (0) i s etched
i nto the face of the pi ni on gear. Thi s number i s the
amount (i n thousandths of an i nch) the depth vari es
from the standard depth setti ng of a pi ni on etched
wi th a (0). The standard setti ng from the center l i ne
of the ri ng gear to the back face of the pi ni on i s 92.1
mm (3.625 i n.). The standard depth provi des the best
gear tooth contact pattern. Refer to Backl ash and
Contact Pattern Anal ysi s paragraph i n thi s secti on
for addi ti onal i nformati on.
Fig. 6 RIGHT AXLE BRACKET
1 - RIGHT AXLE BRACKET
2 - FRONT BRACKET BOLT
3 - REAR BRACKET BOLT
Fig. 7 LEFT REAR AXLE BRACKET
1 - LEFT REAR AXLE BRACKET
2 - BRACKET BOLT
Fig. 8 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Compensati on for pi ni on depth vari ance i s
achi eved wi th a sel ect shi m/oi l sl i nger. The shi ms are
pl aced between the rear pi ni on beari ng and the pi n-
i on gear head (Fi g. 9).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on. Add or subtract thi s number from the
thi ckness of the ori gi nal depth shi m/oi l sl i nger to
compensate for the di fference i n the depth vari ances.
Refer to the Pi ni on Gear Depth Vari ance chart.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the pi ni on
gear head (1, 2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
Fig. 9 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL SLINGER
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
5 - COLLAPSIBLE SPACER
PINION DEPTH MEASUREMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the housi ng. Take
measurements wi th Pi ni on Gauge Set and Di al I ndi -
cator C-3339 (Fi g. 10).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 8804 and rear pi ni on beari ng onto Screw 6741
(Fi g. 10).
(2) I nsert hei ght gauge components i nto the hous-
i ng through pi ni on beari ng cups.
(3) I nstal l front pi ni on beari ng and hand ti ght
Cone-nut 6740 onto the screw.
(4) Posi ti on Arbor Di sc 6732 and Arbor D-115-3
i nto the housi ng beari ng cradl es. I nstal l di fferenti al
beari ng caps on Arbor Di scs and ti ghten bol ts to 41
Nm (30 ft. l bs.) (Fi g. 11).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Posi ti on Scooter Bl ock/Di al I ndi cator fl ush on
the pi ni on hei ght bl ock. Hol d the scooter bl ock and
zero the di al i ndi cator.
(7) Sl owl y sl i de the scooter bl ock across the pi ni on
hei ght bl ock over to the arbor (Fi g. 12). Move the
scooter bl ock ti l l the di al i ndi cator probe crests the
arbor and record the hi ghest readi ng.
(8) Sel ect a shi m/oi l sl i nger equal to the di al i ndi -
cator readi ng pl us the pi ni on depth vari ance number
etched i n the face of the pi ni on (Fi g. 8). For exampl e,
i f the depth vari ance i s 2, add +0.002 i n. to the di al
i ndi cator readi ng.
DIFFERENTIAL
Di fferenti al beari ng prel oad and gear backl ash i s
adjusted by the use of sel ecti ve shi ms. The shi ms are
l ocated between the di fferenti al beari ng cups and the
di fferenti al housi ng. The proper shi m thi ckness can
be determi ned usi ng sl i p-fi t Dummy Beari ngs D-348
i n pl ace of the di fferenti al si de beari ngs and a Di al
I ndi cator C-3339. Before proceedi ng wi th the di ffer-
enti al beari ng prel oad and gear backl ash measure-
ments, measure the pi ni on gear depth and prepare
the pi ni on for i nstal l ati on. Establ i shi ng proper pi ni on
gear depth i s essenti al to establ i shi ng gear backl ash
and tooth contact patterns. After the overal l shi m
thi ckness to take up di fferenti al si de pl ay i s mea-
sured, the pi ni on i s i nstal l ed, and the gear backl ash
Fig. 10 PINION GEAR DEPTH TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 11 DEPTH TOOLS IN HOUSING
2 - ARBOR DISC
3 - ARBOR
4 - PINION BLOCK
shi m thi ckness i s measured. The overal l shi m thi ck-
ness i s the total of the di al i ndi cator readi ng and the
prel oad speci fi cati on added together. The gear back-
l ash measurement determi nes the thi ckness of the
shi m used on the ri ng gear si de of the di fferenti al
case. Subtract the gear backl ash shi m thi ckness from
the total overal l shi m thi ckness and sel ect that
amount for the pi ni on gear si de of the di fferenti al
(Fi g. 13). Di fferenti al shi m measurements are per-
formed wi th spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(3) I nstal l Dummy Beari ngs D-348 on di fferenti al
case.
(4) I nstal l di fferenti al case i n the housi ng.
(5) Record the thi ckness of Dummy Shi ms 8107.
I nsert the shi ms between the dummy beari ngs and
the di fferenti al housi ng (Fi g. 14).
Fig. 12 PINION DEPTH MEASUREMENT
1 - SCOOTER BLOCK
2 - ARBOR
3 - DIAL INDICATOR
1 - PINION GEAR DEPTH SHIM/OIL SLINGER
3 - RING GEAR
Fig. 14 DUMMY SHIMS
1 - DUMMY SHIM
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
(6) I nstal l the beari ng caps i n thei r correct posi -
ti ons and snug the bol ts (Fi g. 15).
(7) Wi th a dead-bl ow hammer, seat the di fferenti al
dummy beari ngs to each si de of the axl e housi ng
(Fi g. 16) and (Fi g. 17).
(8) Thread Pi l ot Stud C-3288-B i nto rear cover bol t
hol e bel ow ri ng gear.
(9) Attach a Di al I ndi cator C-3339 to the Pi l ot
Stud. Posi ti on the di al i ndi cator pl unger on fl at sur-
face between the ri ng gear bol ts.
(10) Push and hol d di fferenti al case to pi ni on gear
si de of the housi ng and zero di al i ndi cator (Fi g. 18).
Fig. 15 BEARING CAP BOLTS
Fig. 16 SEAT DUMMY BEARINGS PINION SIDE
1 - HAMMER
3 - DIFFERENTIAL
Fig. 17 SEAT DUMMY BEARING RING GEAR SIDE
1 - DIFFERENTAIL HOUSING
2 - HAMMER
3 - RING GEAR
Fig. 18 DIFFERENTIAL PINION GEAR SIDE
1 - PINION SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
(11) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng and record di al i ndi cator readi ng
(Fi g. 19).
(12) Add 0.152 mm (0.006 i n.) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(13) Rotate di al i ndi cator out of the way on the
pi l ot stud.
(14) Remove di fferenti al case and dummy beari ngs
from the housi ng.
(15) I nstal l the pi ni on gear i n the housi ng. I nstal l
the pi ni on yoke and establ i sh the correct pi ni on
rotati ng torque.
(16) I nstal l di fferenti al case and Dummy Beari ngs
D-348 i n the housi ng.
(17) I nstal l a si ngl e dummy shi m i n the ri ng gear
si de. I nstal l beari ng caps and ti ghten bol ts snug.
(18) Seat ri ng gear si de dummy beari ng (Fi g. 17).
(19) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads.
(20) Push and hol d di fferenti al case toward pi ni on
gear and zero di al i ndi cator (Fi g. 20).
si de of the housi ng and record di al i ndi cator readi ng
(Fi g. 21). Add dummy shi m thi ckness to thi s readi ng.
Thi s wi l l be the total shi m thi ckness to achi eve zero
backl ash.
(22) Subtract 0.076 mm (0.003 i n.) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness
shi m requi red to achi eve proper backl ash.
(23) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
(24) Rotate di al i ndi cator out of the way on pi l ot
stud.
from the housi ng.
(26) I nstal l si de beari ngs and cups on di fferenti al
case.
(27) I nstal l spreader W-129-B wi th Adapter Set
6987 on the housi ng and spread axl e openi ng enough
to recei ve di fferenti al case.
CAUTION: Never spread the differential housing
over 0.34 mm (0.013 in.). If the housing is over-
spread, it could be distorted or damaged.
Fig. 19 DIFFERENTIAL RING GEAR SIDE
1 - DIAL INDICATOR
Fig. 20 DIFFERENTIAL PINION GEAR SIDE
1 - DIAL INDICATOR
2 - PINION GEAR
3 - RING GEAR
Fig. 21 DIFFERENTIAL RING GEAR SIDE
1 - DIAL INDICATOR
2 - PINION GEAR
3 - RING GEAR
(28) Pl ace the beari ng prel oad shi ms i n the axl e
housi ng, agai nst the axl e tubes.
(29) I nstal l di fferenti al case i nto the housi ng.
(30) Remove spreader from the housi ng.
(31) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(32) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 22).
(33) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(34) Zero di al i ndi cator face to poi nter.
(35) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the housi ng to the other (Fi g.
23).
(36) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern Anal ysi s procedure.
GEAR CONTACT PATTERN
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the hous-
i ng. I t wi l l al so show i f the ri ng gear backl ash has
been adjusted correctl y. The backl ash can be adjusted
wi thi n speci fi cati ons to achi eve desi red tooth contact
patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de or
equi val ent to the dri ve and coast si de of the ri ng gear
teeth.
(2) Wrap, twi st and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Wi th a boxed end wrench on a ri ng gear bol t,
rotate the di fferenti al case one compl ete revol uti on i n
both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
24)and adjust pi ni on depth and gear backl ash as nec-
essary.
Fig. 22 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 23 BACKLASH SHIMS
Fig. 24 GEAR TOOTH CONTACT PATTERNS
DIFFERENTIAL BEARING PRELOAD CHECK
The fi nal check on the di fferenti al assembl y before
i nstal l i ng the axl es, i s torque to rotate pi ni on and
di fferenti al combi ned. Thi s wi l l veri fy the correct di f-
ferenti al beari ng prel oad.
Torque to rotate the di fferenti al and pi ni on i s the
torque to rotate the pi ni on pl us:
Gear Rati o 3.73 . . . . 0.45-0.75 Nm (3.9-6.6 i n. l bs.)
SPECIFICATIONS - FRONT AXLE
SPECIFICATIONS
Axle Ratio 3.73, 3.92, 4.10
Ring Gear Diameter 186 mm (7.33 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth 92.1 mm (3.625 in.)
Pinion Bearing Preload 1.69-2.82 Nm (15-25 in. lbs.)
Differential Bearing Preload
Added To Pinion Torque To Rotate
Gear Ratio 3.73 0.45-0.75 Nm (3.9-6.6 in. lbs.)
Ring Gear Bolts 95-122 70-90 -
Differential Bearing Cap
Bolts
54-67 39-50 -
Differential Cover Bolts 19-26 14-19 -
Pinion Nut 217-352 160-260 -
Left Axle Bracket Bolts 61 45 -
Front Axle Bracket Bolts 61 45 -
Right Axle Bracket Bolts 88 65 -
Axle Brackets To Frame
Bolts
88 65 -
SPECIAL TOOLS
FRONT AXLE
PULLER C-293-PA
PLUG SP-3289
ADAPTER C-293-39
PULLER C-452
DIAL INDICATOR C-3339
INSTALLER C-3716-A
HANDLE C-4171
INSTALLER D-146
REMOVER D-149
INSTALLER W-162-D
CUP 8109
PINION DEPTH SET 6774
PINION BLOCK 8804
SPANNER WRENCH 6958
SPREADER W-129-B
ADAPTER KIT 6987B
PILOT STUD C-3288-B
REMOVER C-4307
INSTALLER C-4308
INSTALLER 6448
ADAPTER C-293-42
INSTALLER 8805
INSTALLER 8806
REMOVER 8420A
REMOVER 7794-A
AXLE SHAFTS
REMOVAL
(1) Pl ace the transmi ssi on i n Neutral .
(3) Remove ri ght wheel and ti re and assembl y.
(4) Remove ri ght hal f shaft from vehi cl e.
(5) Remove snap ri ng from axl e shaft.
(6) Assembl e Remover 8420A onto the shaft (Fi g.
25). Thread sl i d hammer i nto remover and remove
shaft.
(7) Sl i de axl e shaft out of the axl e tube.
NOTE: Use care to prevent damage to axle shaft
bearing and seal, which will remain in axle shaft
tube.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng
(Fi g. 26) and engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal.
(2) Push on the axl e shaft unti l the axl e shaft
snap-ri ng passes through the si de gear.
(3) I nstal l ri ght hal f shaft.
(4) I nstal l ri ght wheel and ti re assembl y.
(5) Check di fferenti al fl ui d l evel .
AXLE SHAFT SEALS
REMOVAL
(1) Remove hal f shaft.
(2) Remove axl e shaft for ri ght si de seal removal .
(3) Remove shaft seal wi th Remover 7794-A and a
sl i de hammer (Fi g. 27).
Fig. 25 AXLE SHAFT PULLER
1 - SNAP RING GROVE
2 - SLID HAMMER THREADS
3 - REMOVER BLOCKS
4 - REMOVER COLLAR
Fig. 26 AXLE SHAFT SEAL
1 - BEARING
2 - SEAL
Fig. 27 SHAFT SEAL REMOVER
1 - SHAFT SEAL
2 - REMOVER
INSTALLATION
(1) Appl y a l i ght coat of l ubri cant on the l i p of the
shaft seal .
(2) I nstal l new shaft seal wi th I nstal l er 8806 and
Handl e C-4171 (Fi g. 28).
(3) I nstal l ri ght axl e shaft i f removed.
(4) I nstal l hal f shaft.
AXLE BEARINGS
REMOVAL
(1) Remove hal f shaft.
(2) Remove axl e shaft for ri ght si de seal removal .
(3) Remove shaft seal wi th Remover 7794-A and a
sl i de hammer.
(4) Remove shaft beari ng wi th Remover 7794-A
and a sl i de hammer (Fi g. 29).
INSTALLATION
(1) I nstal l new shaft beari ng wi th I nstal l er 8805
and Handl e C-4171.
(2) Appl y a l i ght coat of l ubri cant on the l i p of the
shaft seal .
(3) I nstal l new shaft seal wi th an appropri ate
i nstal l er.
(4) I nstal l ri ght axl e shaft i f removed.
(5) I nstal l hal f shaft.
PINION SEAL
REMOVAL
(3) Remove brake cal i pers and rotors, refer to 5
Brakes for procedures.
(4) Mark propel l er shaft and pi ni on compani on
fl ange for i nstal l ati on reference.
(5) Remove propel l er shaft from the pi ni on com-
pani on fl ange.
(6) Rotate pi ni on gear a mi ni mum of ten ti mes and
veri fy the pi ni on rotates smoothl y.
(7) Record the torque to rotate the pi ni on gear
(Fi g. 30) wi th a i nch pound torque wrench.
Fig. 28 SEAL INSTALLER
1 - SEAL BORE
2 - INSTALLER
Fig. 29 SHAFT BEARING REMOVER
1 - SHAFT BEARING
2 - REMOVER
Fig. 30 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
AXLE SHAFT SEALS (Continued)
(8) Usi ng a short pi ece of pi pe and Spanner
Wrench 6958 to hol d the pi ni on compani on fl ange
(Fi g. 31) and remove the pi ni on nut.
(9) Remove pi ni on compani on fl ange (Fi g. 32) wi th
Remover C-452 and Spanner Wrench 6958.
(10) Remove pi ni on seal wi th Remover 7794-A and
a sl i de hammer (Fi g. 33).
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th an appropri ate
i nstal l er (Fi g. 34).
(2) I nstal l pi ni on compani on fl ange on the pi ni on
gear wi th I nstal l er W-162-D, Cup 8109 and Wrench
6958.
CAUTION: Do not exceed the minimum tightening
torque 216 Nm (160 ft. lbs.) while installing pinion
nut at this point. Damage to collapsible spacer or
bearings may result.
(3) I nstal l a new nut on the pi ni on gear. Tighten
the nut only enough to remove the shaft end
play.
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
installed.
Fig. 31 PINION FLANGE NUT
1 - SPANNER WRENCH
Fig. 32 PINION FLANGE REMOVER
1 - SPANNER WRENCH
2 - REMOVER
Fig. 33 PINION SEAL
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
Fig. 34 PINION SEAL INSTALLATION
1 - HANDLE
2 - INSTALLER
PINION SEAL (Continued)
(4) Rotate pi ni on a mi ni mum of ten ti me and ver-
i fy pi ni on rotates smoothl y. Rotate the pi ni on shaft
wi th an i nch pound torque wrench. Rotati ng torque
shoul d be equal to the readi ng recorded duri ng
removal pl us 0.56 Nm (5 i n. l bs.) (Fi g. 35).
(5) I f the rotati ng torque i s l ow, use Spanner
Wrench 6958 to hol d the pi ni on compani on fl ange
and ti ghten the pi ni on shaft nut i n 6.8 Nm (5 ft.
l bs.) i ncrements unti l proper rotati ng torque i s
achi eved.
CAUTION: If maximum tightening torque is reached
prior to reaching the required rotating torque, the
collapsible spacer may have been damaged.
Replace the collapsible spacer.
(6) I nstal l propel l er shaft wi th i nstal l ati on refer-
ence marks al i gned.
(8) I nstal l brake rotors and cal i pers.
(10) Lower the vehi cl e.
DIFFERENTIAL
REMOVAL
(1) Remove axl e from the vehi cl e.
(2) Remove di fferenti al housi ng cover (Fi g. 36).
(3) Push ri ght axl e shaft out of si de gear (Fi g. 37)
and remove the shaft.
(4) Mark di fferenti al beari ng caps for i nstal l ati on
reference.
(5) Loosen the beari ng cap bol ts.
2 - TORQUE WRENCH
Fig. 36 DIFFERENTIAL COVER
1 - COVER
2 - VENT TUBE
Fig. 37 RIGHT SHAFT IN SIDE GEAR
1 - AXLE SHAFT
2 - SCREWDRIVER
3 - SIDE GEAR
(6) Posi ti on Spreader W-129-B onto the di fferenti al
l ocati ng hol es and i nstal l the safety hol ddown cl amps
(Fi g. 38). Ti ghten the tool turnbuckl e fi nger-ti ght.
(7) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
(8) Spread the housi ng to remove the di fferenti al
case from the housi ng. Measure the di stance wi th the
di al i ndi cator (Fi g. 39).
over 0.34 mm (0.013 in). If housing is over-spread, it
could be distorted or damaged.
(9) Remove the di al i ndi cator.
(10) Hol di ng the di fferenti al case i n posi ti on, and
remove beari ng cap bol ts and caps.
(11) Remove the di fferenti al from the housi ng (Fi g.
40). Ensure di fferenti al beari ng cups and shi ms
remai n i n posi ti on on the di fferenti al beari ngs.
(12) Tag di fferenti al beari ng cups and shi ms to
i ndi cate thei r l ocati on.
(13) Remove spreader from housi ng.
DISASSEMBLY
(1) Remove ri ng gear.
(2) Remove rol l -pi n hol di ng mate shaft i n housi ng.
(3) Remove pi ni on gear mate shaft.
(4) Rotate di fferenti al si de gears and remove the
pi ni on mate gears and thrust washers (Fi g. 41).
(5) Remove di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l di fferenti al si de gears and thrust wash-
ers.
(2) I nstal l pi ni on mate gears and thrust washers.
(3) I nstal l pi ni on gear mate shaft.
(4) Al i gn hol e i n the pi ni on gear mate shaft wi th
the hol e i n the di fferenti al case.
Fig. 38 DIFFERENTIAL SPREADER
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
Fig. 39 SPREAD DIFFERENTIAL CASE
1 - PILOT STUD
2 - DIAL INDICATOR
3 - SPREADER
DIFFERENTIAL (Continued)
(5) I nstal l the rol l -pi n i n the di fferenti al case wi th
a hammer and punch (Fi g. 42). Peen the edge of the
rol l -pi n hol e i n the di fferenti al case i n two pl aces
180 apart.
(6) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
(7) I nstal l ri ng gear.
INSTALLATION
NOTE: If differential bearings or differential case are
replaced, Refer to adjustments fore Differential
Bearing Preload and Gear Backlash procedures.
(1) Posi ti on Spreader W-129-B on di fferenti al l oca-
ti on hol es and i nstal l safety hol ddown cl amps.
Ti ghten the tool turnbuckl e fi nger-ti ght.
(2) I nstal l Pi l ot Stud C-3288-B to the l eft si de of
to pi l ot stud. Load the i ndi cator pl unger agai nst the
(3) Spread the housi ng to i nstal l the di fferenti al
case and prel oad shi ms i n the housi ng. Measure the
di stance wi th the di al i ndi cator.
over 0.34 mm (0.013 in). If housing is over-spread, it
could be distorted or damaged.
Fig. 40 DIFFERENTIAL CASE
3 - DIFFERENTIAL BEARINGS
Fig. 41 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 42 PINION MATE SHAFT ROLL-PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
(5) I nstal l di fferenti al case i n the housi ng. Ensure
di fferenti al beari ng cups remai n on the beari ngs and
prel oad shi ms are seated i n the housi ng. Tap di ffer-
enti al case to ensure beari ngs cups are seated i n the
housi ng.
(6) I nstal l beari ng caps to thei r ori gi nal l ocati ons
and l oosel y i nstal l cap bol ts.
(7) Remove di fferenti al housi ng spreader (Fi g. 43).
(8) Ti ghten the beari ng cap bol ts i n a cri ss-cross
pattern to 54-68 Nm (39-50 ft. l bs.).
(9) I nstal l the ri ght axl e shaft.
(10) Appl y a 6.38mm (1/4 i n.) bead of red Mopar
Si l i cone Seal er or equi val ent to the housi ng cover.
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
(11) I nstal l di fferenti al housi ng cover and ti ghten
bol ts i n a cri ss-cross pattern to 19-26 Nm (14-19 ft.
l bs.).
(12) I nstal l axl e assembl y i n vehi cl e.
(13) Fi l l di fferenti al wi th l ubri cant and i nstal l fi l l
pl ug.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al from the housi ng.
(2) Remove beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, Adapters C-293-39 and
Pl ug SP-3289 (Fi g. 44).
Fig. 43 DIFFERENTIAL SPREADER
2 - SAFETY CLAMPS
3 - SPREADER
4 - TURNBUCKLE
Fig. 44 DIFFERENTIAL BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
INSTALLATION
(1) I nstal l di fferenti al case beari ngs wi th I nstal l er
C-3716-A and Handl e C-4171 (Fi g. 45).
(2) I nstal l di fferenti al i nto the housi ng.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced as a
matched set. Never replace ring gear without
replacing the matched pinion gear.
(1) Rai se and support vehi cl e
(2) Mark pi ni on compani on fl ange and propel l er
shaft for i nstal l ati on al i gnment.
(3) Remove propel l er shaft from pi ni on compani on
fl ange and ti e propel l er shaft to underbody.
(4) Remove axl e assembl y from the vehi cl e.
(5) Remove di fferenti al from axl e housi ng.
(6) Pl ace di fferenti al case i n a vi se wi th soft metal
jaw (Fi g. 46).
(7) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(8) Dri ver ri ng gear off the di fferenti al case wi th a
rawhi de hammer (Fi g. 46).
(9) Wi th Spanner Wrench 6958 and a short l ength
of 1 i n. pi pe, hol d pi ni on compani on fl ange and
remove pi ni on nut (Fi g. 47).
Fig. 45 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 46 RING GEAR
2 - RING GEAR
3 - HAMMER
Fig. 47 PINION COMPANION FLANGE
1 - SPANNER WRENCH
DIFFERENTIAL CASE BEARINGS (Continued)
(10) Remove pi ni on compani on fl ange from pi ni on
shaft wi th Remover C-452 and Fl ange Wrench
C-3281 (Fi g. 48).
(11) Remove pi ni on gear and col l apsi bl e spacer
from housi ng (Fi g. 49).
(12) Remove front pi ni on beari ng cup, beari ng, oi l
sl i nger and pi ni on seal wi th Remover C-149 and
Handl e C-4171 (Fi g. 50).
(13) Remove rear pi ni on beari ng cup (Fi g. 51) wi th
Remover C-4307 and Handl e C-4171.
Fig. 48 PINION FLANGE REMOVER
1 - SPANNER WRENCH
2 - REMOVER
Fig. 49 PINION GEAR
1 - RAWHIDE HAMMER
Fig. 50 FRONT BPINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 51 REAR PINION BEARING CUP
1 - REMOVER
2 - HANDLE
PINION GEAR/RING GEAR (Continued)
(14) Remove col l apsi bl e prel oad spacer from pi ni on
gear (Fi g. 52).
(15) Remove rear pi ni on beari ng from the pi ni on
wi th Pul l er/Press C-293-PA and Adapters C-293-39
(Fi g. 53). Remove oi l sl i nger/pi ni on depth shi m from
the pi ni on shaft and record thi ckness.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing and the pinion gear head to
achieve proper ring and pinion gear mesh. If ring
and pinion gears are reused, the pinion oil slinger/
depth shim should not require replacement. Refer
to Adujstments (Pinion Gear Depth) to select the
proper thickness shim before installing pinion gear.
(1) Appl y Mopar Door Ease or equi val ent l ubri cant
to outsi de surface of pi ni on beari ng cups.
(2) I nstal l rear beari ng cup wi th I nstal l er C-4308
and Handl e C-4171 and veri fy cup i s seated.
(3) I nstal l front beari ng cup wi th I nstal l er D-146
and Handl e C-4171 (Fi g. 54) and veri fy cup i s seated.
(4) I nstal l front pi ni on beari ng, and oi l sl i nger i f
equi pped.
Fig. 52 COLLAPSIBLE PRELOAD SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
Fig. 53 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
Fig. 54 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
l i p of pi ni on seal and i ntal l seal wi th an appropri ate
(6) I nstal l rear pi ni on beari ng and oi l sl i nger/depth
shi m onto the pi ni on shaft wi th I nstal l er 6448 and a
press (Fi g. 56).
(7) I nstal l a new col l apsi bl e spacer on pi ni on shaft
and i nstal l the pi ni on i nto the housi ng (Fi g. 57).
(8) I nstal l pi ni on compani on fl ange, wi th I nstal l er
W-162-D, Cup 8109 and Spanner Wrench 6958.
(9) I nstal l pi ni on a new nut onto the pi ni on gear
and ti ghten the nut to 216 Nm (160 ft. l bs.). Do not
over-tighten.
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified
preload torque. If preload torque is exceeded a new
collapsible spacer must be installed.
Fig. 55 PINION SEAL
1 - HANDLE
2 - INSTALLER
1 - INSTALLER
2 - OIL SLINGER
3 - PINION GEAR
4 - REAR PINION BEARING
5 - PRESS
Fig. 57 COLLAPSIBLE PRELOAD SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
(10) Use Fl ange Wrench 6958, a l ength of 1 i n.
pi pe and a torque wrench set at 678 Nm (500 ft. l bs.)
and crush col l apsi bl e spacer unti l beari ng end pl ay i s
taken up (Fi g. 58).
(11) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l b.)
i ncrements unti l the requi red rotati ng torque i s
achi eved. Measure the rotati ng torque frequentl y to
avoi d over crushi ng the col l apsi bl e spacer (Fi g. 59).
(12) Rotate the pi ni on a mi ni mum of ten ti mes.
Veri fy pi ni on rotates smoothl y and check rotati ng
torque wi th an i nch pound torque wrench (Fi g. 59).
Pi ni on gear rotati ng torque i s:
Ori gi nal Beari ngs: 1 to 2.25 Nm (10 to 20 i n.
l bs.).
New Beari ngs: 1.69 to 2.82 Nm (15 to 25 i n.
l bs.).
(13) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(14) I nvert the di fferenti al case i n the vi se. I nstal l
new ri ng gear bol ts and al ternatel y ti ghten to 108
Nm (80 ft. l bs.) (Fi g. 60).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(15) I nstal l di fferenti al i n housi ng and veri fy di f-
ferenti al beari ng prel oad, gear mesh and contact pat-
tern. Refer to Adjustment for procedure.
(16) I nstal l di fferenti al cover and fi l l wi th gear
l ubri cant.
(17) I nstal l propel l er shaft wi th reference marks
al i gned.
(18) Remove supports and l ower vehi cl e.
Fig. 58 PINION FLANGE NUT
1 - SPANNER WRENCH
2 - TORQUE WRENCH
Fig. 60 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - RING GEAR BOLTS
3 - RING GEAR
REAR AXLE - 198RBI
TABLE OF CONTENTS
page page
REAR AXLE - 198RBI
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 55
SPECIFICATIONS - REAR AXLE . . . . . . . . . . . . 62
SPECIAL TOOLS
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 63
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65
AXLE BEARING/SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
COLLAPSIBLE SPACER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOK . . . . . 74
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 75
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 77
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82
REAR AXLE - 198RBI
DESCRIPTION
The Rear Beam-desi gn I ron (RBI ) axl e housi ng has
an i ron center casti ng (di fferenti al housi ng) wi th axl e
shaft tubes extendi ng from ei ther si de. The tubes are
pressed i nto and wel ded to the di fferenti al housi ng to
form a one-pi ece axl e housi ng. The axl es are
equi pped wi th semi fl oati ng axl e shafts, meani ng
that l oads are supported by the axl e shaft and bear-
i ngs. The axl e shafts are retai ned by the uni t bear-
i ng, retai ner pl ate and bol ts.
The i ntegral type, hypoi d gear desi gn, housi ng has
the centerl i ne of the pi ni on set bel ow the centerl i ne
of the ri ng gear. The di fferenti al case i s a one-pi ece
desi gn. The di fferenti al pi ni on mate shaft i s retai ned
wi th a threaded screw. Di fferenti al beari ng prel oad
and ri ng gear backl ash i s adjusted by the use of
sel ecti ve spacer shi ms. Pi ni on beari ng prel oad i s set
and mai ntai ned by the use of a col l apsi bl e spacer
(Fi g. 1).
The cover provi des a means for servi ci ng the di ffer-
enti al wi thout removi ng the axl e. The axl e has a vent
hose to rel i eve i nternal pressure caused by l ubri cant
vapori zati on and i nternal expansi on.
Axl es equi pped wi th a Trac-Lok di fferenti al are
opti onal . A Trac-Lok di fferenti al has a one-pi ece di f-
ferenti al case, and the same i nternal components as
a standard di fferenti al , pl us two cl utch di sc packs.
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
KJ REAR AXLE - 198RBI 3 - 49
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
STANDARD DIFFERENTIAL
speed.
TRAC-LOK DIFFERENTIAL
The Trac-l ok cl utches are engaged by two concur-
rent forces. The fi rst bei ng the prel oad force exerted
through Bel l evi l l e spri ng washers wi thi n the cl utch
packs. The second i s the separati ng forces generated
by the si de gears as torque i s appl i ed through the
ri ng gear (Fi g. 4).
Fig. 2 DIFFERENTIAL-STRAIGHT AHEAD DRIVING
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
Fig. 3 DIFFERENTIAL-ON TURNS
Fig. 4 TRAC-LOK DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
3 - 50 REAR AXLE - 198RBI KJ
REAR AXLE - 198RBI (Continued)
The Trac-l ok desi gn provi des the di fferenti al
acti on needed for turni ng corners and for dri vi ng
strai ght ahead duri ng peri ods of unequal tracti on.
When one wheel l ooses tracti on, the cl utch packs
transfer addi ti onal torque to the wheel havi ng the
most tracti on. Trac-l ok di fferenti al s resi st wheel
spi n on bumpy roads and provi de more pul l i ng power
when one wheel l ooses tracti on. Pul l i ng power i s pro-
vi ded conti nuousl y unti l both wheel s l oose tracti on. I f
both wheel s sl i p due to unequal tracti on, Trac-l ok
operati on i s normal . I n extreme cases of di fferences
of tracti on, the wheel wi th the l east tracti on may
spi n.
GEAR NOISE
cant, i ncorrect backl ash, i ncorrect pi ni on depth, tooth
contact, worn/damaged gears, or the carri er housi ng
not havi ng the proper offset and squareness.
greatl y:
Gear damage.
cl e turns. A worn pi ni on shaft can al so cause a snap-
pi ng or a knocki ng noi se.
BEARING NOISE
source.
LOW SPEED KNOCK
U-joi nt or by worn si degear thrust washers. A worn
VIBRATION
caused by a:
Worn or out-of-bal ance wheel s.
Worn U-joi nt(s).
Check for l oose or damaged front-end components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
i nto gear (or the cl utch engaged), can be caused by:
Worn U-joi nts.
DIAGNOSTIC CHART
properly.
and quantity.
and quantity.
wheel/tire.
level.
cover.
damage.
adjustment.
contact pattern. Adjust backlash or
pinion depth.
pinion.
pre-load.
bolts.
REMOVAL
(2) Posi ti on a l i ft/jack under the axl e and secure
axl e to devi ce.
(3) Remove wheel s and ti res.
(4) Mark propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove propel l er shaft and suspend under the
vehi cl e.
(6) Remove brake drums, parki ng brake cabl es and
speed sensor from the axl e.
(7) Di sconnect the brake hose at the body juncti on
bl ock.
(8) Remove brakes and backi ng pl ates.
(9) Remove vent hose from the axl e shaft tube.
(10) Remove the stabi l i zer bar (Fi g. 5).
(11) Remove upper control arm bal l joi nt pi nch
bol t from bracket (Fi g. 6).
(12) Remove shock absorbers from axl e brackets
(Fi g. 7).
(13) Loosen al l l ower control arms mounti ng bol ts
(Fi g. 8).
(14) Lower axl e enough to remove coi l spri ngs and
spri ng i nsul ators.
(15) Remove l ower control arm bol ts from the axl e
brackets.
(16) Lower and remove the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before the lower control arms
are tightened. This must be done to maintain vehi-
cle ride height and prevent premature bushing fail-
ure.
(1) Rai se the axl e under the vehi cl e.
(2) I nstal l l ower control arms onto the axl e brack-
ets and l oosel y i nstal l the mounti ng bol ts.
(3) I nstal l coi l spri ng i sol ators and spri ng.
(4) Rai se axl e up unti l spri ngs are seated.
(5) I nstal l upper control arm bal l joi nt i nto axl e
bracket and ti ghten pi nch bol t to torque speci fi cati on.
(6) I nstal l shock absorbers and ti ghten nuts to
torque speci fi cati on.
(7) I nstal l stabi l i zer bar and ti ghten nuts to torque
speci fi cati on.
(8) I nstal l brake backi ng pl ates, parki ng brake
cabl es, brake drums and speed sensor.
(9) I nstal l brake hose to the body juncti on bl ock
and bl eed the brakes.
Fig. 5 STABILIZER BAR MOUNTS
1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM
2 - PINCH BOLT
Fig. 7 SHOCK ABSORBER
1 - UPPER MOUNTING BOLT
2 - LOWER MOUNTING BOLT
(11) I nstal l propel l er shaft wi th reference marks.
(12) I nstal l the wheel s and ti res.
(13) Add gear l ubri cant to speci fi cati ons, i f neces-
sary.
(14) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
(15) Ti ghten the l ower control arm bol ts to torque
speci fi cati on.
ADJ USTMENTS
ADJUSTMENT
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
9). A pl us (+) number, mi nus () number or zero (0) i s
etched i nto the face of the pi ni on gear. Thi s number
i s the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
etched wi th a (0). The standard setti ng from the cen-
ter l i ne of the ri ng gear to the back face of the pi ni on
i s 96.850 mm (3.813 i n.). The standard depth pro-
vi des the best teeth contact pattern. Refer to Back-
l ash and Contact Pattern Anal ysi s Paragraph i n thi s
secti on for addi ti onal i nformati on.
achi eved wi th sel ect shi ms. The shi ms are pl aced
under the i nner pi ni on beari ng cone (Fi g. 10).
ment pi ni on gear. Add or subtract the thi ckness of
the ori gi nal depth shi ms to compensate for the di ffer-
ence i n the depth vari ances. Refer to the Depth Vari -
ance charts.
mi nus amount needed.
Note the etched number on the face of the dri ve
pi ni on gear (1, 2, 0, +1, +2, etc.). The numbers rep-
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
Fig. 8 LOWER SUSPENSION ARM
1 - AXLE BRACKET BOLT
3 - BODY BRACKET BOLT
Fig. 9 PINION GEAR ID NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 10 Shim Locations
3 - RING GEAR
Original Pinion
Gear Depth
Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n the housi ng. Take measure-
ments wi th a Pi ni on Gauge Set, Pi ni on Bl ock 6735,
Arbor Di scs 6732 and Di al I ndi cator C-3339 (Fi g. 11).
(Fi g. 11).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto the housi ng through pi n-
i on beari ng cups (Fi g. 12).
(3) I nstal l front pi ni on beari ng and Cone 6740
hand ti ght.
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 13).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts. Refer to the Torque Speci fi cati ons.
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
Fig. 11 PINION DEPTH TOOLS
1 - DIAL INDICATOR
2 - ARBOR
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 12 PINION HEIGHT BLOCK
1 - PINION BLOCK
the pi ni on hei ght bl ock. Hol d scooter bl ock and zero
the di al i ndi cator.
arbor bar and record the hi ghest readi ng. I f the di al
i ndi cator can not achi eve the zero readi ng, the rear
beari ng cup or the pi ni on depth gauge set i s not
i nstal l ed correctl y.
(8) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
etched i n the face of the pi ni on gear (Fi g. 9) usi ng
the opposi te si gn on the vari ance number. For exam-
pl e, i f the depth vari ance i s 2, add +0.002 i n. to the
di al i ndi cator readi ng.
(9) Remove the pi ni on depth gauge components
from the housi ng
DIFFERENTIAL BEARING PRELOAD
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the housi ng. The proper shi m thi ck-
ness can be determi ned usi ng sl i p-fi t Dummy Bear-
i ngs D-348 i n pl ace of the di fferenti al si de beari ngs
and a Di al I ndi cator C-3339. Before proceedi ng wi th
the di fferenti al beari ng prel oad and gear backl ash
measurements, measure the pi ni on gear depth and
prepare the pi ni on gear for i nstal l ati on. Establ i shi ng
proper pi ni on gear depth i s essenti al to establ i shi ng
gear backl ash and tooth contact patterns. After the
overal l shi m thi ckness to take up di fferenti al si de
pl ay i s measured, the pi ni on gear i s i nstal l ed and the
gear backl ash shi m thi ckness i s measured. The over-
al l shi m thi ckness i s the total of the di al i ndi cator
readi ng, starti ng poi nt shi m thi ckness and the pre-
l oad speci fi cati on added together. The gear backl ash
measurement determi nes the thi ckness of the shi m
used on the ri ng gear si de of the di fferenti al case.
Subtract the gear backl ash shi m thi ckness from the
total overal l shi m thi ckness and sel ect that amount
for the pi ni on gear si de of the di fferenti al (Fi g. 15).
Fig. 13 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
Fig. 14 Pinion Gear Depth Measurement
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 15 Shim Locations
3 - RING GEAR
PRELOAD SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove si de beari ngs from di fferenti al case.
(2) I nstal l ri ng gear, i f necessary, on di fferenti al
case and ti ghten bol ts to speci fi cati on.
(3) I nstal l Dummy Beari ngs D-348 on di fferenti al
case.
(5) I nsert Dummy Shi ms 8107 (0.118 i n. /3.0 mm)
starti ng poi nt shi ms between the dummy beari ng
and the housi ng (Fi g. 16).
(6) I nstal l beari ng caps i n thei r correct posi ti ons
and snug the bol ts.
(7) Use a dead-bl ow hammer to seat the di fferen-
ti al dummy beari ngs to each si de of the housi ng (Fi g.
17) and (Fi g. 18).
Fig. 16 DUMMY SHIMS
1 - DUMMY SHIM
4 - DUMMY BEARINGS
Fig. 17 SEAT DUMMY BEARING PINION GEAR SIDE
Fig. 18 SEAT DUMMY BEARING RING GEAR SIDE
2 - DEAD-BLOW HAMMER
(8) Thread Pi l ot Stud C-3288-B i nto rear cover bol t
hol e bel ow ri ng gear (Fi g. 19).
(9) Attach Di al I ndi cator C-3339 to the pi l ot stud
and posi ti on i ndi cator pl unger on a fl at surface of the
ri ng gear bol t head (Fi g. 19).
(10) Push the di fferenti al case fi rml y to the pi ni on
gear si de of the housi ng (Fi g. 20) and zero di al i ndi -
cator.
(11) Push di fferenti al case fi rml y to the ri ng gear
si de and record di al i ndi cator readi ng (Fi g. 21).
(12) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi ckness to determi ne total shi m thi ck-
ness to achi eve zero di fferenti al end pl ay.
(13) Add 0.2 mm (0.008 i n.) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(14) Rotate di al i ndi cator out of the way.
(15) Remove di fferenti al case, dummy beari ngs
and starti ng poi nt shi ms from the housi ng.
(16) I nstal l pi ni on gear i n the housi ng. I nstal l the
yoke and establ i sh the correct pi ni on rotati ng torque.
(17) I nstal l di fferenti al case and dummy beari ngs
i n the housi ng (wi thout shi ms) and ti ghten retai ni ng
cap bol ts.
(18) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads (Fi g. 19).
(19) Push and hol d di fferenti al case toward pi ni on
gear.
si de of the housi ng and record di al i ndi cator readi ng.
(22) Subtract 0.05 mm (0.002 i n.) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness of
shi m requi red to achi eve proper backl ash.
(23) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
housi ng.
Fig. 19 DIFFERENTIAL SIDE PLAY
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 20 ZERO DIAL INDICATOR
1 - FORCE CASE TO PINION SIDE
2 - PILOT STUD
3 - DIAL INDICATOR EXTENSION
4 - DIAL INDICATOR
Fig. 21 RECORD DIAL INDICATOR
1 - DIAL INDICATOR
2 - FORCE CASE TO RING GEAR SIDE
(24) Rotate di al i ndi cator out of the way on pi l ot
stud.
from the housi ng.
(26) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(27) I nstal l spreader W-129-B and some compo-
nents of Adapter Set 6987 on di fferenti al housi ng and
spread axl e openi ng enough to recei ve di fferenti al
case.
(28) Pl ace si de beari ng shi ms i nto the housi ng
agai nst the axl e tubes.
(30) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(31) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 22).
(32) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(34) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.13-0.20 mm (0.005-0.008
i n.). I f backl ash i s not wi thi n speci fi cati ons transfer
the necessary amount of shi m thi ckness from one
si de of the di fferenti al housi ng to the other (Fi g. 23).
(35) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform the
Gear Contact Pattern Anal ysi s procedure.
patterns.
equi val ent to the dri ve and coast si de of the ri ng gear
teeth.
(2) Wrap, twi st, and hol d a shop towel around the
tern.
shop towel .
degree of contact agai nst the pi ni on teeth wi l l
squeeze the compound to the areas wi th the l east
amount of contact. Note and compare patterns on the
ri ng gear teeth to Gear Tooth Contact Patterns chart
(Fi g. 24) and adjust pi ni on depth and gear backl ash
as necessary.
Fig. 22 RING GEAR BACKLASH
1 - DIAL INDICATOR
Fig. 23 BACKLASH SHIM
Fig. 24 GEAR TOOTH CONTACT PATTERNS
DIFFERENTIAL BEARING PRELOAD CHECK
The fi nal check on the di fferenti al assembl y before
i nstal l i ng the axl es i s torque to rotate pi ni on and di f-
ferenti al combi ned. Thi s wi l l veri fy the correct di ffer-
enti al beari ng prel oad.
Torque to rotate the di fferenti al and pi ni on i s the
torque to rotate the pi ni on pl us:
Gear Rati o 3.73 . . . . . . . 0.45-0.76 Nm (4-7 i n. l bs.)
Gear Rati o 4.10 . . . . . . 0.41-0.69 Nm (3.6-6 i n. l bs.)
SPECIFICATIONS - REAR AXLE
SPECIFICATIONS
Axle Ratio 3.73 4.10
Ring Gear Diameter 198 mm (7.795 in.)
Pinion Gear Standard Depth 96.85 mm (3.813 in.)
Pinion Bearing Preload - New Bearings 1.69-2.82 Nm (15-25 in. lbs.)
Differential Side Gear Clearance 0-0.15 mm (0-0.006 in.)
Differential Bearing Preload 0.20 mm (0.008 in.)
Differential Bearing Preload Added To Pinion Torque To Rotate
3.73 Gear Ratio 0.45-0.76 Nm (4-7 in. lbs.)
4.10 Gear Ratio 0.41-0.69 Nm (3.6-6 in. lbs.)
Ring Gear Bolts 129-142 95-105 -
Differential Bearing Cap
Bolts
64-91 47-67 -
Differential Cover Bolts 38-45 28-33 -
Pinion Nut (Minimum) 271 200 -
Cross Shaft Lock Screw 11-22 8-16 -
SPECIAL TOOLS
REAR AXLE
PULLER C-293-PA
ADAPTER 8352
ADAPTER C-293-39
PLUG SP-3289
PULLER C-452
WRENCH C-3281
SPANNER WRENCH 6958
HANDLE C-4171
INSTALLER C-3716-A
INSTALLER D-130
INSTALLER D-146
REMOVER D-103
REMOVER D-149
INSTALLER W-262
PINION DEPTH 6774
TRAC-LOK TOOLS 6960
FIXTURE 6965
SHIMS DUMMY 8107
SPREADER W-129-B
ADAPTER KIT 6987
AXLE SHAFTS
REMOVAL
(1) Pl ace transmi ssi on i n neutral and rai se and
support vehi cl e.
(3) Remove brake drum.
(4) Remove axl e retai ner pl ate nuts from the rear
of the axl e fl ange.
(5) Pul l axl e shaft from the axl e wi th Sl i de Ham-
mer 7420 and Adapter 6790. Mount the adapter to
the axl e wi th l ug nuts.
NOTE: It is normal that the axle bearing race is
loose in the axle tube.
INSTALLATION
(1) I nsal l axl e i nto the axl e tube wi th the fl at area
of the retai ner pl ate upward.
(2) I nsert retai ni ng pl ate studs i nto the brake
backi ng pl ate and axl e tube fl ange.
(3) I nstal l retai ner nuts and ti ghten to 47-75 Nm
(35-55 ft. l bs.).
(4) I nstal l the brake drum.
(5) I nstal l wheel and ti re.
(6) Check and fi l l the di fferenti al wi th gear l ubri -
cant.
PILOT STUDS C-3288-B
PULLER 6790
DIAL INDICATOR C-3339
INSTALLER C-3718
AXLE BEARING/SEAL
REMOVAL
(1) Remove axl e shaft from vehi cl e.
(2) Dri l l a shal l ow hol e i nto soft steel axl e beari ng
retai ni ng ri ng wi th a 3/8 i n. dri l l bi t (Fi g. 25). Use a
dri l l depth stop to avoi d marki ng the axl e.
(3) Wi th a col d chi sel cut the retai ni ng ri ng across
dri l l ed hol e. (Fi g. 26)
(4) Sl i de retai ni ng ri ng from axl e shaft.
(5) Remove axl e beari ng from the shaft wi th a
press and Spl i tter 1130 pl aced between the seal and
beari ng (Fi g. 27).
(6) Remove seal from axl e.
(7) Remove retai ni ng pl ate from axl e shaft.
Fig. 25 DRILL RETAINING RING
1 - DRILL BIT
2 - AXLE
3 - RETAINING PLATE
4 - RETAINING RING
Fig. 26 CUT RETAINING RING
1 - AXLE
2 - COLD CHISEL
3 - VISE
4 - RETAINING RING
Fig. 27 AXLE BEARING AND SEAL
1 - SPLITTER
2 - AXLE SHAFT
3 - BLOCKS
4 - BLOCKS
INSTALLATION
NOTE: Verify axle shaft retaining plate is flat with a
straight edge. If the plate is warped replace the
plate.
(1) I nstal l retai ni ng pl ate on the axl e shaft (Fi g.
28).
(2) Appl y a coat of mul ti -purpose grease on seal i ng
surface of axl e seal .
(3) I nstal l seal on the axl e shaft wi th cavi ty away
from retai ni ng pl ate (Fi g. 28).
(4) Lubri cate beari ng wi th Mopar Wheel Beari ng
Grease or equi val ent. Wi pe excess grease from the
beari ng.
(5) I nstal l beari ng on the axl e shaft wi th I nstal l er
7913 and a press (Fi g. 29).
(6) Press retai ni ng ri ng onto axl e shaft wi th
I nstal l er 7913 and a press (Fi g. 30).
(7) I nstal l axl e i n vehi cl e.
Fig. 29 BEARING ON AXLE
1 - PRESS RAM
2 - INSTALLER - 7913
3 - AXLE BEARING
4 - SEAL
5 - RETAINING PLATE
6 - AXLE
Fig. 30 BEARING RETAINING RING ON AXLE
1 - PRESS
2 - AXLE
3 - AXLE BEARING
4 - INSTALLER
5 - SOFT METAL RETAINING RING
Fig. 28 AXLE BEARING AND SEAL COMPONENTS
1 - RETAINING RING
2 - SEAL
3 - AXLE
4 - RETAINING PLATE
5 - AXLE BEARING
AXLE BEARING/SEAL (Continued)
PINION SEAL
REMOVAL
(3) Remove rear brake rotors drums.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate pi ni on gear three or four ti mes and ver-
i fy that pi ni on rotates smoothl y.
(7) Measure and record torque to rotate the pi ni on
gear wi th an i nch pound di al -type torque wrench.
(8) Wi th a short pi ece of pi pe and Spanner Wrench
6958 remove the pi ni on nut and washer (Fi g. 31).
(9) Remove pi ni on compani on fl ange wi th Remover
C-452 and Fl ange Wrench C-3281. (Fi g. 32)
INSTALLATION
seal i nstal l er (Fi g. 34).
(2) I nstal l yoke on the pi ni on gear wi th I nstal l er
C-3718 and Spanner Wrench 6958 (Fi g. 35).
(3) I nstal l a new nut on the pi ni on gear. Tighten
the nut only enough to remove the shaft end
play.
CAUTION: Do not exceed the minimum torque 271
Nm (200 ft. lbs.) when installing the pinion yoke
retaining nut at this point. Damage to collapsible
spacer or bearings may result.
(4) Rotate the pi ni on a mi ni mum of ten ti mes and
veri fy pi ni on rotates smoothl y.
(5) Measure and recore pi ni on torque to rotate
wi th an i nch pound torque wrench. Torque to rotate
shoul d be equal to the readi ng recorded duri ng
removal , pl us 0.56 Nm (5 i n. l bs.) (Fi g. 36).
Fig. 31 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - WRENCH
3 - PIPE
Fig. 32 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
Fig. 33 PINION SEAL REMOVER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
(6) I f rotati ng torque i s l ow, hol d pi ni on yoke wi th
Wrench 6958 (Fi g. 37) and ti ghten pi ni on shaft nut
i n 6.8 Nm (5 ft. l bs.) i ncrements unti l rotati ng
torque i s achi eved.
CAUTION: If maximum tightening torque is reached
prior to reaching the required rotating torque, the
collapsible spacer may have been damaged.
Replace the collapsible spacer.
(7) Al i gn the i nstal l ati on reference marks on the
propel l er shaft and pi ni on yoke and i nstal l the pro-
pel l er shaft.
Fig. 34 PINION SEAL INSTALLATION
1 - HANDLE
2 - INSTALLER
Fig. 35 PINION YOKE INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - WRENCH
Fig. 36 PINION GEAR ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
1 - PINION YOKE
2 - WRENCH
3 - PIPE
(9) I nstal l the brake drums
COLLAPSIBLE SPACER
REMOVAL
(3) Remove rear brake drums.
(4) Mark the propel l er shaft and pi ni on yoke for
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure and record torque to rotate the pi ni on
gear wi th an i nch pound di al -type torque wrench.
(8) Hol d pi ni on yoke wi th Spanner Wrench 6958
and remove pi ni on nut and washer.
(9) Remove the pi ni on yoke wi th Remover C-452
and Fl ange Wrench C-3281 (Fi g. 38).
(10) Remove pi ni on shaft seal wi th a pry tool or a
sl i de hammer mounted screw.
(11) Remove front pi ni on beari ng usi ng a pai r of
pi ck tool s. Pul l the beari ng strai ght off the pi ni on
gear shaft. I f the beari ng becomes bound on the pi n-
i on shaft, l i ghtl y tap the end of the pi ni on gear wi th
a rawhi de/rubber hammer.
(12) Remove the col l apsi bl e spacer.
INSTALLATION
(1) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft.
(2) I nstal l pi ni on front beari ng.
l i p of pi ni on seal and i nstal l a new seal wi th an
appropri ate i nstal l er (Fi g. 39).
(4) I nstal l yoke wi th Screw 8112, Cup 8109 and
Spanner Wrench 6958 (Fi g. 40).
(5) I nstal l yoke washer and new nut on the pi ni on
gear. Ti ghten the nut to 271 Nm (200 ft. l bs.).
pinion gear bearing rotating torque and never
exceed specified preload torque. If preload torque
or rotating torque is exceeded a new collapsible
spacer must be installed.
Fig. 38 PINION YOKE
1 - FLANGE WRENCH
2 - YOKE
3 - REMOVER
Fig. 39 PINION SEAL
1 - HANDLE
2 - INSTALLER
1 - INSTALLER
2 - PINION YOKE
3 - WRENCH
(6) Usi ng yoke wi th Spanner Wrench 6958 and a
torque wrench set at 474 Nm (350 ft. l bs.), (Fi g. 41)
sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l bs.) i ncre-
ments unti l the rotati ng torque i s achi eved. Measure
the rotati ng torque frequentl y to avoi d over crushi ng
the col l apsi bl e spacer (Fi g. 42).
NOTE: If more than 474 Nm (350 ft. lbs.) torque is
required to crush the collapsible spacer, the spacer
is defective and must be replaced.
(7) Check rotati ng torque wi th an i nch pound
torque wrench (Fi g. 42). The rotati ng torque of the
pi ni on gear shoul d be, the readi ng recorded duri ng
removal pl us an addi ti onal 0.56 Nm (5 i n. l bs.).
(8) I nstal l propel l er shaft wi th reference marks
al i gned.
(9) I nstal l rear brake drums.
(10) Add gear l ubri cant, i f necessary.
DIFFERENTIAL
REMOVAL
(2) Remove di fferenti al cover and drai n fl ui d.
(3) Cl ean the housi ng cavi ty wi th fl ushi ng oi l , l i ght
engi ne oi l or l i nt free cl oth.
NOTE: Do not use water, steam, kerosene or gaso-
line for cleaning.
(4) Remove axl e shafts.
(5) Note the reference l etters stamped on the beari ng
caps and housi ng machi ned seal i ng surface (Fi g. 43). Fig. 41 YOKE SPANNER WRENCH
1 - PINION YOKE
2 - WRENCH
3 - PIPE
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 43 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
COLLAPSIBLE SPACER (Continued)
(6) Loosen the di fferenti al beari ng cap bol ts.
(7) Wi th Spreader W-129-B and adapters from
Adapter set 6987, posi ti on the adapters i n the di ffer-
enti al hol es (Fi g. 44). I nstal l hol d-down cl amps and
ti ghten the tool turnbuckl e fi nger-ti ght.
(8) I nstal l Pi l ot Stud C-3288-B at the l eft si de of
opposi te si de of the housi ng (Fi g. 45) and zero the
i ndi cator.
(9) Spread the housi ng whi l e measuri ng the di s-
tance wi th the di al i ndi cator. Spread the housi ng
enough to remove the di fferenti al case (Fi g. 46).
CAUTION: Do not spread over 0.38 mm (0.015 in). If
housing is over-spread, it could be distorted or
damaged.
(10) Remove the di al i ndi cator and pi l ot stud.
(11) Remove di fferenti al beari ng cap bol ts and caps
whi l e hol di ng the case.
Fig. 44 SPREADER LOCATION
2 - ADAPTER
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
Fig. 45 DIAL INDICATOR LOCATION
1 - CLAMP
2 - DIAL INDICATOR
3 - LEVER ADAPTER
4 - SPREADER
5 - PILOT STUD
Fig. 46 SPREAD DIFFERENTIAL HOUSING
1 - DIAL INDICATOR
2 - SPREADER
(12) Remove di fferenti al from the housi ng. Ensure
that the di fferenti al beari ng cups remai n i n posi ti on
on the di fferenti al beari ngs (Fi g. 47).
(13) Remove beari ng cups from the di fferenti al and
tag them to i ndi cate thei r l ocati on.
(14) Remove di fferenti al case prel oad shi ms from
the housi ng and tag them to i ndi cate thei r l ocati on.
(15) Remove spreader from housi ng.
INSTALLATION
NOTE: If differential bearings or differential case are
replaced, differential bearing preload shim require-
ments may change. Refer Adjustments (Differential
Bearing Preload and Gear Backlash) to determine
the proper shim selection.
(1) Wi th Spreader W-129-B and adapters from
Adapter set 6987, posi ti on the adapters i n the di ffer-
enti al hol es (Fi g. 48). I nstal l the hol d-down cl amps
and ti ghten the tool turnbuckl e fi nger-ti ght.
(2) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
(3) Spread the housi ng whi l e measuri ng the di s-
tance wi th the di al i ndi cator. Spread the housi ng
enough to i nstal l the di fferenti al case.
CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is overspread, it could be distorted or
damaged.
(5) I nstal l di fferenti al case i n the housi ng (Fi g. 49)
wi th beari ng cups and prel oad shi ms i n thei r ori gi nal
l ocati ons. Tap the di fferenti al case to ensure the
beari ngs cups and shi ms are ful l y seated i n the hous-
i ng.
3 - BEARING CUPS
Fig. 48 SPREADER LOCATION
2 - ADAPTER
3 - SAFETY HOLD DOWN
4 - SPREADER
5 - TURNBUCKLE
3 - BEARING CUPS
(6) I nstal l the beari ng caps i n thei r ori gi nal l oca-
ti ons (Fi g. 50).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten the beari ng cap bol ts to 64-91 Nm
(47-67 ft. l bs.).
(10) I nstal l the axl e shafts.
(11) Appl y a 6.35mm (1/4 i n.) bead of red Mopar
Si l i cone Rubber Seal ant or equi val ent to the housi ng
cover (Fi g. 51).
(12) I nstal l the cover and ti ghten cover bol ts i n a
cri ss-cross pattern to 38-45 Nm (28-33 ft. l bs.).
(13) Refi l l the di fferenti al wi th l ubri cant and
i nstal l fi l l pl ug.
(14) Remove support and l ower the vehi cl e.
DIAGNOSIS AND TESTING - TRAC-LOK
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng the uni t for repai r,
drai n, fl ush and refi l l the axl e wi th the speci fi ed
l ubri cant. A contai ner of Mopar Trac-l ok Lubri cant
(fri cti on modi fi er) shoul d be added after repai r ser-
vi ce or duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 52).
(6) I f rotati ng torque i s l ess than 41 Nm (56 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
Fig. 50 BEARING CAP REFERENCE
Fig. 51 DIFFERENTIAL COVER - TYPICAL
1 - SEALING SURFACE
2 - SEALANT BEAD
3 - SEALANT THICKNESS
DISASSEMBLY
(1) Cl amp si de gear Fi xture 6965 i n a vi se and set
di fferenti al case on the fi xture (Fi g. 53).
(2) Remove ri ng gear i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(3) Remove pi ni on gear mate shaft l ock screw (Fi g.
54).
(4) Remove pi ni on gear mate shaft wi th a dri ft and
hammer.
(5) I nstal l and l ubri cate Step Pl ate 6960-3 (Fi g.
55).
Fig. 52 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 53 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 54 MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 55 Step Plate
1 - LOWER SIDE GEAR
3 - STEP PLATE
DIFFERENTIAL - TRAC-LOK (Continued)
(6) Assembl e Threaded Adapter 6960-1 i nto top
si de gear. Thread Forci ng Screw C-6960-4 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(7) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter Di sc 6960-3 (Fi g. 56) to prevent
adapter from turni ng.
(8) I nstal l Forci ng Screw 6960-4 and ti ghten screw
to 122 Nm (90 ft. l bs.) maxi mum to compress
Bel l evi l l e spri ngs i n cl utch packs (Fi g. 57).
(9) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 58).
Fig. 56 THREAD ADAPTER DISC
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - STEP PLATE
5 - THREADED ROD
6 - ADAPTER DISC
Fig. 57 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
Fig. 58 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
(10) I nsert Turni ng Bar 6960-2 i nto the pi ni on
mate shaft hol e i n the case (Fi g. 59).
(11) Loosen the Forci ng Screw i n smal l i ncrements
unti l the cl utch pack tensi on i s rel i eved and the di f-
ferenti al case can be turned usi ng Turni ng Bar.
(12) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(13) Remove pi ni on gears from di fferenti al case.
(14) Remove Forci ng Screw, Step Pl ate and
Threaded Adapter.
(15) Remove top si de gear, cl utch pack retai ner
and cl utch pack. Keep pl ates i n order duri ng removal
(Fi g. 60).
(16) Remove di fferenti al case from the Hol di ng
Fi xture. Remove si de gear, cl utch pack retai ner and
cl utch pack. Keep pl ates i n order duri ng removal .
CLEANING
Cl ean al l components i n cl eani ng sol vent and dry
components wi th compressed ai r.
INSPECTION
I nspect cl utch pack pl ates for wear, scori ng or dam-
age. Repl ace both cl utch packs i f any one component
i n ei ther pack i s damaged. I nspect si de and pi ni on
gears for cracks chi ps or damage and repl ace as nec-
essary. I nspect di fferenti al case and pi ni on shaft and
repl ace i f worn or damaged.
ASSEMBLY
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(1) Lubri cate components wi th gear l ubri cant.
(2) Assembl e cl utch di scs i nto packs and secure
di sc packs wi th retai ni ng cl i ps (Fi g. 61).
NOTE: Dished plate is position with the convex side
against the side gear.
Fig. 59 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
Fig. 60 SIDE GEARS AND CLUTCH DISCS
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 61 CLUTCH PACK
1 - DISCS
2 - DISHED PLATE
3 - RETAINER
4 - SIDE GEAR
5 - RETAINER
6 - PLATES
(3) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(4) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 62).Verify
clutch pack retaining clips are in position and
seated in the case pockets.
(5) Posi ti on the di fferenti al case on the Hol di ng
Fi xture 6965.
(6) I nstal l l ubri cated Step Pl ate 6960-3 i n l ower
si de gear (Fi g. 63).
(7) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 63).
(8) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter 6960-1 i nto top si de gear.
to sl i ghtl y compress cl utch di sc.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th Turni ng Bar 6960-2 unti l the
pi ni on mate shaft hol es i n pi ni on gears al i gn wi th
hol es i n case. I t may be necessary to sl i ghtl y ti ghten
the forci ng screw i n order to i nstal l the pi ni on gears.
(12) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove Forci ng Screw, Step Pl ate and
Threaded Adapter.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
Fig. 62 CLUTCH PACK AND LOWER SIDE GEAR
2 - SIDE GEAR AND CLUTCH PACK
Fig. 63 CLUTCH PACK AND UPPER SIDE GEAR
3 - STEP PLATE
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
(2) Remove si de beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, Adapters 8352 and Pl ug
SP-3289 (Fi g. 64).
INSTALLATION
NOTE: If differential side bearings or differential
case are replaced, differential side bearing shim
requirements may change. Refer to Adjustments
(Differential Bearing Preload and Gear Backlash) for
procedures.
(1) I nstal l di fferenti al si de beari ngs wi th I nstal l er
C-3716-A and Handl e C-4171 (Fi g. 65).
(2) I nstal l di fferenti al case i n housi ng.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without the
other gear.
(2) Mark pi ni on yoke and propel l er shaft for
(3) Di sconnect propel l er shaft from pi ni on yoke
and ti e shaft to underbody.
(4) Remove di fferenti al from housi ng.
jaw.
case.
Fig. 64 DIFFERENTIAL CASE BEARING
1 - ADAPTERS
2 - BEARING
3 - DIFFERENTIAL
4 - PLUG
5 - PULLER
Fig. 65 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
(7) Dri ve ri ng gear from di fferenti al case wi th a
rawhi de hammer (Fi g. 66).
(8) Hol d pi ni on yoke wi th Spanner Wrench 6958
and remove pi ni on yoke nut and washer (Fi g. 67).
(9) Remove pi ni on yoke from pi ni on shaft wi th
Remover C-452 and Wrench C-3281 (Fi g. 68).
(10) Remove pi ni on gear from housi ng (Fi g. 69).
Fig. 66 RING GEAR
2 - RING GEAR
3 - RAWHIDE HAMMER
1 - PINION YOKE
2 - WRENCH
3 - PIPE
Fig. 68 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
Fig. 69 PINION GEAR
1 - RAWHIDE HAMMER
PINION GEAR/RING GEAR/TONE RING (Continued)
(12) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(13) Remove front pi ni on beari ng cup wi th
Remover D-103 and Handl e C-4171 (Fi g. 71).
(14) Remove rear beari ng cup from housi ng (Fi g.
72) wi th Remover D-149 and Handl e C-4171.
(15) Remove col l apsi bl e prel oad spacer (Fi g. 73).
Fig. 70 PINION SEAL REMOVER
1 - REMOVER
2 - SLIDE HAMMER
3 - PINION SEAL
1 - REMOVER
2 - HANDLE
1 - DRIVER
2 - HANDLE
Fig. 73 COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - PINION DEPTH SHIM
5 - REAR BEARING
(16) Remove rear beari ng from the pi ni on wi th
Pul l er/Press C-293-PA and Adapters C-293-39 (Fi g.
74).
(17) Remove depth shi ms from pi ni on gear shaft
and record shi m thi ckness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
(1) Appl y Mopar Door Ease or equi val ent l ubri -
cant to outsi de surface of beari ng cup.
(2) I nstal l pi ni on rear beari ng cup wi th I nstal l er
C-146 and Dri ver Handl e C-4171 (Fi g. 75) and veri fy
cup i s seated.
(3) Appl y Mopar Door Ease or equi val ent l ubri -
cant to outsi de surface of beari ng cup.
(4) I nstal l pi ni on front beari ng cup wi th I nstal l er
D-130 and Handl e C-4171 (Fi g. 76) and veri fy cup i s
seated.
(5) I nstal l pi ni on front beari ng and oi l sl i nger, i f
equi pped.
Fig. 74 REAR PINION BEARING PULLER
1 - PULLER
2 - VISE
3 - ADAPTERS
1 - INSTALLER
2 - HANDLE
1 - INSTALLER
2 - HANDLE
(7) I nstal l pi ni on depth shi m on the pi ni on gear.
(8) I nstal l rear beari ng on the pi ni on gear wi th
I nstal l er W-262 and a press (Fi g. 78).
i on shaft and i nstal l pi ni on gear i n the housi ng (Fi g.
79).
(10) I nstal l yoke wi th I nstal l er C-3718 and Span-
ner Wrench 6958 (Fi g. 80).
Fig. 77 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION GEAR REAR BEARING
Fig. 79 COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
5 - REAR BEARING
1 - INSTALLER
2 - PINION YOKE
3 - WRENCH
(11) I nstal l the yoke washer and a new nut on the
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
(12) Ti ghten the nut to 271 Nm (200 ft. l bs.).
pinion gear bearing rotating torque and never
exceed specified preload torque. If preload torque
or rotating torque is exceeded a new collapsible
spacer must be installed.
(13) Usi ng Spanner Wrench 6958 and a torque
wrench set at 474 Nm (350 ft. l bs.), (Fi g. 81) sl owl y
ti ghten the nut i n 6.8 Nm (5 ft. l bs.) i ncrements
unti l the rotati ng torque i s achi eved.
CAUTION: Measure torque to rotate frequently to
avoid over crushing the collapsible spacer.
NOTE: If more than 474 Nm (350 ft. lbs.) torque is
required to crush the collapsible spacer, the spacer
is defective and must be replaced.
(14) Check pi ni on torque to rotate wi th a i nch
pound torque wrench (Fi g. 82). The pi ni on torque to
rotate shoul d be:
Ori gi nal Beari ngs: 1 to 2.25 Nm (10 to 20 i n.
l bs.).
New Beari ngs: 1.69 to 2.82 Nm (15 to 25 i n.
l bs.).
1 - PINION YOKE
2 - WRENCH
3 - PIPE
Fig. 82 PINION GEAR ROTATING TORQUE
1 - TORQUE WRENCH
2 - PINION YOKE
(15) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(16) I nvert the di fferenti al case i n the vi se.
(17) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 129-142 Nm (95-105 ft. l bs.) (Fi g. 83).
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
(18) I nstal l di fferenti al i n housi ng.
(19) Veri fy di fferenti al beari ng prel oad, gear mesh
and contact pattern. Refer to Ajustments for proce-
dure.
(20) I nstal l di fferenti al cover and fi l l wi th gear
l ubri cant.
(21) I nstal l the propel l er shaft wi th the reference
marks al i gned.
Fig. 83 RING GEAR
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
REAR AXLE - 8 1/4
TABLE OF CONTENTS
page page
REAR AXLE - 8 1/4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 86
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 92
SPECIFICATIONS
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SPECIAL TOOLS
8 1/4 AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 98
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 103
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 105
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 105
DIAGNOSIS AND TESTING - TRAC-LOK . . . . 106
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 107
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 109
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110
PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 112
REAR AXLE - 8 1/4
DESCRIPTION
The axl e housi ngs consi st of a cast i ron center sec-
ti on wi th axl e tubes extendi ng from ei ther si de. The
tubes are pressed i nto and wel ded to the di fferenti al
housi ng to form a one-pi ece axl e housi ng. The axl es
are equi pped wi th semi -fl oati ng axl e shafts, meani ng
vehi cl e l oads are supported by the axl e shaft and
beari ngs. The axl e shafts are retai ned by C-l ocks i n
the di fferenti al si de gears.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash are set and mai ntai ned by threaded
adjusters at the outsi de of the di fferenti al housi ng.
Pi ni on beari ng prel oad i s set and mai ntai ned by the
use of a col l apsi bl e spacer.
The di fferenti al cover provi des a means for i nspec-
ti on and servi ce wi thout removi ng the compl ete axl e
from the vehi cl e. A vent hose i s used to rel i eve i nter-
nal pressure caused by l ubri cant vapori zati on and
i nternal expansi on.
Axl es equi pped wi th a Trac-Lok di fferenti al are
opti onal . A di fferenti al has a one-pi ece di fferenti al
case, and the same i nternal components as a stan-
dard di fferenti al , pl us two cl utch di sc packs.
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
3 - 86 REAR AXLE - 8 1/4 KJ
STANDARD DIFFERENTIAL
speed.
TRAC-LOK DIFFERENTIAL
Thi s di fferenti al s cl utches are engaged by two con-
current forces. The fi rst bei ng the prel oad force
exerted through Bel l evi l l e spri ng washers wi thi n the
cl utch packs. The second i s the separati ng forces gen-
erated by the si de gears as torque i s appl i ed through
the ri ng gear (Fi g. 3).
Thi s desi gn provi des the di fferenti al acti on needed
for turni ng corners and for dri vi ng strai ght ahead
duri ng peri ods of unequal tracti on. When one wheel
l ooses tracti on, the cl utch packs transfer addi ti onal
torque to the wheel havi ng the most tracti on. Thi s
di fferenti al resi st wheel spi n on bumpy roads and
provi de more pul l i ng power when one wheel l ooses
Fig. 1 Differential Operation - Straight Ahead Driving
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
Fig. 2 Differential Operation - On Turns
Fig. 3 Trac-lok Limited Slip Differential
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
KJ REAR AXLE - 8 1/4 3 - 87
REAR AXLE - 8 1/4 (Continued)
tracti on. Pul l i ng power i s provi ded conti nuousl y unti l
both wheel s l oose tracti on. I f both wheel s sl i p due to
unequal tracti on, Trac-l ok operati on i s normal . I n
extreme cases of di fferences of tracti on, the wheel
wi th the l east tracti on may spi n.
GEAR NOISE
cant, i ncorrect backl ash, i ncorrect pi ni on depth, tooth
contact, worn/damaged gears, or the carri er housi ng
not havi ng the proper offset and squareness.
greatl y:
Gear damage.
cl e turns. A worn pi ni on shaft can al so cause a snap-
pi ng or a knocki ng noi se.
BEARING NOISE
source.
LOW SPEED KNOCK
U-joi nt or by worn si degear thrust washers. A worn
VIBRATION
caused by a:
Worn or out-of-bal ance wheel s.
Worn U-joi nt(s).
Check for l oose or damaged front-end components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
i nto gear (or the cl utch engaged), can be caused by:
Worn U-joi nts.
3 - 88 REAR AXLE - 8 1/4 KJ
DIAGNOSTIC CHART
properly.
and quantity.
and quantity.
wheel/tire.
KJ REAR AXLE - 8 1/4 3 - 89
level.
cover.
damage.
adjustment.
contact pattern. Adjust backlash or
pinion depth.
pinion.
pre-load.
bolts.
3 - 90 REAR AXLE - 8 1/4 KJ
REMOVAL
(2) Posi ti on a l i ft/jack under the axl e and secure
axl e to devi ce.
(3) Remove wheel s and ti res.
(5) Remove propel l er shaft and suspend under the
vehi cl e.
(6) Remove brake drums, parki ng brake cabl es and
speed sensor from the axl e.
(7) Di sconnect the brake hose at the body juncti on
bl ock.
(8) Remove brakes and backi ng pl ates.
(9) Remove vent hose from the axl e shaft tube.
(10) Remove the stabi l i zer bar (Fi g. 4).
(11) Remove upper control arm bal l joi nt pi nch
bol t from bracket (Fi g. 5).
(12) Remove shock absorbers from axl e brackets
(Fi g. 6).
(13) Loosen al l l ower control arms mounti ng bol ts
(Fi g. 7).
(14) Lower axl e enough to remove coi l spri ngs and
spri ng i nsul ators.
(15) Remove l ower control arm bol ts from the axl e
brackets.
(16) Lower and remove the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before the lower control arms
are tightened. This must be done to maintain vehi-
cle ride height and prevent premature bushing fail-
ure.
(1) Rai se the axl e under the vehi cl e.
(2) I nstal l l ower control arms onto the axl e brack-
ets and l oosel y i nstal l the mounti ng bol ts.
(3) I nstal l coi l spri ng i sol ators and spri ng.
(4) Rai se axl e up unti l spri ngs are seated.
(5) I nstal l upper control arm bal l joi nt i nto axl e
bracket and ti ghten pi nch bol t to torque speci fi cati on.
(6) I nstal l shock absorbers and ti ghten nuts to
(7) I nstal l stabi l i zer bar and ti ghten nuts to torque
speci fi cati on.
(8) I nstal l brake backi ng pl ates, parki ng brake
cabl es, brake drums and speed sensor.
(9) I nstal l brake hose to the body juncti on bl ock
and bl eed the brakes.
Fig. 4 STABILIZER BAR MOUNTS
1 - STABILIZER BAR MOUNTING BOLTS
2 - LOWER SUSPENSION ARM
2 - PINCH BOLT
Fig. 6 SHOCK ABSORBER
KJ REAR AXLE - 8 1/4 3 - 91
(11) I nstal l propel l er shaft wi th reference marks.
(12) I nstal l the wheel s and ti res.
(13) Add gear l ubri cant to speci fi cati ons, i f neces-
sary.
(14) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
(15) Ti ghten the l ower control arm bol ts to torque
speci fi cati on.
ADJUSTMENTS
Ri ng gears and pi ni ons are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng gear
and pi ni on are etched/marked onto each gear (Fi g. 8).
A pl us (+) number, mi nus () number or zero (0) i s
etched/marked on the face or shaft of the pi ni on. Thi s
number i s the amount (i n thousandths of an i nch)
the depth vari es from the standard depth setti ng of a
pi ni on etched wi th a (0). The standard depth pro-
vi des the best gear tooth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s paragraph i n
thi s secti on for addi ti onal i nformati on.
achi eved wi th sel ect shi ms. The shi ms are pl aced
behi nd the rear pi ni on beari ng (Fi g. 9).
ment pi ni on. Add or subtract the thi ckness of the
ori gi nal depth shi ms to compensate for the di fference
i n the depth vari ances. Refer to the Depth Vari ance
chart.
mi nus the amount needed.
Note the etched number on the face of the pi ni on
gear head (1, 2, 0, +1, +2, etc.). The numbers rep-
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
Fig. 7 LOWER SUSPENSION ARM
1 - AXLE BRACKET BOLT
3 - BODY BRACKET BOLT
Fig. 8 Pinion Gear ID Numbers - Typical
2 - DRIVE PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
Fig. 9 Adjustment Shim Locations
5 - PINION GEAR
6 - BEARING CUP
3 - 92 REAR AXLE - 8 1/4 KJ
Original Pinion
Gear Depth
Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
Measurements are taken wi th pi ni on beari ng cups and
pi ni on beari ngs i nstal l ed i n the housi ng. Take measure-
ments wi th Pi ni on Gauge Set and Di al I ndi cator C-3339.
(Fi g. 10).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng, and screw i nto the housi ng through
pi ni on beari ng cups (Fi g. 11).
(3) I nstal l front pi ni on beari ng and Cone-Nut 6740
hand ti ght (Fi g. 10).
(4) Pl ace Arbor Di sc 8541 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 12).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts to 41 Nm (30 ft. l bs.).
NOTE: Arbor Discs 8541 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
Fig. 10 Pinion Depth Gauge Tools
1 - DIAL INDICATOR
2 - ARBOR
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOOK
8 - ARBOR DISC
Fig. 11 Pinion Height Block
1 - PINION BLOCK
KJ REAR AXLE - 8 1/4 3 - 93
the pi ni on hei ght bl ock. Hol d scooter bl ock and zero
the di al i ndi cator.
arbor, then record the hi ghest readi ng.
(8) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
etched/marked on the pi ni on (Fi g. 8). For exampl e, i f
the depth vari ance i s 2, add +0.002 i n. to the di al
i ndi cator readi ng.
BEARING PRELOAD AND GEAR BACKLASH
The fol l owi ng must be consi dered when adjusti ng
beari ng prel oad and gear backl ash:
The maxi mum ri ng gear backl ash vari ati on i s
0.076 mm (0.003 i nch).
Mark the gears so the same teeth are meshed
duri ng al l backl ash measurements.
Mai ntai n the torque whi l e adjusti ng the beari ng
prel oad and ri ng gear backl ash.
Excessi ve adjuster torque wi l l i ntroduce a hi gh
beari ng l oad and cause premature beari ng fai l ure.
I nsuffi ci ent adjuster torque can resul t i n excessi ve
di fferenti al case free-pl ay and ri ng gear noi se.
I nsuffi ci ent adjuster torque wi l l not support the
ri ng gear correctl y and can cause excessi ve di fferen-
ti al case free-pl ay and ri ng gear noi se.
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
Maintain the gear teeth engaged (meshed) as
marked.
The bearings must be seated by rapidly rotat-
ing the pinion gear a half turn back and forth.
Do this five to ten times each time the threaded
adjusters are adjusted.
(1) Adjust each threaded adjuster i nward wi th
Wrench C-4164 unti l the di fferenti al beari ng free-
pl ay i s el i mi nated (Fi g. 14). Al l ow some ri ng gear
backl ash, approxi matel y 0.25 mm (0.01 i n.) between
the ri ng and pi ni on gear. Seat the beari ng cups wi th
the procedure descri bed above.
Fig. 12 Gauge Tools In Housing
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
Fig. 13 Pinion Gear Depth Measurement
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 14 Threaded Adjuster
1 - AXLE TUBE
2 - BACKING PLATE
3 - ADJUSTER WRENCH
3 - 94 REAR AXLE - 8 1/4 KJ
(2) I nstal l di al i ndi cator and posi ti on the pl unger
agai nst the dri ve si de of a ri ng gear tooth (Fi g. 15).
Measure the backl ash at 4 posi ti ons (90 degrees
apart) around the ri ng gear. Locate and mark the
area of mi ni mum backl ash.
(3) Rotate the ri ng gear to the posi ti on of the l east
backl ash. Mark the gear so that al l future backl ash
measurements wi l l be taken wi th the same gear
teeth meshed.
(4) Loosen the ri ght-si de, ti ghten the l eft-si de
threaded adjuster. Obtai n backl ash of 0.076 to 0.102
mm (0.003 to 0.004 i n.) wi th each adjuster ti ghtened
to 14 Nm (10 ft. l bs.). Seat the beari ng cups wi th the
procedure descri bed above.
(5) Ti ghten the di fferenti al beari ng cap bol ts i n a
cri ss-cross pattern to 95 Nm (70 ft. l bs.).
(6) Ti ghten the ri ght-si de threaded adjuster to 102
Nm (75 ft. l bs.). Seat the beari ng cups wi th the pro-
cedure descri bed above. Conti nue to ti ghten the
ri ght-si de adjuster and seat beari ng cups unti l the
torque remai ns constant at 102 Nm (75 ft. l bs.)
(7) Measure the ri ng gear backl ash. The range of
backl ash i s 0.15 to 0.203 mm (0.006 to 0.008 i n.).
(8) Conti nue i ncreasi ng the torque at the ri ght-
si de threaded adjuster unti l the speci fi ed backl ash i s
obtai ned.
NOTE: The left-side threaded adjuster torque
should have approximately 102 Nm (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.
(9) Ti ghten the l eft-si de threaded adjuster unti l
102 Nm (75 ft. l bs.) torque i s i ndi cated. Seat the
beari ng rol l ers wi th the procedure descri bed above.
Do thi s unti l the torque remai ns constant.
(10) I nstal l the threaded adjuster l ocks and
ti ghten the l ock screws to 10 Nm (90 i n. l bs.).
After the proper backl ash i s achi eved, perform the
Gear Contact Pattern procedure.
patterns.
equi val ent, to the dri ve and coast si de of the ri ng
gear teeth.
(2) Wrap, twi st and hol d a shop towel around the
tern.
shop towel .
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
16) and adjust pi ni on depth and gear backl ash as
necessary.
Fig. 15 Ring Gear Backlash
1 - DIAL INDICATOR
2 - RING GEAR
3 - EXCITER RING
KJ REAR AXLE - 8 1/4 3 - 95
Fig. 16 Gear Tooth Contact Patterns
3 - 96 REAR AXLE - 8 1/4 KJ
SIDE GEAR CLEARANCE
NOTE: When measuring side gear clearance, check
each gear independently. If it necessary to replace a
side gear, replace both gears as a matched set.
(1) I nstal l the axl e shafts, C-l ocks and pi ni on mate
shaft.
(2) Measure each si de gear cl earance. I nsert a
matched pai r of feel er gauge bl ades between the gear
and di fferenti al housi ng on opposi te si des of the hub
(Fi g. 17).
(3) I f si de gear cl earances i s no more than 0.005
i nch. Determi ne i f the axl e shaft i s contacti ng the
pi ni on mate shaft. Do not remove the feeler
gauges, inspect the axle shaft with the feeler
gauge inserted behind the side gear. I f the end of
the axl e shaft i s not contacti ng the pi ni on mate
shaft, the si de gear cl earance i s acceptabl e.
(4) I f cl earance i s more than 0.005 i nch (axl e shaft
not contacti ng mate shaft), record the si de gear cl ear-
ance. Remove the thrust washer and measure i ts
thi ckness wi th a mi crometer. Add the washer thi ck-
ness to the recorded si de gear cl earance. The sum of
gear cl earance and washer thi ckness wi l l determi ne
requi red thi ckness of repl acement thrust washer
(Fi g. 18).
I n some cases, the end of the axl e shaft wi l l move
and contact the mate shaft when the feel er gauge i s
i nserted. The C-l ock i s preventi ng the si de gear from
sl i di ng on the axl e shaft.
(5) I f there i s no si de gear cl earance, remove the
C-l ock from the axl e shaft. Use a mi crometer to mea-
sure the thrust washer thi ckness. Record the thi ck-
ness and re-i nstal l the thrust washer. Assembl e the
di fferenti al case wi thout the C-l ock i nstal l ed and re-
measure the si de gear cl earance.
(6) Compare both cl earance measurements. I f the
di fference i s l ess than 0.012 i nch (0.305 mm), add
cl earance recorded when the C-l ock was i nstal l ed to
thrust washer thi ckness measured. The sum wi l l
determi ne the requi red thi ckness of the repl acement
thrust washer.
(7) I f cl earance i s 0.012 i nch (0.305 mm) or
greater, both si de gears must be repl aced (matched
set) and the cl earance measurements repeated.
(8) I f cl earance (above) conti nues to be 0.012 i nch
(0.305 mm) or greater, the case must be repl aced.
Fig. 17 Side Gear Clearance
1 - FEELER GAUGE BLADES
2 - SIDE GEAR
Fig. 18 Side Gear Calculations
KJ REAR AXLE - 8 1/4 3 - 97
SPECIFICATIONS
REAR AXLE
AXLE SPECIFICATIONS
Axle Ratio 3.07, 3.55, 4.10
Differential Case Flange Runout 0.076 mm (0.003 in.)
Differential Case Clearance 0.12 mm (0.005 in.)
Ring Gear Diameter 209.5 mm (8.25 in.)
Ring Gear Runout 0.12 mm (0.005 in.)
Pinion Bearing Preload - Original Bearings 1-2 Nm (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 1-3.4 Nm (10-30 in. lbs.)
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 136 100 -
Ring Gear Bolts 95 70 -
Pinion Nut Minimum 285 210 -
Pinion Mate Shaft Screw 16.25 12 -
SPECIAL TOOLS
8 1/4 AXLE
PULLER 6790
REMOVER 6310
INSTALLER C-4198
HANDLE C-4171
3 - 98 REAR AXLE - 8 1/4 KJ
INSTALLER C-4076-B
HANDLE C-4735-1
HOLDER 6719
PULLER C-452
INSTALLER C-3718
ADJUSTMENT WRENCH C-4164
PULLER/PRESS C-293PA
ADAPTERS C-293-48
ADAPTER PLUG SP-3289
ADAPTERS C-293-47
INSTALLER C-4340
KJ REAR AXLE - 8 1/4 3 - 99
FIXTURE 8138
INSTALLER C-4345
REMOVER C-4307
INSTALLER C-4308
INSTALLER D-130
INSTALLER 6448
TRAC-LOK TOOLS 8140
TRAC-LOK TOOLS 6960
PINION BLOCK 8540
ARBOR DISCS 8541
PINION GAUGE SET
3 - 100 REAR AXLE - 8 1/4 KJ
AXLE SHAFTS
REMOVAL
(1) Pl ace the transmi ssi on i n NEUTRAL and rai se
and support vehi cl e.
(3) Remove brake drum.
(4) Remove the housi ng cover and drai n l ubri cant.
(5) Rotate di fferenti al case to access the pi ni on
shaft l ock screw. Remove l ock screw and pi ni on shaft
from di fferenti al case (Fi g. 19).
(6) Push axl e shaft i nward then remove axl e shaft
C-l ock (Fi g. 20).
(7) Remove axl e shaft bei ng careful l not to damage
shaft beari ng and seal .
(8) I nspect axl e shaft seal for l eakage or damage.
(9) I nspect axl e shaft beari ng contact surface for
si gns of bri nel l i ng, gal l i ng and pi tti ng.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng and
engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(2) I nsert C-l ock i n end of axl e shaft. Push axl e
shaft outward to seat C-l ock i n si de gear.
(3) I nsert pi ni on shaft i nto di fferenti al case and
through thrust washers and di fferenti al pi ni ons.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te on the
threads. Ti ghten l ock screw to 11 Nm (8 ft. l bs.).
(5) I nstal l cover and fi l l wi th gear l ubri cant to the
bottom of the fi l l pl ug hol e.
(6) I nstal l brake drum.
AXLE SHAFT SEALS
REMOVAL
(2) Remove axl e shaft.
(3) Remove axl e shaft seal from the axl e tube wi th
a smal l pry bar (Fi g. 21).
Fig. 19 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 20 Axle Shaft C-Lock
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
Fig. 21 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR
KJ REAR AXLE - 8 1/4 3 - 101
INSTALLATION
(1) Wi pe the axl e tube bore cl ean. Remove any ol d
seal er or burrs from the tube.
(2) I nstal l a new axl e seal wi th I nstal l er C-4076-B
and Handl e C-4735-1. When the tool contacts the
axl e tube, the seal i s i nstal l ed to the correct depth.
(3) Coat the l i p of the seal wi th axl e l ubri cant for
protecti on pri or to i nstal l i ng the axl e shaft.
(4) I nstal l the axl e shaft.
(5) Check and fi l l gear l ubri cant.
AXLE BEARINGS
REMOVAL
(2) Remove axl e shaft.
(3) Remove axl e shaft seal from the axl e tube wi th
a smal l pry bar (Fi g. 22).
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(4) Remove axl e shaft beari ng wi th Beari ng
Removal Tool Set 6310 and Adapter Foot 6310-9 (Fi g.
23).
INSTALLATION
(1) Wi pe the axl e tube bore cl ean. Remove any ol d
seal er or burrs from the tube.
(2) I nstal l axl e shaft beari ng wi th I nstal l er C-4198
and Handl e C-4171.
NOTE: Install bearing with part number against the
installer.
(3) I nstal l a new axl e seal wi th I nstal l er C-4198
and Handl e C-4171. When the tool contacts the axl e
tube, the seal i s i nstal l ed to the correct depth.
(4) Coat the l i p of the seal wi th axl e l ubri cant for
protecti on pri or to i nstal l i ng the axl e shaft.
(5) I nstal l the axl e shaft.
(6) Check and fi l l gear l ubri cant.
PINION SEAL
REMOVAL
(2) Mark the uni versal joi nt, pi ni on yoke and pi n-
i on shaft for i nstal l ati on reference.
(3) Remove propel l er shaft from pi ni on yoke.
(4) Remove the wheel and ti re assembl i es.
(5) Remove the brake drums.
(6) Rotate the pi ni on yoke three or four ti mes.
Fig. 22 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR
Fig. 23 Axle Shaft Bearing
1 - NUT
2 - GUIDE PLATE
3 - GUIDE
4 - THREADED ROD
5 - ADAPTER
6 - FOOT
7 - AXLE TUBE
3 - 102 REAR AXLE - 8 1/4 KJ
AXLE SHAFT SEALS (Continued)
(7) Measure rotati ng torque of the pi ni on gear
wi th an i nch pound torque wrench and record the
readi ng for i nstal l ati on reference.
(8) Hol d the pi ni on yoke wi th Hol der 6719 and
remove the pi ni on nut and washer.
(9) Remove yoke wi th Remover C-452 (Fi g. 24).
(10) Remove pi ni on seal wi th a pry tool or screw
mounted to a sl i de-hammer mounted.
INSTALLATION
l i p of pi ni on seal .
NOTE: The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of
sealant is not required.
(2) I nstal l the new pi ni on seal (Fi g. 25) wi th
I nstal l er C-4076-A and Handl e C-4735.
(3) I nstal l pi ni on yoke on the shaft wi th the refer-
ence marks al i gned.
(4) Seat yoke on pi ni on shaft wi th I nstal l er C-3718
and Hol der 6719A.
(5) Remove the tool s and i nstal l the pi ni on yoke
washer. The convex si de of the washer must face out-
ward.
(6) Usi ng yoke Hol der 6719A ti ghten shaft nut to
285 Nm (210 ft. l bs.) (Fi g. 26). Rotate the pi ni on sev-
eral revol uti ons to ensure the beari ng rol l ers are
seated.
(7) Rotate the pi ni on usi ng an i nch pound torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal , pl us an addi ti onal 0.56
Nm (5 i n. l bs.) (Fi g. 27).
load torque. If preload torque is exceeded a new
collapsible spacer must be installed.
(8) I f the rotati ng torque i s l ow, use Hol der 6719A
(Fi g. 26) and ti ghten the pi ni on nut i n 6.8 Nm (5 ft.
Fig. 24 Pinion Yoke
1 - PINION YOKE
2 - REMOVER
Fig. 25 Pinion Seal Installer
1 - HANDLE
3 - INSTALLER
Fig. 26 Tightening Pinion Nut
2 - YOKE HOLDER
3 - TORQUE WRENCH
KJ REAR AXLE - 8 1/4 3 - 103
l bs.) i ncrements unti l proper rotati ng torque i s
achi eved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, it indicates a binding
condition.
(9) The seal repl acement i s unacceptabl e i f the
fi nal pi ni on nut torque i s l ess than 285 Nm (210 ft.
l bs.).
(10) I nstal l the propel l er shaft wi th the i nstal l a-
ti on reference marks al i gned.
(11) I nstal l the brake drums.
(12) Check the di fferenti al housi ng l ubri cant l evel .
(13) I nstal l wheel and ti re assembl i es and l ower
the vehi cl e.
DIFFERENTIAL
REMOVAL
(2) Remove fi l l hol e pl ug from the di fferenti al
housi ng cover.
(3) Remove di fferenti al housi ng cover and drai n
housi ng.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth. Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the axl e shafts.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(6) Mark the di fferenti al housi ng and beari ng caps
for i nstal l ati on reference (Fi g. 28).
(7) Remove beari ng threaded adjuster l ocks from
each beari ng cap.
(8) Loosen beari ng cap bol ts, them l oosen the
threaded adjusters wi th Wrench C-4164 (Fi g. 29).
Fig. 27 Pinion Rotation Torque
1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH Fig. 28 Reference Mark
1 - REFERENCE MARKS
2 - REFERENCE MARKS
4 - BEARING CAP
Fig. 29 Threaded Adjuster
1 - AXLE TUBE
2 - BACKING PLATE
3 - THREAD ADJUSTER WRENCH
3 - 104 REAR AXLE - 8 1/4 KJ
(9) Hol d the di fferenti al case whi l e removi ng bear-
i ng caps and adjusters.
(10) Remove the di fferenti al case.
NOTE: Tag bearing cups and threaded adjusters
location, for installation reference.
DISASSEMBLY
(1) Remove pi ni on shaft l ock screw (Fi g. 30).
(2) Remove pi ni on shaft.
(3) Rotate di fferenti al si de gears and remove di f-
ferenti al pi ni ons and thrust washers (Fi g. 31).
(4) Remove di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l di fferenti al si de gears and thrust wash-
ers.
(2) I nstal l di fferenti al pi ni on and thrust washers.
(3) I nstal l the pi ni on shaft.
(4) Al i gn the hol e i n the pi ni on shaft wi th the hol e
i n the di fferenti al case and i nstal l the pi ni on shaft
l ock screw.
INSTALLATION
(1) Appl y a coati ng of hypoi d gear l ubri cant to the
di fferenti al beari ngs, beari ng cups and threaded
adjusters. A dab of grease can be used to keep the
adjusters i n posi ti on. Careful l y posi ti on the assem-
bl ed di fferenti al case i n the housi ng.
(2) I nstal l di fferenti al beari ng caps i n thei r ori gi -
nal l ocati ons (Fi g. 32).
(3) I nstal l beari ng cap bol ts and ti ghten the upper
bol ts to 14 Nm (10 ft. l bs.). Ti ghten the l ower bol ts
fi nger-ti ght unti l the bol t head i s seated.
(4) Perform the di fferenti al beari ng prel oad and
adjustment procedure.
(5) Ti ghten beari ng cap bol ts i n a cri ss-cross pat-
tern to 95 Nm (70 ft.l bs).
Fig. 30 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 31 Differential Case
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
Fig. 32 Bearing Caps & Bolts
1 - REFERENCE MARKS
2 - REFERENCE MARKS
4 - BEARING CAP
KJ REAR AXLE - 8 1/4 3 - 105
(6) I nstal l adjuster l ocks on the beari ng caps.
(7) I nstal l axl e shafts.
(8) Appl y a bead of red Mopar si l i cone rubber axl e
seal ant or equi val ent to the housi ng cover (Fi g. 33).
(9) I nstal l cover and ti ghten bol ts i n a cri ss-cross
pattern to 41 Nm (30 ft. l bs.).
(10) Fi l l di fferenti al wi th gear l ubri cant to bottom
of the fi l l pl ug hol e.
(11) I nstal l the fi l l hol e pl ug.
(14) Trac-l ok di fferenti al equi pped vehi cl es shoul d
be road tested by maki ng 10 to 12 sl ow fi gure-ei ght
turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
DIAGNOSIS AND TESTING - TRAC-LOK
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng the uni t for repai r,
drai n, fl ush and refi l l the axl e wi th the speci fi ed
l ubri cant. A contai ner of Mopar Trac-l ok Lubri cant
(fri cti on modi fi er) shoul d be added after repai r ser-
vi ce or duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 34).
(6) I f rotati ng torque i s l ess than 41 Nm (56 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
Fig. 33 Differential Cover Sealant
1 - SEALANT
2 - DIFFERNTIAL COVER
Fig. 34 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
3 - 106 REAR AXLE - 8 1/4 KJ
DISASSEMBLY
(1) Cl amp si de gear Fi xture 8138 i n a vi se and set
di fferenti al case on the fi xture (Fi g. 35).
(2) Remove ri ng gear i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(3) Remove pi ni on gear mate shaft l ock screw.
(4) Remove pi ni on gear mate shaft wi th a dri ft and
hammer.
(5) I nstal l Di scs 8140 wi thout threaded hol e i n the
l ower si de gear (Fi g. 36).
(6) I nstal l Di sc 8140 wi th threaded hol e i n the
upper si de gear. Thread Forci ng Screw 6960-4
through the upper di sc unti l i t becomes centered i n
l ower di sc.
(7) I nsert a screw dri ver i n sl ot of upper di sc (Fi g.
37) to prevent di sc from turni ng.
Fig. 36 LOWER DISC
1 - LOWER SIDE GEAR
3 - DISC
Fig. 37 TRAK-LOC TOOLS
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - LOWER DISC
5 - THREADED ROD
6 - UPPER DISC
Fig. 35 DIFFERENTIAL CASE FIXTURE
1 - FIXTURE
2 - VISE
3 - DIFFERENTIAL
KJ REAR AXLE - 8 1/4 3 - 107
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 38).
(9) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 39).
(10) I nsert Turni ng Bar 6960-2 i nto the pi ni on
mate shaft hol e i n the case (Fi g. 40).
(11) Loosen the Forci ng Screw i n smal l i ncrements
unti l the cl utch pack tensi on i s rel i eved and the di f-
ferenti al case can be turned usi ng Turni ng Bar.
(12) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(13) Remove pi ni on gears from di fferenti al case.
(14) Remove Forci ng Screw and di scs.
(15) Remove top si de gear, cl utch pack retai ner
and cl utch pack. Keep pl ates i n order duri ng removal
(Fi g. 41).
Fig. 38 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
Fig. 39 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 40 PINION GEARS
1 - PINION GEARS
2 - TURNING BAR
Fig. 41 SIDE GEARS AND CLUTCH DISCS
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
3 - 108 REAR AXLE - 8 1/4 KJ
(16) Remove di fferenti al case from the fi xture.
Remove si de gear, cl utch pack retai ner and cl utch
pack. Keep pl ates i n order duri ng removal .
CLEANING
Cl ean al l components i n cl eani ng sol vent and dry
components wi th compressed ai r.
INSPECTION
I nspect cl utch pack pl ates for wear, scori ng or dam-
age. Repl ace both cl utch packs i f any one component
i n ei ther pack i s damaged. I nspect si de and pi ni on
gears for cracks chi ps or damage and repl ace as nec-
essary. I nspect di fferenti al case and pi ni on shaft and
repl ace i f worn or damaged.
ASSEMBLY
Lubri cate each component wi th gear l ubri cant
before assembl y.
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 42).
(2) I nstal l assembl ed cl utch di sc packs on the si de
gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 43).Verify
clutch pack retaining clips are in position and
seated in the case pockets.
(4) Set di fferenti al case on Fi xture 8138.
(5) I nstal l l ubri cated Di sc 8140 wi thout the hol e i n
l ower si de gear (Fi g. 44).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 44).
(7) Hol d assembl y i n posi ti on. I nsert Di sc 8140
wi th threaded hol e i nto top si de gear.
to sl i ghtl y compress cl utch di sc.
(9) Pl ace pi ni on gears i n posi ti on i n si de gears and
veri fy that the pi ni on mate shaft hol e i s al i gned.
(10) Rotate case wi th Turni ng Bar 6960-2 unti l the
pi ni on mate shaft hol es i n pi ni on gears al i gn wi th
hol es i n case. I t may be necessary to sl i ghtl y ti ghten
the forci ng screw i n order to i nstal l the pi ni on gears.
maxi mum to compress the Bel l evi l l e spri ngs.
(12) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(13) Remove forci ng screw and di scs.
Fig. 42 CLUTCH DISC PACK
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 43 CLUTCH PACK AND LOWER SIDE GEAR
2 - LOWER SIDE GEAR AND CLUTCH PACK
KJ REAR AXLE - 8 1/4 3 - 109
(14) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(15) I nstal l pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e.
(2) Remove di fferenti al beari ngs from the case
wi th Pul l er/Press C-293-PA and Adapters C-293-48
and Pl ug SP-3289 (Fi g. 45).
INSTALLATION
(1) I nstal l di fferenti al si de beari ngs wi th I nstal l er
C-4340 and Handl e C-4171 (Fi g. 46).
(2) I nstal l di fferenti al case i n axl e.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
CAUTION: The ring and pinion gears are serviced in
a matched set. Never replace one gear without
replacing the other matched gear.
(1) Mark pi ni on yoke and propel l er shaft for
(2) Remove propel l er shaft from pi ni on yoke and
ti e propel l er shaft to underbody.
(3) Remove di fferenti al from axl e housi ng.
jaw (Fi g. 47).
case.
(6) Dri ve ri ng gear from the di fferenti al case wi th
a rawhi de hammer.
Fig. 44 CLUTCH PACK AND UPPER SIDE GEAR
3 - LOWER DISC
Fig. 45 Differential Bearing Puller
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
3 - 110 REAR AXLE - 8 1/4 KJ
(7) Hol d pi ni on yoke wi th Hol der 6719A and
remove pi ni on yoke nut and washer.
(8) Remove pi ni on yoke from pi ni on shaft wi th
Remover C-452 (Fi g. 48).
(9) Remove pi ni on from the housi ng (Fi g. 49).
Fig. 46 Differential Bearing Installer
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 47 Ring Gear
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 48 Pinion Yoke
1 - PINION YOKE
2 - REMOVER
Fig. 49 Pinion Gear
1 - RAWHIDE HAMMER
KJ REAR AXLE - 8 1/4 3 - 111
(10) Remove pi ni on shaft seal wi th a pry tool or
sl i de-hammer mounted screw.
(11) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(12) Remove front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C-4171 (Fi g. 50).
(13) Remove rear beari ng cup from housi ng (Fi g.
51) wi th Remover C-4307 and Handl e C-4171.
(14) Remove col l apsi bl e prel oad spacer (Fi g. 52).
(15) Remove rear beari ng from the pi ni on (Fi g. 53)
wi th Pul l er/Press C-293-PA and Adapters C-293-47.
(16) Remove depth shi ms from the pi ni on shaft
and record the shi ms thi ckness.
INSTALLATION
NOTE: A pinion depth shim/oil baffle is placed
between the rear pinion bearing cone and pinion
gear. If the ring and pinion gears are reused, the
original pinion depth shim/oil baffle can be used.
Refer to Adjustments (Pinion Gear Depth) to select
the proper shim thickness if ring and pinion gear
are replaced.
(1) Appl y Mopar Door Ease or equi val ent l ubri cant
to outsi de surface of pi ni on beari ng cups.
(2) I nstal l rear pi ni on beari ng cup (Fi g. 54) wi th
I nstal l er C-4308 and Handl e C-4171 and veri fy cup i s
seated.
(3) I nstal l front pi ni on beari ng cup (Fi g. 55) wi th
I nstal l er D-130 and Handl e C-4171 and veri fy cup i s
seated.
Fig. 50 Front Pinion Bearing Cup
1 - REMOVER
2 - HANDLE
Fig. 51 Rear Pinion Bearing Cup
1 - DRIVER
2 - HANDLE
Fig. 52 Collapsible Spacer
2 - SHOULDER
3 - PINION
5 - REAR BEARING
3 - 112 REAR AXLE - 8 1/4 KJ
(4) I nstal l pi ni on front beari ng and oi l sl i nger, i f
equi pped.
l i p of pi ni on seal and i nstal l seal wi th I nstal l er
C-4076-B and Handl e C-4735 (Fi g. 56).
(6) Pl ace proper thi ckness depth shi m on the pi n-
i on.
(7) I nstal l rear beari ng and sl i nger i f equi pped, on
the pi ni on shaft (Fi g. 57) wi th I nstal l er 6448 and a
press.
i on shaft and i nstal l pi ni on i n housi ng (Fi g. 58).
(9) I nstal l pi ni on i n housi ng.
(10) I nstal l yoke wi th I nstal l er C-3718 and Yoke
Hol der 6719A.
Fig. 53 Rear Pinion Bearing Puller
1 - PULLER
2 - VISE
3 - ADAPTERS
Fig. 54 Rear Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 55 Front Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 56 Pinion Seal
1 - HANDLE
3 - INSTALLER
KJ REAR AXLE - 8 1/4 3 - 113
(11) I nstal l yoke washer and a new nut on the pi n-
i on. The convex si de of the washer must face out-
ward.
(12) Ti ghten the nut to 285 Nm (210 ft. l bs.).
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
installed.
(13) Hol di ng the yoke wi th Hol der 6719A sl owl y
ti ghten the nut i n 6.8 Nm (5 ft. l bs.) i ncrements
unti l the desi red rotati ng torque i s achi eved. Mea-
sure the rotati ng torque frequentl y to avoi d over
crushi ng the spacer (Fi g. 59).
(14) Check beari ng rotati ng torque wi th an i nch
pound torque wrench (Fi g. 59). The pi ni on gear rotat-
i ng torque shoul d be:
Ori gi nal Beari ngs: 1 to 2 Nm (10 to 20 i n. l bs.).
New Beari ngs: 1 to 5 Nm (10 to 30 i n. l bs.).
Fig. 57 Rear Pinion Bearing
1 - PRESS
2 - INSTALLATION
3 - PINION GEAR
Fig. 58 Collapsible Preload Spacer
2 - SHOULDER
3 - PINION
5 - REAR BEARING
Fig. 59 Pinion Rotating Torque
1 - TORQUE WRENCH
2 - PINION YOKE
3 - 114 REAR AXLE - 8 1/4 KJ
(15) I nvert the di fferenti al case.
(16) I nstal l ri ng gear on the di fferenti al case and
start two ri ng gear bol ts. Thi s wi l l provi de case-to-
ri ng gear bol t hol e al i gnment.
(17) I nvert the di fferenti al case i n the vi se.
(18) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 102 Nm (75 ft. l bs.) (Fi g. 60).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(19) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh refer to Adjustments (Gear Contact Pat-
tern).
(20) I nstal l di fferenti al cover fi l l wi th gear l ubri -
cant.
(21) I nstal l the propel l er shaft wi th reference
marks al i gned.
(22) I nstal l wheel and ti re assembl i es and l ower
the vehi cl e.
Fig. 60 Ring Gear
1 - TORQUE WRENCH
2 - BOLTS
3 - RING GEAR
KJ REAR AXLE - 8 1/4 3 - 115
BRAKES
TABLE OF CONTENTS
page page
POWER BRAKE BOOSTER
REMOVAL - RHD . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION - RHD . . . . . . . . . . . . . . . . . . . . . 1
POWER BRAKE BOOSTER
REMOVAL - RHD
(1) Remove the ai r box (Refer to 9 - ENGI NE/AI R
I NTAKE SYSTEM/AI R CLEANER ELEMENT -
REMOVAL).
(2) Rel ocate the crui se control servo to gai n access
to the booster for removal .
(3) Remove the brake l i nes from the master cyl i n-
der.
(4) Remove the master cyl i nder (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/MASTER
CYLI NDER - REMOVAL).
(5) Di sconnect vacuum hose from booster check
val ve.
(6) Remove knee bl ocker under the steeri ng col um-
n,(Refer to 23 - BODY/I NSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(7) Remove the brake l i ght swi tch.(Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI OR/
BRAKE LAMP SWI TCH - REMOVAL)
(8) Remove retai ni ng cl i p that secures booster
push rod to brake pedal (Fi g. 1).
(9) Remove nuts attachi ng booster to the dash
panel (Fi g. 2).
(10) I n engi ne compartment, sl i de booster studs
out of dash panel , ti l t booster upward, and remove
booster from engi ne compartment.
INSTALLATION - RHD
(1) Al i gn and posi ti on booster on the dash panel .
(2) I nstal l booster mounti ng nuts. Ti ghten nuts
just enough to hol d booster i n pl ace.
(3) Sl i de booster push rod onto the brake pedal .
Then secure push rod to pedal pi n wi th retai ni ng
cl i p.
NOTE: Lubricate the pedal pin with Mopar multi-
mileage grease before installation.
(4) Ti ghten booster mounti ng nuts to 39 Nm (29
ft. l bs.).
(5) I nstal l the brake l i ght swi tch.
(6) I nstal l the knee bl ocker,(Refer to 23 - BODY/
I NSTRUMENT PANEL/KNEE BLOCKER - I NSTAL-
LATI ON).
(7) I f ori gi nal master cyl i nder i s bei ng i nstal l ed,
check condi ti on of seal at rear of master cyl i nder.
Repl ace seal i f cut, or torn.
(8) Cl ean cyl i nder mounti ng surface of brake
booster. Use shop towel wetted wi th brake cl eaner for
Fig. 1 BOOSTER PUSH ROD
1 - BRAKE PEDAL
2 - BOOSTER ROD
Fig. 2 BOOSTER MOUNTING
1 - BRAKE BOOSTER
KJ BRAKES 5s - 1
thi s purpose. Di rt, grease, or si mi l ar materi al s wi l l
prevent proper cyl i nder seati ng and coul d resul t i n
vacuum l eak.
(9) Al i gn and i nstal l master cyl i nder on the
booster studs. I nstal l mounti ng nuts and ti ghten to
17.5 Nm (155 i n. l bs.).
(10) Connect vacuum hose to booster check val ve.
(11) Remount the crui se control servo to the ori gi -
nal l ocati on. Ti ghten bracket mounti ng nuts to 17.5
Nm (155 i n. l bs.).
(12) Connect and secure the brake l i nes to HCU
and master cyl i nder. Start al l brake l i ne fi tti ngs by
hand to avoi d cross threadi ng.
(13) Connect the wi re to fl ui d reservoi r.
(14) I nstal l the ai r box.
(15) Fi l l and bl eed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
(16) Veri fy proper brake operati on before movi ng
vehi cl e.
5s - 2 BRAKES KJ
POWER BRAKE BOOSTER (Continued)
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - CLUTCH . . . . . . . . 2
SPECIFICATIONS - CLUTCH . . . . . . . . . . . . . . . 5
CLUTCH DISC
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLUTCH RELEASE BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FLYWHEEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - FLYWHEEL . . . . . . 8
PILOT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LINKAGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MASTER CYLINDER
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CLUTCH PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH SWITCH OVERRIDE RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - CLUTCH PEDAL
POSITION SWITCH . . . . . . . . . . . . . . . . . . . . 11
CLUTCH
DESCRIPTION
The cl utch mechani sm consi sts of a fl ywheel , dry-
type di sc, di aphragm styl e pressure pl ate and
hydraul i c l i nkage. The fl ywheel i s bol ted to the rear
fl ange of the crankshaft. The cl utch pressure pl ate i s
bol ted to the fl ywheel wi th the cl utch di sc between
these two components. The cl utch system provi des
the mechani cal , l i nk between the engi ne and the
transmi ssi on. The system i s desi gned to transfer the
torque output of the engi ne, to the transmi ssi on
whi l e i sol ati ng the transmi ssi on from the engi ne fi r-
i ng pul ses to mi ni mi ze concerns such as gear rattl e.
OPERATION
The cl utch operates wi th l everage, cl ampi ng force
and fri cti on. The di sc serves as the fri cti on el ement,
the di aphragm spri ng and pressure pl ate provi de the
cl ampi ng force. The cl utch pedal , hydraul i c l i nkage,
rel ease l ever and beari ng provi de the l everage.
The cl utch master cyl i nder push rod i s connected
to the cl utch pedal . When the cl utch pedal i s
depressed, the sl ave cyl i nder i s operated by the
cl utch master cyl i nder mounted on the dash panel .
The rel ease fork i s actuated by the hydraul i c sl ave
cyl i nder mounted on the transmi ssi on housi ng. The
rel ease beari ng i s operated by a rel ease fork pi voti ng
on a bal l stud mounted i n the transmi ssi on housi ng.
The rel ease beari ng then depresses the pressure
pl ate spri ng fi ngers, thereby rel easi ng pressure on
the cl utch di sc and al l owi ng the engi ne crankshaft to
spi n i ndependentl y of the transmi ssi on i nput shaft.
KJ CLUTCH 6 - 1
WARNING
WARNING:: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. FACTORY INSTALLED
CLUTCH DISCS DO NOT CONTAIN ASBESTOS
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
CONTAIN ASBESTOS FIBERS FROM AFTERMAR-
KET COMPONENTS. BREATHING EXCESSIVE CON-
CENTRATIONS OF THESE FIBERS CAN CAUSE
SERIOUS BODILY HARM. WEAR A RESPIRATOR
DURING SERVICE AND NEVER CLEAN CLUTCH
COMPONENTS WITH COMPRESSED AIR OR WITH
A DRY BRUSH. EITHER CLEAN THE COMPONENTS
WITH A WATER DAMPENED RAGS OR USE A VAC-
UUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING ASBESTOS FIBERS AND DUST. DO NOT
CREATE DUST BY SANDING A CLUTCH DISC.
REPLACE THE DISC IF THE FRICTION MATERIAL IS
DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS. THIS WILL
HELP MINIMIZE EXPOSURE TO YOURSELF AND TO
OTHERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL SAFETY AGENCY
(EPA), FOR THE HANDLING AND DISPOSAL OF
PRODUCTS CONTAINING ASBESTOS.
DIAGNOSIS AND TESTING - CLUTCH
Dri ve the vehi cl e at normal speeds. Shi ft the trans-
mi ssi on through al l gear ranges and observe cl utch
acti on. I f the cl utch chatters, grabs, sl i ps or does not
rel ease properl y, remove and i nspect the cl utch com-
ponents. I f the probl em i s noi se or hard shi fti ng, fur-
ther di agnosi s may be needed as the transmi ssi on or
another dri vel i ne component may be at faul t.
NOTE: Vehicles equipped with a Dual Mass Fly-
wheel may produce a rattle when the engine is shut
off. This noise is considered normal.
CLUTCH CONTAMINATION
Fl ui d contami nati on i s a frequent cause of cl utch
mal functi ons. Oi l , water or cl utch fl ui d on the cl utch
di sc and pressure pl ate surfaces wi l l cause chatter,
sl i p and grab. I nspect components for oi l , hydraul i c
fl ui d or water/road spl ash contami nati on.
Oi l contami nati on i ndi cates a l eak at ei ther the
rear mai n seal or transmi ssi on i nput shaft. Cl utch
fl ui d l eaks are usual l y from damaged sl ave cyl i nder
push rod seal s. Heat bui l dup caused by sl i ppage
between the pressure pl ate, di sc and fl ywheel can
bake the oi l resi due onto the components. The gl aze-
l i ke resi due ranges i n col or from amber to bl ack.
Road spl ash contami nati on i s di rt/water enteri ng
the cl utch housi ng due to l oose bol ts, housi ng cracks.
Dri vi ng through deep water puddl es can force water/
road spl ash i nto the housi ng through such openi ngs.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Cl utch rel ease or engagement probl ems are caused
by wear or damage cl utch components. A vi sual
i nspecti on of the rel ease components wi l l usual l y
reveal the probl em part.
Rel ease probl ems can resul t i n hard shi fti ng and
noi se. Look for l eaks at the cl utch cyl i nders and
i nterconnecti ng l i ne and l oose sl ave cyl i nder bol ts.
Al so worn/l oose rel ease fork, pi vot stud, cl utch di sc,
pressure pl ate or rel ease beari ng.
Engagement probl ems can resul t i n sl i p, chatter/
shudder and noi sy operati on. The causes may be
cl utch di sc contami nati on, wear, di storti on or fl y-
wheel damage. Vi sual l y i nspect to determi ne the
actual cause of the probl em.
CLUTCH MISALIGNMENT
Cl utch components must be i n proper al i gnment
wi th the crankshaft and transmi ssi on i nput shaft.
Mi sal i gnment caused by excessi ve runout or warpage
of any cl utch component wi l l cause grab, chatter and
i mproper cl utch rel ease.
PRESSURE PLATE AND DISC RUNOUT
Check the cl utch di sc before i nstal l ati on. Axi al
(face) runout of a new di sc shoul d not exceed 0.50
mm (0.020 i n.). Measure runout about 6 mm (1/4 i n.)
from the outer edge of the di sc faci ng. Obtai n
another di sc i f runout i s excessi ve.
Check condi ti on of the cl utch before i nstal l ati on. A
warped cover or di aphragm spri ng wi l l cause grab
and i ncompl ete rel ease or engagement. Be careful
when handl i ng the cover and di sc. I mpact can di stort
the cover, di aphragm spri ng, rel ease fi ngers and the
hub of the cl utch di sc.
Use an al i gnment tool when posi ti oni ng the di sc on
the fl ywheel . The tool prevents acci dental mi sal i gn-
ment whi ch coul d resul t i n cover di storti on and di sc
damage.
A frequent cause of cl utch cover di storti on (and
consequent mi sal i gnment) i s i mproper bol t ti ghten-
i ng.
FLYWHEEL RUNOUT
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
6 - 2 CLUTCH KJ
CLUTCH (Continued)
Common causes of runout are:
heat warpage
i mproper machi ni ng
i ncorrect bol t ti ghteni ng
i mproper seati ng on crankshaft fl ange shoul der
forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. Mi nor fl y-
wheel scori ng can be cl eaned up by hand wi th 180
gri t emery or wi th surface gri ndi ng equi pment.
Remove onl y enough materi al to reduce scori ng
(approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal or equi val ent.
Ti ghten fl ywheel bol ts to speci fi ed torque onl y. Over-
ti ghteni ng can di stort the fl ywheel hub causi ng
runout.
DIAGNOSIS CHART
The di agnosi s charts Di agnosi s Chart descri be
common cl utch probl ems, causes and correcti on. Con-
di ti ons, causes and correcti ve acti on are outl i ned i n
the i ndi cated col umns.
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.
2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.
3. Replace cover and disc.
Clutch disc facing contaminated with
oil, grease, or clutch fluid.
1. Leak at rear main engine seal or
transmission input shaft seal.
1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.
2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.
3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.
1. Release bearing sticking or
binding and does not return to the
normal running position.
1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.
1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.
1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.
1. Rough handling. Impact bent
cover, spring, or disc.
1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.
2. Tighten clutch cover using proper
procedure.
KJ CLUTCH 6 - 3
CLUTCH (Continued)
Facing on flywheel side of disc torn,
gouged, or worn.
1. Flywheel surface scored or
nicked.
2. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.
2. Lubricate splines with high
temperature graese.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
1. Frequent operation under high
loads or hard acceleration
conditions.
1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
Clutch disc binds on input shaft
splines.
1. Clutch disc hub splines damaged
during installation.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.
1. Clutch not used for and extended
period of time (e.g. long term
vehicle storage).
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers
are worn.
1. Bearing cocked during
installation.
1. Install and lubricate a new
bearing.
2. Bearing defective. 2. Install and lubricate a new
bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.
4. Replace clutch cover.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.
6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.
7. Replace hydraulic linkage
assembly.
6 - 4 CLUTCH KJ
CLUTCH (Continued)
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.
2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.
3. Replace and lubricate bushings.
Clutch master or slave cylinder
plunger dragging andr binding
1. Master or slave cylinder
components worn or corroded.
1. Replace clutch hydraulic linkage
assembly.
Release bearing is noisy. 1. Release bearing defective or
damaged.
1. Replace release bearing.
Contact surface of release bearing
damaged.
1. Clutch cover incorrect or release
fingers bent or distorted.
1. Replace clutch cover and release
bearing.
2. Release bearing defective or
damaged.
2. Replace the release bearing.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Clutch pressure plate position
incorrect.
1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
fingers bent or distorted.
2. Replace clutch disc and cover.
3. Clutch disc damaged or
distorted.
2. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andr
clutch housing. Correct as
necessary.
SPECIFICATIONS - CLUTCH
Pressure Plate Bolts -
2.4L
31 23 -
Pressure Plate Bolts -
3.7L
50 37 -
Clutch Cylinder Bolts 23 - 200
Flywheel Bolts - 2.4L 81 60 -
Flywheel Bolts - 3.7L 81 60 -
KJ CLUTCH 6 - 5
CLUTCH (Continued)
CLUTCH DISC
REMOVAL
(1) Remove transmi ssi on.
(2) Mark posi ti on of pressure pl ate on fl ywheel
wi th pai nt or a scri ber for assembl y reference, i f
cl utch i s not bei ng repl aced.
(3) Loosen pressure pl ate bol ts evenl y and i n rota-
ti on to rel i eve spri ng tensi on and avoi d warpi ng the
pl ate.
(4) Remove pressure pl ate bol ts and pressure pl ate
and di sc.
INSTALLATION
(1) Li ghtl y scuff sand fl ywheel face wi th 180 gri t
emery cl oth, then cl ean wi th a wax and grease
remover.
(2) Lubri cate pi l ot beari ng wi th Mopar hi gh tem-
perature beari ng grease or equi val ent.
(3) Check runout and operati on of new cl utch di sc.
NOTE: Disc must slide freely on transmission input
shaft splines.
(4) Wi th the di sc on the i nput shaft, check face
runout wi th di al i ndi cator. Check runout at di sc hub
6 mm (1/4 i n.) from outer edge of faci ng. Obtai n
another cl utch di sc i f runout exceed 0.5 mm (0.020
i n.).
(5) Posi ti on cl utch di sc on fl ywheel wi th si de
marked fl ywheel agai nst the fl ywheel .
NOTE: If not marked, the flat side of disc hub goes
towards the flywheel on the 3.7L engine and
towards the transmission on 2.4L engine.
(6) I nsert cl utch al i gnment tool through the cl utch
di sc and i nto the pi l ot beari ng (Fi g. 1).
(7) Posi ti on cl utch pressure pl ate over di sc and on
the fl ywheel (Fi g. 1).
(8) I nstal l pressure pl ate bol ts fi nger ti ght.
CAUTION: Use only the factory bolts to mount the
pressure plate. The bolts must be the correct size.
If bolts are too short, there isnt enough thread
engagement, if too long bolts interfere with the Dual
Mass Flywheel.
(9) Ti ghten pressure pl ate bol ts evenl y and i n rota-
ti on a few threads at a ti me.
CAUTION: The bolts must be tightened evenly and
to specified torque to avoid distorting the pressure
plate.
(10) Ti ghten pressure pl ate bol ts to 31 Nm (23 ft.
l bs.) on 2.4L engi nes and 50 Nm (37ft. l bs.) on 3.7L
engi nes.
(11) Appl y l i ght coat of Mopar hi gh temperature
beari ng grease or equi val ent to cl utch di sc hub and
spl i nes of transmi ssi on i nput shaft.
CAUTION: Do not over lubricate shaft splines. This
will result in grease contamination of disc.
(12) I nstal l transmi ssi on.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmi ssi on.
(2) Di sconnect rel ease beari ng from rel ease l ever
and remove the beari ng (Fi g. 2).
(3) I nspect beari ng sl i de surface of transmi ssi on
front beari ng retai ner. Repl ace retai ner i f sl i de sur-
face i s scored, worn, or cracked.
(4) I nspect rel ease fork and fork pi vot. Be sure
pi vot i s secure and i n good condi ti on. Be sure fork i s
not di storted or worn. Repl ace rel ease fork retai ner
spri ng i f bent or damaged.
INSTALLATION
(1) Lubri cate crankshaft pi l ot beari ng wi th Mopar
hi gh temperature beari ng grease or equi val ent. Appl y
grease to end of l ong shank, smal l di ameter fl at
bl ade screwdri ver. Then i nsert tool through cl utch
di sc hub to reach beari ng.
Fig. 1 ALIGNING CLUTCH DISC
1 - FLYWHEEL
2 - PRESSURE PLATE
3 - CLUTCH DISC ALIGNMENT TOOL
6 - 6 CLUTCH KJ
(2) Lubri cate i nput shaft spl i nes, beari ng retai ner
sl i de surface, fork pi vot and rel ease fork pi vot sur-
face.
(3) I nstal l new rel ease beari ng. Be sure beari ng i s
properl y secured to rel ease fork.
(4) I nstal l transmi ssi on.
FLYWHEEL
DESCRIPTION
STANDARD FLYWHEEL
The standard fl ywheel i s used on the 3.7L engi ne.
The fl ywheel (Fi g. 3) i s a heavy pl ate bol ted to the
rear of the crankshaft. The fl ywheel i ncorporates the
ri ng gear around the outer ci rcumference to mesh
wi th the starter to permi t engi ne cranki ng. The rear
face of the fl ywheel serves as the dri vi ng member to
the cl utch di sc.
DUAL MASS FLYWHEEL
The Dual Mass Fl ywheel i s used on the 2.4 l
engi ne (Fi g. 4). The fl ywheel i ncorporates the ri ng
gear around the outer ci rcumference to mesh wi th
the starter to permi t engi ne cranki ng. The pri mary
fl ywheel si de i s bol ted to the crankshaft. The second-
ary fl ywheel face serves as the dri vi ng member to the
cl utch di sc. I nternal spri ngs between the fl ywheel s
are use to dampen energy.
OPERATION
The fl ywheel serves to dampen the engi ne fi ri ng
pul ses. The heavy wei ght of the fl ywheel rel ati ve to
the rotati ng mass of the engi ne components serves to
stabi l i ze the fl ow of power to the remai nder of the
dri vetrai n. The crankshaft has the tendency to
attempt to speed up and sl ow down i n response to
the cyl i nder fi ri ng pul ses. The fl ywheel dampens
these i mpul ses by absorbi ng energy when the crank-
shaft speeds and rel easi ng the energy back i nto the
system when the crankshaft sl ows down.
Fig. 2 CLUTCH RELEASE BEARING
1 - RELEASE BEARING
2 - RELEASE FORK
Fig. 3 FLYWHEEL
1 - CRANKSHAFT
2 - RING GEAR
3 - FLYWHEEL
Fig. 4 DUAL MASS FLYWHEEL
1 - LOCATING STUD
2 - BEARING
3 - SECONDARY FLYWHEEL
4 - DAMPER SPRING
5 - RING GEAR
6 - PRIMARY FLYWHEEL
7 - FRICTION DISC
KJ CLUTCH 6 - 7
CLUTCH RELEASE BEARING (Continued)
On a Dual Mass Fl ywheel the addi ti onal secondary
mass coupl ed to the transmi ssi on l owers the natural
frequency of the transmi ssi on rotati ng el ements. Thi s
decreases the transmi ssi on gear rattl e. The damper
spri ngs between the two fl ywheel masses repl ace the
cl utch di sc damper spri ngs and assi st i n a smooth
transfer of torque to the transmi ssi on.
CAUTION: The Dual Mass Flywheel is serviced as
an assembly only and should never be taken apart.
DIAGNOSIS AND TESTING - FLYWHEEL
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
Common causes of runout are:
heat warpage
i mproper machi ni ng
i ncorrect bol t ti ghteni ng
i mproper seati ng on crankshaft fl ange shoul der
forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. Mi nor fl y-
wheel scori ng can be cl eaned up by hand wi th 180
gri t emery or wi th surface gri ndi ng equi pment.
Remove onl y enough materi al to reduce scori ng
(approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal or equi val ent.
Ti ghten fl ywheel bol ts to speci fi ed torque onl y. Over-
ti ghteni ng can di stort the fl ywheel hub causi ng
runout.
PILOT BEARING
REMOVAL
(1) Remove the transmi ssi on.
(2) Remove pressure pl ate and cl utch di sc.
(3) Remove pi l ot beari ng wi th an i nternal (bl i nd
hol e) pul l er.
INSTALLATION
(1) Lubri cate new beari ng wi th Mopar hi gh tem-
perature beari ng grease or equi val ent.
(2) Start new beari ng i nto crankshaft by hand.
Then seat beari ng wi th cl utch al i gnment tool (Fi g. 5).
(3) Li ghtl y scuff sand fl ywheel surface wi th 180
gri t emery cl oth. Then cl ean surface wi th wax and
grease remover.
(4) I nstal l cl utch di sc and pressure pl ate.
(5) I nstal l the transmi ssi on.
LINKAGE
REMOVAL
NOTE: The clutch master cylinder, slave cylinder
and connecting line are serviced as an assembly
only. The linkage components cannot be over-
hauled or serviced separately. The cylinders and
connecting line are sealed units.
(1) Rai se vehi cl e.
(2) Remove fasteners attachi ng sl ave cyl i nder to
cl utch housi ng.
(3) Remove sl ave cyl i nder from cl utch housi ng
(Fi g. 6).
(4) Di sengage cl utch fl ui d l i ne from body cl i ps, i f
appl i cabl e.
(6) Veri fy cap on cl utch master cyl i nder reservoi r
i s ti ght to avoi d spi l l i ng fl ui d duri ng removal .
(7) Remove cl utch master cyl i nder attachi ng nuts
(Fi g. 7).
(8) Di sengage captured bushi ng on cl utch master
cyl i nder actuator from pi vot pi n on pedal arm.
Fig. 5 Pilot Bearing Installer
1 - PILOT BEARING
2 - ALIGNMENT TOOL
6 - 8 CLUTCH KJ
FLYWHEEL (Continued)
(9) Sl i de actuator off pi vot pi n.
(10) Di sconnect cl utch i nterl ock safety swi tch
wi res.
(11) Remove cl utch hydraul i c l i nkage through
engi ne compartment.
INSTALLATION
NOTE: The clutch master cylinder, slave cylinder
and connecting line are serviced as an assembly
only. The linkage components cannot be over-
hauled or serviced separately. The cylinders and
connecting line are sealed units.
(1) Be sure reservoi r cover on cl utch master cyl i n-
der i s ti ght to avoi d spi l l s.
(2) Posi ti on cl utch l i nkage components i n vehi cl e.
Work connecti ng l i ne and sl ave cyl i nder downward
past engi ne and adjacent to cl utch housi ng.
(3) Posi ti on cl utch master cyl i nder on dash panel .
(4) Attach cl utch master cyl i nder actuator to pi vot
pi n on cl utch pedal .
(5) I nstal l and ti ghten cl utch master cyl i nder
attachi ng nuts to 38 Nm (28 ft. l bs.).
(7) I nsert sl ave cyl i nder push rod through cl utch
housi ng openi ng and i nto rel ease l ever. Be sure cap
on end of rod i s securel y engaged i n l ever. Check thi s
before i nstal l i ng cyl i nder attachi ng nuts.
(8) I nstal l and ti ghten sl ave cyl i nder attachi ng
nuts to 23 Nm (17 ft. l bs.).
(9) Secure cl utch fl ui d l i ne i n body and transmi s-
si on cl i ps.
(11) Connect cl utch i nterl ock safety swi tch wi res.
MASTER CYLINDER
INSPECTION
The cl utch fl ui d reservoi r, master cyl i nder, sl ave
cyl i nder and fl ui d l i nes are pre-fi l l ed wi th fl ui d at
the factory duri ng assembl y operati ons.
The hydraul i c system shoul d not requi re addi ti onal
fl ui d under normal ci rcumstances. The reservoir
fluid level will actually increase as normal
clutch wear occurs. Avoid overfilling or remov-
ing fluid from the reservoir.
Cl utch fl ui d l evel i s checked at the master cyl i nder
reservoi r. An i ndi cator ri ng i s provi ded on the outsi de
of the reservoi r. Wi th the cap and di aphragm
removed, fl ui d l evel shoul d not be above i ndi cator
ri ng.
To avoi d contami nati ng the hydraul i c fl ui d duri ng
i nspecti on, wi pe reservoi r and cover cl ean before
removi ng the cap.
Fig. 6 SLAVE CYLINDER
1 - CLUTCH SLAVE CYLINDER
Fig. 7 CLUTCH PEDAL
1 - CYLINDER
2 - ACTUATOR SHAFT
3 - ACTUATOR EYE
4 - PEDAL PIN
5 - CONNECTOR
KJ CLUTCH 6 - 9
LINKAGE (Continued)
CLUTCH PEDAL
REMOVAL
(1) Remove steeri ng col umn l ower cover and knee
bl ocker for access.
(2) Di sconnect cl utch pedal posi ti on swi tch wi res.
(3) Di sengage captured bushi ng l ock tabs attach-
i ng cl utch master cyl i nder actuator to pedal pi vot.
(4) Remove nuts attachi ng pedal and bracket to
dash panel and upper cowl support (Fi g. 8).
(5) Separate pedal assembl e from vehi cl e.
INSTALLATION
(1) Pl ace cl utch pedal and bracket over studs on
dash panel and cowl support.
(2) I nstal l nuts to attach pedal and bracket to
dash panel and upper cowl support. Ti ghten nuts to
39 Nm (29 ft. l bs.) torque
(3) Engage captured bushi ng and actuator on
brake pedal pi vot.
(4) Connect cl utch pedal posi ti on swi tch wi res.
CLUTCH SWITCH OVERRIDE
RELAY
DESCRIPTION
The cl utch pedal posi ti on swi tch overri de rel ay i s
l ocated i n the Power Di stri buti on Center (PDC).
Refer to PDC cover l abel for l ocati on wi thi n PDC.
OPERATION
Refer to Cl utch Pedal Posi ti on Swi tch Operati on
for i nformati on.
REMOVAL
The Cl utch Swi tch Overri de Rel ay i s l ocated i n the
Power Di stri buti on Center (PDC) (Fi g. 9). Refer to
l abel on PDC cover for rel ay l ocati on.
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
The Cl utch Swi tch Overri de Rel ay i s l ocated i n the
Power Di stri buti on Center (PDC). Refer to l abel on
PDC cover for rel ay l ocati on.
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
Fig. 8 CLUTCH PEDAL
1 - CYLINDER
2 - ACTUATOR SHAFT
3 - ACTUATOR EYE
4 - PEDAL PIN
5 - CONNECTOR
Fig. 9 POWER DISTRIBUTION CENTER (PDC)
1 - BATTERY
2 - PDC
3 - PDC COVER
6 - 10 CLUTCH KJ
CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
The cl utch pedal posi ti on swi tch i s l ocated under
the i nstrument panel . I t i s attached to the cl utch
master cyl i nder push rod (Fi g. 10). The wi ri ng har-
ness connecti on for the swi tch i s made i n the engi ne
compartment (Fi g. 10).
The cl utch pedal posi ti on swi tch overri de rel ay i s
l ocated i n the Power Di stri buti on Center (PDC).
Refer to PDC cover l abel for l ocati on wi thi n PDC.
OPERATION
The cl utch pedal posi ti on swi tch i s used to prevent
starter motor engagement unl ess the cl utch pedal i s
depressed.
4WD Feature: The cl utch pedal posi ti on swi tch
overri de rel ay wi l l i nhi bi t operati on of the posi ti on
swi tch when the vehi cl e transfer case i s i n the four
wheel dri ve (4WD) l ow-range posi ti on (onl y). Thi s
feature wi l l al l ow operati on of the starter motor,
wi thout the need for depressi ng the cl utch pedal , for
certai n off-road appl i cati ons. I f any Di agnosti c Trou-
bl e Codes (DTCs) for ei ther the overri de rel ay or
transfer case swi tch are stored, the overri de rel ay
feature wi l l be i nhi bi ted.
An i nput from thi s swi tch i s al so used to ei ther
shut down and/or prevent operati on of the speed con-
trol system when the cl utch pedal i s depressed.
DIAGNOSIS AND TESTING - CLUTCH PEDAL
POSITION SWITCH
(1) Locate swi tch 2wi re el ectri cal connector i n
engi ne compartment (Fi g. 10). Di sconnect wi ri ng at
thi s poi nt.
(2) Check for swi tch conti nui ty wi th an ohmmeter
whi l e operati ng cl utch pedal up and down. Conti nu-
i ty shoul d be broken and reappl i ed each ti me pedal i s
pressed.
(3) I f conti nui ty i s not present, or i s al ways
present at any pedal posi ti on, repl ace swi tch. Swi tch
i s not servi ced separatel y. Repl ace cl utch master
cyl i nder.
Fig. 10 CLUTCH PEDAL POSITION SWITCH
1 - CLUTCH MASTER CYLINDER
2 - CLUTCH PEDAL POSITION SWITCH
3 - CLUTCH PEDAL PIN
4 - MASTER CYLINDER PUSHROD
5 - ELECTRICAL CONNECTION (IN ENGINE COMPARTMENT)
KJ CLUTCH 6 - 11
COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 3.7L
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - COOLING SYSTEM
ROUTING 3.7L ENGINE. . . . . . . . . . . . . . . . . . 2
DESCRIPTION - HOSE CLAMPS . . . . . . . . . . . 2
OPERATION
OPERATION - COOLING SYSTEM . . . . . . . . . 2
OPERATION - HOSE CLAMPS . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTICS (OBD) . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAKS . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - COOLING
SYSTEM DIAGNOSIS CHART . . . . . . . . . . . . . 6
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING
COOLING SYSTEM 3.7L ENGINE . . . . . . . . . 12
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 3.7L ENGINE . . . . . . . . . 12
STANDARD PROCEDURE - COOLING
SYSTEM - REVERSE FLUSHING. . . . . . . . . . 12
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 32
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM 3. 7L
ENGINE
The cool i ng system consi sts of the fol l owi ng i tems:
El ectri c cool i ng fan - Standard.
El ectri c cool i ng fan and mechani cal thermal vi s-
cous fan wi th l ow di sengaged - Heavy duty cool i ng
onl y
Radi ator
Hot bottl e pressure cap
Thermostat
Cool ant reserve/overfl ow system
Radi ator i n-tank transmi ssi on oi l cool er (i f
equi pped wi th an automati c transmi ssi on)
Cool ant
Water pump
Hoses and hose cl amps
KJ COOLING 7 - 1
DESCRIPTION - COOLING SYSTEM ROUTING
3. 7L ENGINE
For cool i ng system routi ng refer to (Fi g. 1).
DESCRIPTION - HOSE CLAMPS
The cool i ng system uti l i zes spri ng type hose
cl amps. I f a spri ng type cl amp repl acement i s neces-
sary, repl ace wi th the ori gi nal Mopar equi pment
spri ng type cl amp.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 2). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 2).
OPERATION
OPERATION - COOLING SYSTEM
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e. I t al so
mai ntai ns normal operati ng temperature and pre-
vents overheati ng.
Fig. 1 Engine Cooling System 3.7L Engine
1 - LH CYL. HEAD
2 - AIR BLEED
3 - THERMOSTAT LOCATION
4 - RH CYL. HEAD
5 - RH BANK CYL. BLOCK
6 - LH BANK CYL. BLOCK
7 - COOLANT TEMP. SENSOR
7 - 2 COOLING KJ
COOLING (Continued)
The cool i ng system al so provi des a means of heat-
i ng the passenger compartment and cool i ng the auto-
mati c transmi ssi on fl ui d (i f equi pped). The cool i ng
system i s pressuri zed and uses a centri fugal water
pump to ci rcul ate cool ant throughout the system.
OPERATION - HOSE CLAMPS
The spri ng type hose cl amp appl i es constant ten-
si on on a hose connecti on. To remove a spri ng type
hose cl amp, onl y use constant tensi on cl amp pl i ers
desi gned to compress the hose cl amp.
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The powertrai n control modul e (PCM) has been
programmed to moni tor certai n cool i ng system com-
ponents:
I f the engi ne has remai ned cool for too l ong a
peri od, such as wi th a stuck open thermostat, a Di ag-
nosti c Troubl e Code (DTC) can be set.
I f an open or shorted condi ti on has devel oped i n
the rel ay ci rcui t control l i ng the el ectri c radi ator fan,
a Di agnosti c Troubl e Code (DTC) can be set.
I f the probl em i s sensed i n a moni tored ci rcui t
often enough to i ndi cated an actual probl em, a DTC
i s stored. The DTC wi l l be stored i n the PCM mem-
ory for eventual di spl ay to the servi ce techni ci an.
(Refer to 25 - EMI SSI ONS CONTROL - DESCRI P-
TI ON).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTCs and to obtai n cool i ng system data,
(Refer to 25 - EMI SSI ONS CONTROL - DESCRI P-
TI ON).
ERASING TROUBLE CODES
After the probl em has been repai red, use the DRB
scan tool to erase a DTC. Refer to the appropri ate
Powertrai n Di agnosti c Procedures servi ce i nforma-
ti on for operati on of the DRB scan tool .
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause:
PROLONGED I DLE
VERY HI GH AMBI ENT TEMPERATURE
SLI GHT TAI L WI ND AT I DLE
SLOW TRAFFI C
TRAFFI C JAMS
HI GH SPEED
STEEP GRADES
Dri vi ng techni ques that avoi d overheati ng are:
I dl e wi th A/C off when temperature gauge i s at
end of normal range.
(1) TRAI LER TOWI NG:
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
(2) RECENT SERVI CE OR ACCI DENT REPAI R:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect cool i ng system.
Thi s may be:
Engi ne adjustments (i ncorrect ti mi ng)
Sl i ppi ng engi ne accessory dri ve bel t(s)
Brakes (possi bl y draggi ng)
Changed parts. I ncorrect water pump, or pump
rotati ng i n wrong di recti on due to bel t not correctl y
routed
Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under fi l l ed or ai r trapped i n system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a qui ck-reference
onl y. Refer to the group text for i nformati on.
Fig. 2 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
KJ COOLING 7 - 3
COOLING (Continued)
DIAGNOSIS AND TESTING - COOLING SYSTEM
LEAKS
ULTRAVIOLET LIGHT METHOD
A l eak detecti on addi ti ve i s avai l abl e through the
parts department that can be added to cool i ng sys-
tem. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). Pour one ounce of addi ti ve i nto
cool i ng system. Pl ace heater control uni t i n HEAT
posi ti on. Start and operate engi ne unti l radi ator
upper hose i s warm to touch. Ai m the commerci al l y
avai l abl e bl ack l i ght tool at components to be
checked. I f l eaks are present, bl ack l i ght wi l l cause
addi ti ve to gl ow a bri ght green col or.
The bl ack l i ght can be used i n conjuncti on wi th a
pressure tester to determi ne i f any external l eaks
exi st (Fi g. 3).
PRESSURE TESTER METHOD
The engi ne shoul d be at normal operati ng temper-
ature. Recheck the system col d i f cause of cool ant
l oss i s not l ocated duri ng the warm engi ne exami na-
ti on.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Careful l y remove radi ator pressure cap from pres-
sure bottl e and check cool ant l evel . Push down on
cap to di sengage i t from stop tabs. Wi pe i nsi de of
fi l l er neck and exami ne l ower i nsi de seal i ng seat for
ni cks, cracks, pai nt, and di rt. I nspect radi ator-to-
reserve/overfl ow tank hose for i nternal obstructi ons.
I nsert a wi re through the hose to be sure i t i s not
obstructed.
I nspect cams on outsi de of fi l l er neck. I f cams are
damaged, seati ng of pressure cap val ve and tester
seal wi l l be affected.
Attach pressure tester (7700 or an equi val ent) to
radi ator fi l l er neck (Fi g. 4).
Operate tester pump to appl y 110 kPa (16 psi )
pressure to system. I f hoses enl arge excessi vel y or
bul ges whi l e testi ng, repl ace as necessary. Observe
gauge poi nter and determi ne condi ti on of cool i ng sys-
tem accordi ng to fol l owi ng cri teri a:
Holds Steady: I f poi nter remai ns steady for two
mi nutes, seri ous cool ant l eaks are not present i n sys-
tem. However, there coul d be an i nternal l eak that
does not appear wi th normal system test pressure. I f
i t i s certai n that cool ant i s bei ng l ost and l eaks can-
not be detected, i nspect for i nteri or l eakage or per-
form I nternal Leakage Test.
Drops Slowly: I ndi cates a smal l l eak or seepage
i s occurri ng. Exami ne al l connecti ons for seepage or
sl i ght l eakage wi th a fl ashl i ght. I nspect radi ator,
hoses, gasket edges and heater. Seal smal l l eak hol es
wi th a Seal er Lubri cant (or equi val ent). Repai r l eak
hol es and i nspect system agai n wi th pressure
appl i ed.
Drops Quickly: I ndi cates that seri ous l eakage i s
occurri ng. Exami ne system for external l eakage. I f
l eaks are not vi si bl e, i nspect for i nternal l eakage.
Large radi ator l eak hol es shoul d be repai red by a
reputabl e radi ator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove engi ne oi l pan drai n pl ug and drai n a
smal l amount of engi ne oi l . I f cool ant i s present i n
Fig. 3 Leak Detection Using Black Light - Typical
1 - TYPICAL BLACK LIGHT TOOL
Fig. 4 Pressure Testing Cooling System - Typical
1 - TYPICAL COOLING SYSTEM PRESSURE TESTER
7 - 4 COOLING KJ
COOLING (Continued)
the pan, i t wi l l drai n fi rst because i t i s heavi er than
oi l . An al ternati ve method i s to operate engi ne for a
short peri od to churn the oi l . After thi s i s done,
remove engi ne di psti ck and i nspect for water gl ob-
ul es. Al so i nspect transmi ssi on di psti ck for water
gl obul es and transmi ssi on fl ui d cool er for l eakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 124 KPA (18 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engi ne wi thout pressure cap on radi ator
unti l thermostat opens. Attach a Pressure Tester to
fi l l er neck. I f pressure bui l ds up qui ckl y i t i ndi cates a
combusti on l eak exi sts. Thi s i s usual l y the resul t of a
cyl i nder head gasket l eak or crack i n engi ne. Repai r
as necessary.
I f there i s not an i mmedi ate pressure i ncrease,
pump the Pressure Tester. Do thi s unti l i ndi cated
pressure i s wi thi n system range of 110 kPa (16 psi ).
Fl uctuati on of gauge poi nter i ndi cates compressi on or
combusti on l eakage i nto cool i ng system.
Because the vehi cl e i s equi pped wi th a catal yti c
converter, do not remove spark pl ug cabl es or short
out cyl i nders to i sol ate compressi on l eak.
I f the needl e on di al of pressure tester does not
fl uctuate, race engi ne a few ti mes to check for an
abnormal amount of cool ant or steam. Thi s woul d be
emi tti ng from exhaust pi pe. Cool ant or steam from
exhaust pi pe may i ndi cate a faul ty cyl i nder head gas-
ket, cracked engi ne cyl i nder bl ock or cyl i nder head.
A conveni ent check for exhaust gas l eakage i nto
cool i ng system i s provi ded by a commerci al l y avai l -
abl e Bl ock Leak Check tool . Fol l ow manufacturers
i nstructi ons when usi ng thi s product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drai n suffi ci ent cool ant to al l ow thermostat
removal . (Refer to 7 - COOLI NG/ENGI NE/ENGI NE
COOLANT THERMOSTAT - REMOVAL). Remove
accessory dri ve bel t (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/DRI VE BELTS - REMOVAL).
Add cool ant to radi ator to bri ng l evel to wi thi n 6.3
mm (1/4 i n) of top of thermostat housi ng.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engi ne and accel erate rapi dl y three ti mes, to
approxi matel y 3000 rpm whi l e observi ng cool ant. I f
i nternal engi ne combusti on gases are l eaki ng i nto
cool i ng system, bubbl es wi l l appear i n cool ant. I f bub-
bl es do not appear, i nternal combusti on gas l eakage
i s not present.
KJ COOLING 7 - 5
COOLING (Continued)
DIAGNOSIS AND TESTING - COOLING SYSTEM DIAGNOSIS CHART
COOLING SYSTEM DIAGNOSIS CHART
TEMPERATURE GAUGE READS
LOW
1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open thermostat?
1. Refer to (Refer to 25 -
EMISSIONS CONTROL -
DESCRIPTION) for On-Board
Diagnostics and DTC information.
Replace thermostat if necessary.
2. Is the temperature sending unit
connected?
2. Check the temperature sensor
connector. (Refer to 7 - COOLING/
ENGINE/ENGINE COOLANT TEMP
SENSOR - DESCRIPTION). Repair
connector if necessary.
3. Is the temperature gauge
operating OK?
3. Check gauge operation. Repair
as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.
4. Check coolant level in the coolant
pressure botttle and the radiator.
Inspect system for leaks. Repair
leaks as necessary.
5. Improper operation of internal
heater doors or heater controls.
5. Inspect heater and repair as
necessary. (Refer to 24 - HEATING
& AIR CONDITIONING -
DIAGNOSIS AND TESTING)
6. Electric fan functioning when not
required.
6. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section. Refer to group
8W for electric cooling fan and relay
circuit schematic data.
1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic, or
engine is being idled with very high
ambient (outside) temperatures and
the air conditioning is on. Higher
altitudes could aggravate these
conditions.
1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause for overheating
and repair.
2. Is the temperature gauge reading
correctly?
2. Check gauge. (Refer to Group 8J
- INSTRUMENT CLUSTER). Repair
as necessary.
3. Is the temperature warning
illuminating unnecessarily?
3. Check warning lamp operation.
(Refer to Group 8J - INSTRUMENT
CLUSTER).Repair as necessary.
4. Coolant low in coolant pressure
bottle and radiator?
4. Check for coolant leaks and
repair as necessary. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
7 - 6 COOLING KJ
COOLING (Continued)
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following Step 6.
5. Tighten cap
6. Poor seals at the radiator cap. 6. (a) Check condition of cap and
cap seals. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING).
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
7. Coolant not flowing through
system.
7. (a) Check condition of pressure
bottle cap and cap seals. (Refer to
7 - COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING).
(b) Check condition of radiator vent
nipple. If neck is damaged, replace
radiator.
(c) Check condition of the hose from
the radiator to the coolant tank. It
should fit tight at both ends without
any kinks or tears. Replace hose if
necessary.
(d) Check pressure bottle/overflow
tank and tanks hoses for blockage.
Repair as necessary.
8. Incorrect coolant concentration 8. Check coolant. (Refer to 7 -
COOLING/ENGINE/COOLANT -
DESCRIPTION) for correct
coolant/water mixture ratio.
9. Fan installed backwards on
viscous drive.
9. Mount fan on drive correctly.
10. Radiator or A/C condenser fins
are dirty or clogged.
10. Remove insects and debris.
(Refer to 7 - COOLING/ENGINE/
RADIATOR - CLEANING).
11. Radiator core is corroded or
plugged.
11. Have radiator re-cored or
replaced.
12. Fuel or ignition system
problems.
12. Refer to FUEL and /or
IGNITION CONTROL for diagnosis.
13. Dragging brakes. 13. Check and correct as
necessary. (Refer to 5 - BRAKES -
DIAGNOSIS AND TESTING) for
correct procedures.
14. Bug screen or cardboard is
being used, reducing airflow.
14. Remove bug screen or
cardboard.
KJ COOLING 7 - 7
COOLING (Continued)
15. Thermostat partially or
completely shut.
15. Check thermostat operation and
replaces necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT -
DIAGNOSIS AND TESTING).
16. Viscous fan drive not operating
properly.
16. Check fan drive operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING).
17. Cylinder head gasket leaking. 17. Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING). For
repair, (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
18. Heater core leaking. 18. Check heater core for leaks.
(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/
HEATER CORE - REMOVAL).
Repair as necessary.
19. Electric fan not functioning. 19. Inspect electric fan for proper
operation. Refer to Electric Cooling
Fan in this section. Refer to Group
8W for electric cooling fan and relay
circuit schematic data.
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)
1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.
1. A normal condition. No correction
is necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.
2. Check operation of gauge and
repair if necessary. Refer to Group
8J, Instrument cluster.
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)
is necessary. Gauge should return
to normal range after vehicle is
driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in cooling
system (air will build up in the
cooling system causing the
thermostat to open late).
5. Check and correct coolant leaks.
(Refer to 7 - COOLING -
7 - 8 COOLING KJ
COOLING (Continued)
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.
6. (a) Check for cylinder head
gasket leaks. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.
7. Check water pump and replace
as necessary. (Refer to 7 -
COOLING/ENGINE/WATER PUMP -
8. Loose accessory drive belt.
(water pump slipping)
8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- DIAGNOSIS AND TESTING).
Check and correct as necessary.
9. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.
9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK
1. Pressure relief valve in pressure
bottle cap is defective.
1. Check condition of radiator cap
and cap seals. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as
necessary.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE READING
HIGH OR HOT
1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.
1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH
1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.
2. Check coolant concentration.
COOLANT - DESCRIPTION) and
adjust ratio as required.
KJ COOLING 7 - 9
COOLING (Continued)
HOSE OR HOSES COLLAPSE
WHILE ENGINE IS RUNNING
1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
reserve/overflow system.
1. (a) Radiator cap relief valve
stuck. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING).
Replace if necessary
(b) Hose between coolant
reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and
repair as necessary.
(d) Reserve/overflow tank is
internally blocked or plugged. Check
for blockage and repair as
necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose - 4.0L. 1. Replace fan blade assembly.
RADIATOR FAN - REMOVAL)
2. Fan blades striking a surrounding
object.
2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or air
conditioning condenser.
3. Remove obstructions and/or
clean debris or insects from radiator
or A/C condenser.
4. Thermal viscous fan drive has
defective bearing - 4.0L
4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN -
REMOVAL).
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION
1. Has a Diagnostic trouble Code
(DTC) been set?
1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
correct procedures and replace
thermostat if necessary
2. Coolant level low 2. (Refer to 7 - COOLING -
3. Obstructions in heater hose/
fittings
3. Remove heater hoses at both
ends and check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping
water to/through the heater core.
When the engine is fully warmed
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 or the
heater core may be plugged.
Accessory drive belt may be
slipping causing poor water pump
operation.
5. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - DIAGNOSIS AND
TESTING). If a slipping belt is
detected, (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- REMOVAL). If heater core
obstruction is detected, (Refer to 7 -
COOLING - STANDARD
PROCEDURE) for cooling system
reverse flushing.
7 - 10 COOLING KJ
COOLING (Continued)
STEAM IS COMING FROM THE
FRONT OF VEHICLE NEAR THE
GRILL AREA WHEN WEATHER IS
WET, ENGINE IS WARMED UP
AND RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE
GAUGE IS IN NORMAL RANGE
1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the
radiator. When the moisture
contacts the hot radiator or
condensor, steam may be emitted.
This usually occurs in cold weather
with no fan or airflow to blow it
away.
1. Occasional steam emitting from
this area is normal. No repair is
necessary.
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.
1. (Refer to 7 - COOLING/ENGINE/
COOLANT - DESCRIPTION) for
coolant concentration information.
Adjust coolant mixture as
necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/OVERFLOW
TANK. TEMPERATURE GAUGE IS
IN NORMAL RANGE
1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
If the level in the tank was between
the FULL and ADD marks at normal
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.
1. A normal condition. No repair is
necessary.
FAN RUNS ALL THE TIME 1. Fan control sensors inoperative. 1. Check for DTCs. Verify sensor
readings.
2. Fan control solenoid stuck on. 2. Check fan operation speeds.
Refer to fan speed operation table.
3. Fan control solenoid harness
damaged.
3. Check for DTC 1499. Repair as
required.
4. Transmission temperature too
high.
4. Check for transmission over
temp. DTC.
5. Engine coolant temperature too
high.
5. (a) Check coolant level. Correct
level as required.
(b) Thermostat stuck. Replace
thermostat.
(c) Water pump failed. Replace
water pump.
(d) Coolant flow restricted. Clean
radiator.
(e) Air flow over radiator
obstructed.Remove obstruction.
KJ COOLING 7 - 11
COOLING (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURE - DRAINING COOLING
SYSTEM 3. 7L ENGINE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS (Fig. 5) OR LOOSEN THE
RADIATOR DRAINCOCK WITH SYSTEM HOT AND
UNDER PRESSURE. SERIOUS BURNS FROM
COOLANT CAN OCCUR.
(1) DO NOT remove radi ator cap fi rst. Wi th engi ne
col d, rai se vehi cl e on a hoi st and l ocate radi ator
drai ncock.
NOTE: Radiator draincock is located on the left/
lower side of radiator facing to rear of vehicle.
(2) Attach one end of a hose to the drai ncock. Put
the other end i nto a cl ean contai ner. Open drai ncock
and drai n cool ant from radi ator. Thi s wi l l empty the
cool ant reserve/overfl ow tank. The cool ant does not
have to be removed from the tank unl ess the system
i s bei ng refi l l ed wi th a fresh mi xture. When tank i s
empty, remove radi ator cap and conti nue drai ni ng
cool i ng system.
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 3. 7L ENGINE
(1) Ti ghten the radi ator drai ncock and the cyl i nder
bl ock drai n pl ug(s) (i f removed).
CAUTION: Failure to purge air from the cooling sys-
tem can result in an overheating condition and
severe engine damage.
(2) .Fi l l system usi ng a 50/50 mi xture of ethyl ene-
gl ycol anti freeze and l ow mi neral content water.Fi l l
pressure bottl e to servi ce l i ne.and i nstal l cap.
NOTE: The engine cooling system will push any
remaining air into the coolant bottle within about an
hour of normal driving. As a result, a drop in cool-
ant level in the pressure bottle may occur. If the
engine cooling system overheats and pushes cool-
ant into the overflow side of the coolant bottle, this
coolant will be sucked back into the cooling system
ONLY IF THE PRESSURE CAP IS LEFT ON THE
BOTTLE. Removing the pressure cap breaks the
vacuum path between the two bottle sections and
the coolant will not return to cooling system.
(3) Wi th heater control uni t i n the HEAT posi ti on,
operate engi ne wi th pressure bottl e cap i n pl ace.
(4) Add cool ant to pressure bottl e as necessary.
Only add coolant to the pressure bottle when
the engine is cold. Coolant level in a warm
engine will be higher due to thermal expansion.
NOTE: The coolant bottle has two chambers. Cool-
ant will normally only be in the outboard (larger) of
the two. The inboard chamber is only to recover
coolant in the event of an overheat or after a recent
service fill. The inboard chamber should normally
be empty. If there is coolant in the overflow side of
the coolant bottle (after several warm/cold cycles of
the engine) and coolant level is above cold full
when cold, disconnect the end of the overflow hose
at the fill neck and lower it into a clean container.
Allow coolant to drain into the container until emp-
tied. Reconnect overflow hose to fill neck.
STANDARD PROCEDURE - COOLING SYSTEM -
REVERSE FLUSHING
CAUTION: The cooling system normally operates at
97-to-110 kPa (14-to -16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system. Thi s i s done
usi ng ai r pressure i n the opposi te di recti on of normal
cool ant fl ow. I t i s usual l y onl y necessary wi th very
di rty systems wi th evi dence of parti al pl uggi ng.
CHEMICAL CLEANING
I f vi sual i nspecti on i ndi cates the formati on of
sl udge or scal y deposi ts, use a radi ator cl eaner
Fig. 5 Drain Plug - 3.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
7 - 12 COOLING KJ
COOLING (Continued)
(Mopar Radi ator Kl een or equi val ent) before fl ushi ng.
Thi s wi l l soften scal e and other deposi ts and ai d the
fl ushi ng operati on.
CAUTION: Be sure instructions on the container are
followed.
REVERSE FLUSHING RADIATOR
Di sconnect the radi ator hoses from the radi ator fi t-
ti ngs. Attach a secti on of radi ator hose to the radi a-
tor bottom outl et fi tti ng and i nsert the fl ushi ng gun.
Connect a water suppl y hose and ai r suppl y hose to
the fl ushi ng gun.
CAUTION: The cooling system normally operates at
97-to-110 kPa (14- to-16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Al l ow the radi ator to fi l l wi th water. When radi ator
i s fi l l ed, appl y ai r i n short bl asts al l owi ng radi ator to
refi l l between bl asts. Conti nue thi s reverse fl ushi ng
unti l cl ean water fl ows out through rear of radi ator
cool i ng tube passages. For more i nformati on, refer to
operati ng i nstructi ons suppl i ed wi th fl ushi ng equi p-
ment. Have radi ator cl eaned more extensi vel y by a
radi ator repai r shop.
REVERSE FLUSHING ENGINE
Drai n the cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE). Remove the thermostat
housi ng and thermostat. I nstal l the thermostat hous-
i ng. Di sconnect the radi ator upper hose from the
radi ator and attach the fl ushi ng gun to the hose. Di s-
connect the radi ator l ower hose from the water
pump. Attach a l ead away hose to the water pump
i nl et fi tti ng.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water suppl y hose and ai r suppl y hose
to the fl ushi ng gun. Al l ow the engi ne to fi l l wi th
water. When the engi ne i s fi l l ed, appl y ai r i n short
bl asts, al l owi ng the system to fi l l between ai r bl asts.
Conti nue unti l cl ean water fl ows through the l ead
away hose. For more i nformati on, refer to operati ng
i nstructi ons suppl i ed wi th fl ushi ng equi pment.
Remove the l ead away hose, fl ushi ng gun, water
suppl y hose and ai r suppl y hose. Remove the thermo-
stat housi ng (Refer to 7 - COOLI NG/ENGI NE/EN-
GI NE COOLANT THERMOSTAT - REMOVAL).
I nstal l the thermostat and housi ng wi th a repl ace-
ment gasket (Refer to 7 - COOLI NG/ENGI NE/EN-
GI NE COOLANT THERMOSTAT -
I NSTALLATI ON). Connect the radi ator hoses. Refi l l
the cool i ng system wi th the correct anti freeze/water
mi xture (Refer to 7 - COOLI NG - STANDARD PRO-
CEDURE).
SPECIFICATIONS
TORQUE
DESCRIPTION Nm Ft. In.
Lbs. Lbs.
Automatic Belt Tensioner to
Mounting
BracketBolt
2.4L - -
4.7L 41 30
Automatic Belt Tensioner
Pulley
Bolt
(3.7L) 61 45
Block HeaterBolt
2.4L - -
3.7L 2 17
Condenser to Radiator Bolts 8 70
Coolant Overflow Bottle to
Plenum mounting bolts - 2.4L
only
8.5 75
Coolant Pressure Bottle to
Plenum mounting bolts -3.7L
only
8.5 75
Electric Fan to Fan Shroud
bolts
5.5 50
Fan Blade Assy. to Viscous
Drive
Bolts 3.7L 23 210
Fan Shroud to Radiator
Mounting Bolts
8 70
Radiator Upper Isolator to
Crossmember - Bolts 9.5 85
Thermostat HousingBolts
2.4L - -
4.7L 13 115
Water PumpBolts
2.4L
4.7L 54 40
KJ COOLING 7 - 13
COOLING (Continued)
SPECIAL TOOLS
COOLING
Pliers 6094
Adapter Pins 8346
Spanner Wrench 6958 with 8346 adapter pins
Pressure Tester 7700A
Coolant Refractometer 8286
7 - 14 COOLING KJ
COOLING (Continued)
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE
DIAGNOSIS AND TESTING - SERPENTINE
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . 15
BELT TENSIONERS
REMOVAL - 3.7L ENGINE . . . . . . . . . . . . . . . . . 17
INSTALLATION - 3.7L ENGINE . . . . . . . . . . . . . 17
DRIVE BELTS - 3.7L
REMOVAL - 3.7L ENGINE . . . . . . . . . . . . . . . . . 17
ACCESSORY DRIVE
DIAGNOSIS AND TESTING - SERPENTINE
DRIVE BELT
When di agnosi ng serpenti ne dri ve bel ts, smal l
cracks that run across ri bbed surface of bel t from ri b
to ri b (Fi g. 1), are consi dered normal . These are not a
reason to repl ace bel t. However, cracks runni ng al ong
a ri b (not across) are not normal . Any bel t wi th
cracks runni ng al ong a ri b must be repl aced (Fi g. 1).
Al so repl ace bel t i f i t has excessi ve wear, frayed cords
or severe gl azi ng.
Refer to SERPENTI NE DRI VE BELT DI AGNOSI S
CHART for further bel t di agnosi s.
Fig. 1 Serpentine Accessory Drive Belt Wear
Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
KJ ACCESSORY DRIVE 7 - 15
SERPENTINE DRIVE BELT DIAGNOSIS CHART
RIB CHUNKING (ONE OR MORE
RIBS HAS SEPARATED FROM
BELT BODY)
1. Foreign objects imbedded in pulley
grooves.
1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage. 2. Replace belt.
RIB OR BELT WEAR 1. Pulley(s) misaligned. 1. Align pulley(s).
2. Abrasive environment. 2. Clean pulley(s). Replace belt if
necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley groove tips. 4. Replace pulley.
5. Rubber deteriorated. 5. Replace belt.
LONGITUDINAL BELT
CRACKING (CRACKS BETWEEN
TWO RIBS)
1. Belt has mistracked from pulley
groove.
1. Replace belt.
2. Pulley groove tip has worn away
rubber to tensile member.
2. Replace belt.
BELT SLIPS 1. Belt slipping because of insufficient
tension.
1. Replace automatic belt tensioner.
2. Belt routed 2. Verify belt routing.
incorrectly
3. Incorrect belt. 3. Replace belt.
4. Belt or pulley subjected to
substance (belt dressing, oil ethylene
glycol) that has reduced friction.
4. Replace belt and clean pulleys.
5. Driven component bearing failure. 5. Replace faulty component
bearing.
6. Belt glazed and hardened from
heat and excessive slippage.
6. Replace belt.
GROOVE JUMPING (BELT
DOES NOT MAINTAIN CORRECT
POSITION ON PULLEY)
1. Belt tension either too high or too
low.
1. Replace automatic belt tensioner.
2. Belt routed 2. Verify belt routing.
incorrectly.
4. Pulley(s) not within design
tolerance.
4. Replace pulley(s).
5. Foreign object(s) in grooves. 5. Remove foreign objects from
grooves.
6. Pulley misalignment. 6. Check and replace.
7. Belt cord line is broken. 7. Replace belt.
7 - 16 ACCESSORY DRIVE KJ
ACCESSORY DRIVE (Continued)
BELT BROKEN (NOTE: IDENTIFY
AND CORRECT PROBLEM
BEFORE NEW BELT IS
INSTALLED)
1. Excessive tension. 1. Replace belt and automatic belt
tensioner.
3. Tensile member damaged during
belt installation.
3. Replace belt.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing failure. 5. Replace defective component
and belt.
NOISE (OBJECTIONABLE
SQUEAL, SQUEAK, OR RUMBLE
IS HEARD OR FELT WHILE
DRIVE BELT IS IN OPERATION)
1. Belt slippage. 1. Replace belt or automatic belt
tensioner.
2. Bearing noise. 2. Locate and repair.
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.
BELT TENSIONERS
REMOVAL - 3. 7L ENGINE
(1) Remove accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(2) Remove tensi oner assembl y from engi ne front
cover (Fi g. 2).
WARNING: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC
TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY
(EXCEPT FOR PULLEY ON TENSIONER).
(3) Remove pul l ey bol t. Remove pul l ey from ten-
si oner.
INSTALLATION - 3. 7L ENGINE
(1) I nstal l pul l ey and pul l ey bol t to tensi oner.
Ti ghten bol t to 61 Nm (45 ft. l bs.) torque.
(2) An i ndexi ng sl ot i s l ocated on back of tensi oner.
Al i gn thi s sl ot to the head of the bol t on the front
cover. I nstal l the mounti ng bol t. Ti ghten bol t to 41
Nm (30 ft. l bs.).
(3) I nstal l dri ve bel t (Refer to 7 - COOLI NG/AC-
CESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
(4) Check bel t i ndexi ng marks (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - I NSTAL-
LATI ON).
DRIVE BELTS - 3.7L
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Fig. 2 Automatic Belt Tensioner
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 Nm (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
KJ ACCESSORY DRIVE 7 - 17
ACCESSORY DRIVE (Continued)
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAM-
AGE MAY OCCUR TO THE TENSIONER.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c ( spri ng l oad ) bel t ten-
si oner.
(1) Di sconnect negati ve battery cabl e from battery.
(2) Rotate bel t tensi oner unti l i t contacts i ts stop.
Remove bel t, then sl owl y rotate the tensi oner i nto
the freearm posi ti on. (Fi g. 3).
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c ( spri ng l oad ) bel t ten-
si oner.
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 3).
(2) I nstal l new bel t (Fi g. 3). Route the bel t around
al l pul l eys except the i dl er pul l ey. Rotate the ten-
si oner arm unti l i t contacts i ts stop posi ti on. Route
the bel t around the i dl er and sl owl y l et the tensi oner
rotate i nto the bel t. Make sure the bel t i s seated onto
al l pul l eys.
(3) Wi th the dri ve bel t i nstal l ed, i nspect the bel t
wear i ndi cator (Fi g. 4). On 3.7L Engi nes the gap
between the tang and the housi ng stop ( measure-
ment A ) must not exceed 24 mm (.94 i nches).
Fig. 3 Belt Routing - 3.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
Fig. 4 Accessory Drive Belt Wear Indicator
1 - AUTOMATIC TENSIONER ASSEMBLY
7 - 18 ACCESSORY DRIVE KJ
DRIVE BELTS - 3.7L (Continued)
ENGINE
TABLE OF CONTENTS
page page
COOLANT RECOVERY PRESS CONTAINER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE COOLANT TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
ENGINE COOLANT THERMOSTAT
DESCRIPTION - 3.7L ENGINE . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING - THERMOSTAT . . . 21
REMOVAL - 3.7L ENGINE . . . . . . . . . . . . . . . . . 21
RADIATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
RADIATOR PRESSURE CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . 25
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RADIATOR FAN - ELECTRIC
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
RADIATOR - FAN - VISCOUS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - VISCOUS FAN
DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
WATER PUMP
DESCRIPTION
DESCRIPTION - WATER PUMP . . . . . . . . . . . 29
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION - WATER PUMP . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
CONTAINER
DESCRIPTION
Thi s system works al ong wi th the radi ator pres-
sure cap. Thi s i s done by usi ng thermal expansi on
and contracti on of the cool ant to keep the cool ant
free of trapped ai r. I t provi des:
A vol ume for cool ant expansi on and contracti on.
A conveni ent and safe method for checki ng/ad-
justi ng cool ant l evel at atmospheri c pressure. Thi s i s
done wi thout removi ng the radi ator pressure cap.
Some reserve cool ant to the radi ator to cover
mi nor l eaks and evaporati on or boi l i ng l osses.
As the engi ne cool s, a vacuum i s formed i n the
cool i ng system of both the radi ator and engi ne. Cool -
ant wi l l then be drawn from the cool ant tank and
returned to a proper l evel i n the radi ator.
The cool ant reservoi r/overfl ow system has a radi a-
tor mounted pressuri zed cap, an overfl ow tube, and a
pl asti c cool ant reservoi r/overfl ow tank, mounted to
the ri ght si de of the cowl . I t i s mounted to the cowl
wi th two nuts on top, and a sl i de bracket on the bot-
tom.
OPERATION
The pressure chamber keeps the cool ant free of
trapped ai r, provi des a vol ume for expansi on and con-
tracti on, and provi des a conveni ent and safe method
for checki ng and adjusti ng cool ant l evel at atmo-
spheri c pressure. I t al so provi des some reserve cool -
ant to cover mi nor l eaks, evaporati on or boi l i ng
l osses. The overfl ow chamber al l ows cool ant recovery
i n case of an overheat.
ENGINE COOLANT
TEMPERATURE SENSOR
DESCRIPTION
The Engi ne Cool ant Temperature (ECT) sensor i s
used to sense engi ne cool ant temperature. The sensor
protrudes i nto an engi ne water jacket.
KJ ENGINE 7 - 19
The ECT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as engi ne cool ant
temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
At key-on, the Powertrai n Control Modul e (PCM)
sends out a regul ated 5 vol t si gnal to the ECT sensor.
The PCM then moni tors the si gnal as i t passes
through the ECT sensor to the sensor ground (sensor
return).
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
The PCM uses i nputs from the ECT sensor for the
fol l owi ng cal cul ati ons:
for engi ne cool ant temperature gauge operati on
through CCD or PCI (J1850) communi cati ons
I njector pul se-wi dth
Spark-advance curves
ASD rel ay shut-down ti mes
I dl e Ai r Control (I AC) motor key-on steps
Pul se-wi dth pri me-shot duri ng cranki ng
O2 sensor cl osed l oop ti mes
Purge sol enoi d on/off ti mes
EGR sol enoi d on/off ti mes (i f equi pped)
Leak Detecti on Pump operati on (i f equi pped)
Radi ator fan rel ay on/off ti mes (i f equi pped)
Target i dl e speed
REMOVAL
2. 4L
i nstal l ed i nto a water jacket at l eft front of cyl i nder
head (Fi g. 1).
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Parti al l y drai n cool i ng system.
(2) Di sconnect el ectri cal connector from sensor.
(3) Remove sensor from cyl i nder head.
3. 7L
i nstal l ed i nto a water jacket at front of i ntake mani -
fol d near rear of generator (Fi g. 2).
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Parti al l y drai n cool i ng system.
(2) Di sconnect el ectri cal connector from sensor.
(3) Remove sensor from i ntake mani fol d.
Fig. 1 ECT AND UPPER TIMING BELT COVER/
BOLTS-2.4L
1 - UPPER TIMING BELT COVER
2 - ELECTRICAL CONNECTOR (ECT)
3 - MOUNTING BOLTS (3)
Fig. 2 MAP SENSOR / ECT SENSOR - 3.7L
1 - MOUNTING SCREWS
2 - MAP SENSOR
3 - ECT SENSOR
7 - 20 ENGINE KJ
ENGINE COOLANT TEMPERATURE SENSOR (Continued)
INSTALLATION
(1) Appl y thread seal ant to sensor threads.
(2) I nstal l sensor to engi ne.
(3) Ti ghten sensor to 11 Nm (8 ft. l bs.) torque.
(4) Repl ace any l ost engi ne cool ant.
ENGINE COOLANT
THERMOSTAT
DESCRIPTION - 3. 7L ENGINE
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
A pel l et-type thermostat control s the operati ng
temperature of the engi ne by control l i ng the amount
of cool ant fl ow to the radi ator. On al l engi nes the
thermostat i s cl osed bel ow 195F (90C). Above thi s
temperature, cool ant i s al l owed to fl ow to the radi a-
tor. Thi s provi des qui ck engi ne warm up and overal l
temperature control . On the 3.7L engi ne the thermo-
stat i s desi gned to bl ock the fl ow of the cool ant
bypass journal by 50% i nstead of compl etel y bl ocki ng
the fl ow. Thi s desi gn control s cool ant temperature
more accuratel y (Fi g. 3).
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes other prob-
l ems. These are: l onger engi ne warmup ti me, unrel i -
abl e warmup performance, i ncreased exhaust
emi ssi ons and crankcase condensati on. Thi s conden-
sati on can resul t i n sl udge formati on.
OPERATION
The wax pel l et i s l ocated i n a seal ed contai ner at
the spri ng end of the thermostat. When heated, the
pel l et expands, overcomi ng cl osi ng spri ng tensi on
and water pump pressure to force the val ve to open.
DIAGNOSIS AND TESTING - THERMOSTAT
ON-BOARD DIAGNOSTICS
Al l model s are equi pped wi th On-Board Di agnos-
ti cs for certai n cool i ng system components.I f the pow-
ertrai n control modul e (PCM) detects l ow engi ne
cool ant temperature, i t wi l l record a Di agnosti c Trou-
bl e Code (DTC). For other DTC numbers, (Refer to 25
- EMI SSI ONS CONTROL - DESCRI PTI ON).
The DTC can al so be accessed through the DRB
scan tool .
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusabl e cool ant. I f sol uti on i s cl ean,
drai n cool ant i nto a cl ean contai ner for reuse.
I f thermostat i s bei ng repl aced, be sure that
repl acement i s speci fi ed thermostat for vehi cl e model
and engi ne type.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Drai n cool i ng system (Refer to 7 - COOLI NG -
STANDARD PROCEDURE).
(3) Rai se vehi cl e on hoi st.
(4) Remove spl ash shi el d.
(5) Remove l ower radi ator hose cl amp and l ower
radi ator hose at thermostat housi ng.
(6) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng and thermostat (Fi g. 4).
Fig. 3 Thermostat
1 - FROM HEATER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
KJ ENGINE 7 - 21
ENGINE COOLANT TEMPERATURE SENSOR (Continued)
(1) Cl ean mati ng areas of ti mi ng chai n cover and
thermostat housi ng.
(2) I nstal l thermostat (spri ng si de down) i nto
recessed machi ned groove on ti mi ng chai n cover (Fi g. 4).
(3) Posi ti on thermostat housi ng on ti mi ng chai n
cover.
(4) I nstal l two housi ng-to-ti mi ng chai n cover bol ts.
Ti ghten bol ts to 13 Nm (115 i n. l bs.) torque.
CAUTION: Housing must be tightened evenly and
thermostat must be centered into recessed groove
in timimg chain cover. If not, it may result in a
cracked housing, damaged timing chain cover
threads or coolant leaks.
(5) I nstal l l ower radi ator hose on thermostat housi ng.
(6) I nstal l spl ash shi el d.
(8) Fi l l cool i ng system (Refer to 7 - COOLI NG -
(9) Connect negati ve battery cabl e to battery.
(10) Start and warm the engi ne. Check for l eaks.
RADIATOR
DESCRIPTION
Al l vehi cl es are equi pped wi th a cross fl ow type
radi ator wi th pl asti c si de tanks (Fi g. 5).
Pl asti c tanks, whi l e stronger than brass, are sub-
ject to damage by i mpact, such as from tool s or
wrenches. Handl e radi ator wi th care.
Fig. 4 Thermostat and Thermostat Housing
1 - THERMOSTAT HOUSING
2 - THERMOSTAT LOCATION
3 - THERMOSTAT AND GASKET
Fig. 5 Cross Flow Radiator - Typical
1 - RADIATOR
7 - 22 ENGINE KJ
ENGINE COOLANT THERMOSTAT (Continued)
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
ING.
Do not waste reusabl e cool ant. I f the sol uti on i s
cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
6094) (Fig. 6). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
tongue of constant tension clamps (Fig. 7). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 8). These are used at the top, bottom
and sides of the radiator and A/C condenser. To
prevent overheating, these seals must be installed
to their original positions.
(1) Di sconnect the negati ve battery cabl e at bat-
tery.
(2) Drai n cool ant from radi ator (Refer to 7 -
COOLI NG - STANDARD PROCEDURE).
Fig. 6 Hose Clamp Tool - Typical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 7 Clamp Number/Letter Location - Typical
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
Fig. 8 Air Seals - Typical
1 - AIR DAM
2 - RADIATOR
3 - AIR DAM
4 - A/C CONDENSER
5 - AIR SEAL
KJ ENGINE 7 - 23
RADIATOR (Continued)
(3) Remove the front gri l l (Refer to 23 - BODY/EX-
TERI OR/GRI LLE - REMOVAL).
(4) Remove the cool i ng fan from the engi ne, i f
equi pped.
(5) Remove the two radi ator mounti ng bol ts.
(6) Di sconnect both transmi ssi on cool er l i nes from
radi ator.
(7) Di sconnect the connector for the el ectri c fan.
(8) Di sconnect the power steeri ng cool er l i ne from
cool er.
(9) Di sconnect the radi ator upper and l ower hoses.
(10) Di sconnect the overfl ow hose from radi ator.
(11) The l ower part of radi ator i s equi pped wi th
two al i gnment dowel pi ns (Fi g. 9). They are l ocated
on the bottom of radi ator tank and fi t i nto rubber
grommets. These rubber grommets are pressed i nto
the radi ator l ower crossmember.
WARNING: THE AIR CONDITIONING SYSTEM (IF
EQUIPPED) IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN, HEATING AND AIR CONDI-
TIONING BEFORE HANDLING ANY AIR
CONDITIONING COMPONENT.
NOTE: The radiator and radiator cooling fan can be
removed as an assembly. It is not necessary to
remove the cooling fan before removing or install-
ing the radiator.
(12) Gentl y l i ft up and remove radi ator from vehi -
cl e. Be careful not to scrape the radi ator fi ns agai nst
any other component. Al so be careful not to di sturb
the ai r condi ti oni ng condenser (i f equi pped).
CLEANING
Cl ean radi ator fi ns Wi th the engi ne col d, appl y col d
water and compressed ai r to the back (engi ne si de) of
the radi ator to fl ush the radi ator and/or A/C con-
denser of debri s.
INSPECTION
The radi ator cool i ng fi ns shoul d be checked for
damage or deteri orati on. I nspect cool i ng fi ns to make
sure they are not bent or crushed, these areas resul t
i n reduced heat exchange causi ng the cool i ng system
to operate at hi gher temperatures. I nspect the pl asti c
end tanks for cracks, damage or l eaks.
I nspect the radi ator neck for damage or di storti on.
INSTALLATION
CAUTION: Before installing the radiator or A/C con-
denser, be sure the radiator-to-body and radiator-to-
A/C condenser rubber air seals are properly
fastened to their original positions. These are used
at the top, bottom and sides of the radiator and A/C
condenser. To prevent overheating, these seals
must be installed to their original positions.
(1) Gentl y l ower the radi ator and fan shroud i nto
the vehi cl e. Gui de the two radi ator al i gnment dowel s
i nto the rubber grommets l ocated i n l ower radi ator
crossmember.
(2) Connect the radi ator upper and l ower hoses
and hose cl amps to radi ator.
CAUTION: The tangs on the hose clamps must be
positioned straight down.
(3) I nstal l cool ant reserve/overfl ow tank hose at
radi ator.
(4) Connect both transmi ssi on cool er l i nes at the
radi ator.
(5) I nstal l both radi ator mounti ng bol ts.
(6) Reconnect the el ectri c cool i ng fan.
(7) I nstal l the gri l l (Refer to 23 - BODY/EXTERI -
OR/GRI LLE - I NSTALLATI ON).
(8) Rei nstal l the cool i ng fan to the engi ne.
(9) Rotate the fan bl ades (by hand) and check for
i nterference at fan shroud.
(10) Refi l l cool i ng system (Refer to 7 - COOLI NG -
(11) Connect battery cabl e at battery.
(12) Start and warm engi ne. Check for l eaks.
Fig. 9 Radiator Alignment Dowels - Typical
1 - RADIATOR
2 - ALIGNMENT DOWEL
3 - RADIATOR LOWER ISOLATOR
4 - RADIATOR LOWER CROSSMEMBER
7 - 24 ENGINE KJ
RADIATOR (Continued)
RADIATOR PRESSURE CAP
DESCRIPTION
The cool i ng system cap i s l ocated on the cool ant
pressure bottl e. The cap constructi on i ncl udes; stai n-
l ess steel swi vel top, rubber seal s and retai ner, mai n
spri ng, and a spri ng l oaded val ve (Fi g. 10).
OPERATION
The pressure cap al l ows the cool i ng system to oper-
ate at hi gher than atmospheri c pressure whi ch rai ses
the cool ant boi l i ng poi nt, thus al l owi ng i ncreased
radi ator cool i ng capaci ty. The pressure cap rel eases
pressure at some poi nt wi thi n a range of 110 kPa
14 kPa (16 psi 2 psi ).
A spri ng-l oaded vent val ve i n the center of the cap
al l ows the system to pressuri ze and depressuri ze
wi thout creati ng a vacuum. I f the val ve i s stuck
open, cool ant wi l l escape to the overfl ow hose. There
i s al so a gasket i n the cap to seal to the top of the
fi l l er neck.
CAUTION: Use only the pressure cap specified for
this vehicle. Use of other pressure caps can lead to
coolant loss and overheating.
DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP
Remove cap from radi ator. Be sure that seal i ng
surfaces are cl ean. Moi sten rubber gasket wi th water
and i nstal l the cap on pressure tester (tool 7700 or
an equi val ent) (Fi g. 11).
Operate the tester pump and observe the gauge
poi nter at i ts hi ghest poi nt. The cap rel ease pressure
shoul d be 124 to 145 kPa (18 to 21 psi ). The cap i s
sati sfactory when the pressure hol ds steady. I t i s al so
good i f i t hol ds pressure wi thi n the 124 to 145 kPa
(18 to 21 psi ) range for 30 seconds or more. I f the
poi nter drops qui ckl y, repl ace the cap.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CLEANING
Cl ean the radi ator pressure cap usi ng a mi l d soap
and water onl y.
INSPECTION
Vi sual l y i nspect the pressure val ve gasket on the
cap. Repl ace cap i f the gasket i s swol l en, torn or
worn. I nspect the area around radi ator fi l l er neck for
whi te deposi ts that i ndi cate a l eaki ng cap.
Fig. 10 PRESSURE CAP
1 - MAIN SPRING
2 - GASKET RETAINER
3 - STAINLESS STEEL SWIVEL TOP
4 - RUBBER SEALS
5 - SPRING LOADED VALVE
6 - COOLANT PRESSURE BOTTLE
7 - FILLER NECK
8 - OVERFLOW NIPPLE
Fig. 11 Pressure Testing Radiator Pressure Cap -
Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
KJ ENGINE 7 - 25
RADIATOR FAN - ELECTRIC
DESCRIPTION
The fan (Fi g. 12) i s el ectri cal l y control l ed by the
powertrai n control modul e (PCM) through the fan
control rel ay. Thi s rel ay i s l ocated on the l eft wheel
house i n the engi ne compartment.
OPERATION
The el ectri c radi ator cool i ng fan i s control l ed by
the Powertrai n Control Modul e (PCM) through the
radi ator cool i ng fan rel ay. The PCM regul ates fan
operati on based on i nput from the engi ne cool ant
temperature sensor, battery temperature sensor,ai r
condi ti oni ng sel ect swi tch and vehi cl e speed.
The fan i s not energi zed duri ng engi ne cranki ng
regardl ess of the el ectri cal i nput from the tempera-
ture sensors and ,ai r condi ti oni ng swi tch. However, i f
engi ne operati on condi ti ons warrant fan engagement,
the fan wi l l run once engi ne starts.
On vehicles NOT equipped with AC: The rel ay
i s energi zed when the cool ant temperature i s above
80 C (176 F), or battery temperature sensor above
12 C (10 F). I t wi l l then de-energi ze when cool ant
temperature drops bel ow 82 C (180 F), or batter
temperature sensor bel ow 9 C ( 16 F).
Vehicles Equipped with AC: I n addi ti on to usi ng
cool ant temperature and battery temperature sensor
to control cool i ng fan operati on, the cool i ng fan wi l l
al so be engaged when the ,ai r condi ti oni ng system i s
acti vated. The rel ay i s al so energi zed when, ai r con-
di ti oni ng i s sel ected and cool ant temperature i s
above 95 C ( 203 F), or , ai r condi ti oni ng i s sel ected
and battery temperature sensor i s above 41 C (106
F). I t wi l l then de-energi ze when , ai r condi ti oni ng i s
sel ected and cool ant temperature i s bel ow 92 C
(198 F), or , ai r condi ti oni ng i s sel ected and battery
temperature i s bel ow 38 C (100 F).
REMOVAL
I f the fan bl ade i s bent, warped, cracked or dam-
aged i n any way, i t must be repl aced only wi th a
repl acement fan bl ade. Do not attempt to repair a
damaged fan blade.
NOTE: For 3.7L Heavy Duty/Max Cool/Trailer Tow
cooling package, the vicous fan cannot be removed
seperate from the shroud. Both fan and shroud
must be removed together.
(1) Di sconnect battery negati ve cabl e.
(2) Usi ng speci al tool 6958 spanner wrench and
8346 adapters, remove the vi cous fan from the water
pump (Fi g. 13).
(3) Gentl y l ay fan i nto shroud.
(4) Di sconnect the el ectri cal connector for the el ec-
tri c fan, then di sconnect connector from shroud.
Fig. 12 Radiator Cooling Fan - Typical
1 - RADIATOR
2 - ELECTRIC COOLING FAN CONNECTOR
3 - FAN SHROUD
4 - ELECTRIC COOLING FAN
Fig. 13 Viscous Fan and Fan Drive 3.7L
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2 - FAN
7 - 26 ENGINE KJ
(5) Remove the two fan shroud mounti ng bol ts con-
necti ng the fan shroud to the radi ator (Fi g. 14).
(6) Remove the shroud and fan from the vehi cl e.
INSTALLATION
NOTE: For 3.7L Heavy Duty/Max Cool/Trailer Tow
cooling package, the vicous fan cannot be installed
seperate from the shroud. Both fan and shroud
must be installed together.
(1) Gentl y l ay vi cous fan i nto shroud.
(2) I nstal l fan shroud assembl y i nto the vehi cl e.
Ti ghten fan shroud to radi ator bol ts to (5.5 Nm (50
i n. l bs.).
(3) Usi ng speci al tool 6958 spanner wrench and
8346 adapters, i nstal l the vi cous fan on the water
pump.
(4) Connect fan motor wi re connector to harness
connector, and attach connector to shroud.
(5) Connect battery negati ve cabl e.
(6) Start engi ne and check fan operati on.
RADIATOR - FAN - VISCOUS
DESCRIPTION
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
The thermal vi scous fan dri ve (Fi g. 15) i s a si l i -
cone-fl ui d-fi l l ed coupl i ng used to connect the fan
bl ades to the water pump shaft. The coupl i ng al l ows
the fan to be dri ven i n a normal manner. Thi s i s
done at l ow engi ne speeds whi l e l i mi ti ng the top
speed of the fan to a predetermi ned maxi mum l evel
at hi gher engi ne speeds.
On the 3.7L engi ne, an el ectri c fan i s standard and
the vi scous fan i s added on for trai l er tow packages
onl y.
OPERATION
A thermostati c bi metal l i c spri ng coi l i s l ocated on
the front face of the vi scous fan dri ve uni t. Thi s
spri ng coi l reacts to the temperature of the radi ator
di scharge ai r. I t engages the vi scous fan dri ve for
hi gher fan speed i f the ai r temperature from the
radi ator ri ses above a certai n poi nt. Unti l addi ti onal
engi ne cool i ng i s necessary, the fan will remain at
a reduced rpm regardless of engine speed. Nor-
mally less than three hundred (300) rpm.
Fig. 14 Radiator Cooling Fan - Typical
1 - RADIATOR
2 - ELECTRIC COOLING FAN CONNECTOR
3 - FAN SHROUD
4 - ELECTRIC COOLING FAN
Fig. 15 Viscous Fan Drive - Typical
1 - VISCOUS FAN DRIVE
2 - THERMOSTATIC SPRING
3 - MOUNTING NUT TO WATER PUMP HUB
KJ ENGINE 7 - 27
RADIATOR FAN - ELECTRIC (Continued)
Onl y when suffi ci ent heat i s present, wi l l the vi s-
cous fan dri ve engage. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on to the
bi metal l i c coi l . I t then i ncreases fan speed to provi de
the necessary addi ti onal engi ne cool i ng.
Once the engi ne has cool ed, the radi ator di scharge
temperature wi l l drop. The bi metal l i c coi l agai n
reacts and the fan speed i s reduced to the previ ous
di sengaged speed.
DIAGNOSIS AND TESTING - VISCOUS FAN
DRIVE
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
spun by hand), repl ace the fan dri ve. Thi s spi n test
must be performed when the engi ne i s cool .
For the fol l owi ng test, the cool i ng system must be
i n good condi ti on. I t al so wi l l ensure agai nst exces-
si vel y hi gh cool ant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Dri l l a 3.18-mm (1/8-i n) di ameter hol e i n the
top center of the fan shroud.
(2) Obtai n a di al thermometer wi th an 8 i nch stem
(or equi val ent). I t shoul d have a range of -18 to
105C (0 to 220 F). I nsert thermometer through the
hol e i n the shroud. Be sure that there i s adequate
cl earance from the fan bl ades.
(3) Connect a tachometer and an engi ne i gni ti on
ti mi ng l i ght (ti mi ng l i ght i s to be used as a strobe
l i ght).
(4) Bl ock the ai r fl ow through the radi ator. Secure
a sheet of pl asti c i n front of the radi ator (or ai r con-
di ti oner condenser). Use tape at the top to secure the
pl asti c and be sure that the ai r fl ow i s bl ocked.
(5) Be sure that the ai r condi ti oner (i f equi pped) i s
turned off.
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 FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start the engi ne and operate at 2400 rpm.
Wi thi n ten mi nutes the ai r temperature (i ndi cated on
the di al thermometer) shoul d be up to 93 C (200 F).
Fan dri ve engagement shoul d have started to occur
at between 91 to 96 C (195 to 205 F). Engage-
ment i s di sti ngui shabl e by a defi ni te increase i n fan
fl ow noi se (roari ng). The ti mi ng l i ght al so wi l l i ndi -
cate an i ncrease i n the speed of the fan.
(7) When the ai r temperature reaches 93 C (200
F), remove the pl asti c sheet. Fan dri ve disengage-
ment shoul d have started to occur at between 62 to
85 C (145 to 185 F). A defi ni te decrease of fan
fl ow noi se (roari ng) shoul d be noti ced. I f not, repl ace
the defecti ve vi scous fan dri ve uni t.
REMOVAL
NOTE: The thermal viscous fan drive/fan blade
assembly is attached (threaded) to water pump hub
shaft.
(2) Remove fan bl ade/vi scous fan dri ve assembl y
from water pump usi ng speci al tool 6958 spanner
wrench and 8346 adapters, by turni ng mounti ng nut
countercl ockwi se as vi ewed from front (Fi g. 16).
Threads on vi scous fan dri ve are RIGHT HAND.
(3) Do not attempt to remove fan/vi scous fan dri ve
assembl y from vehi cl e at thi s ti me.
(4) Do not unbol t fan bl ade assembl y from vi scous
fan dri ve at thi s ti me.
(5) Remove fan shroud to radi ator bol ts.
(6) Remove fan shroud and fan bl ade/vi scous fan
dri ve assembl y as a compl ete uni t from vehi cl e.
(7) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace vi scous fan dri ve i n hori zon-
tal posi ti on. I f stored hori zontal l y, si l i cone fl ui d i n
the vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
PINS 8346
2 - FAN
7 - 28 ENGINE KJ
RADIATOR - FAN - VISCOUS (Continued)
CAUTION: Do not remove water pump pulley-to-wa-
ter pump bolts. This pulley is under belt tension.
(8) Remove four bol ts securi ng fan bl ade assembl y
to vi scous fan dri ve.
CLEANING
Cl ean the fan bl ades usi ng a mi l d soap and water.
Do not use an abrasi ve to cl ean the bl ades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan bl ade assembl y from vi scous fan
dri ve uni t (four bol ts).
(2) Lay fan on a fl at surface wi th l eadi ng edge fac-
i ng down. Wi th ti p of bl ade touchi ng fl at surface,
repl ace fan i f cl earance between opposi te bl ade and
surface i s greater than 2.0 mm (.090 i nch). Rocki ng
moti on of opposi te bl ades shoul d not exceed 2.0 mm
(.090 i nch). Test al l bl ades i n thi s manner.
(3) I nspect fan assembl y for cracks, bends, l oose
ri vets or broken wel ds. Repl ace fan i f any damage i s
found.
INSTALLATION
(1) Assembl e fan bl ade to vi scous fan dri ve.
Ti ghten mounti ng bol ts to 27 Nm (20 ft. l bs.) torque.
NOTE: The vicous fan and fan shroud must be
installed as an assembly.
(2) Gentl y l ay vi cous fan i nto fan shroud.
(3) I nstal l the fan shroud to radi ator mounti ng
bol ts, torque bol ts to (5.5NM or 50 i nl bs).
(4) Thread the fan and fan dri ve onto the water
pump pul l ey, and ti ghten nut usi ng speci al tool 6958
spanner wrench and 8346 adapters.
(5) Connect the el ectri cal connector for the el ectri c
fan.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction. (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)
for correct belt routing.
WATER PUMP
DESCRIPTION
DESCRIPTION - WATER PUMP
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
si ngl e serpenti ne dri ve bel t.
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has two smal l hol es to al l ow
seepage to escape. The water pump seal s are l ubri -
cated by the anti freeze i n the cool ant mi xture. No
addi ti onal l ubri cati on i s necessary.
Both heater hoses are connected to fi tti ngs on the
ti mi ng chai n front cover. The water pump i s al so
mounted di rectl y to the ti mi ng chai n cover and i s
equi pped wi th a non servi ceabl e i ntegral pul l ey (Fi g.
17).
DESCRIPTION
The 3.7L engi ne uses an i nternal water/cool ant
bypass system. The desi gn uses gal l eri es i n the ti m-
i ng chai n cover to ci rcul ate cool ant duri ng engi ne
warm-up preventi ng the cool ant from fl owi ng
Fig. 17 Water Pump and Timing Chain Cover
1 - INTEGRAL WATER PUMP PULLEY
3 - THERMOSTAT HOUSING
4 - HEATER HOSE FITTINGS
5 - WATER PUMP
KJ ENGINE 7 - 29
RADIATOR - FAN - VISCOUS (Continued)
through the radi ator. The thermostat uses a stub
shaft l ocated at the rear of the thermostat to control
fl ow through the bypass gal l ery.
OPERATION - WATER PUMP
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core,
thi s cool ant absorbs the heat generated when the
engi ne i s runni ng. The pump i s dri ven by the engi ne
crankshaft vi a a dri ve bel t.
REMOVAL
The water pump on 3.7L engi nes i s bol ted di rectl y
to the engi ne ti mi ng chai n case cover.
(3) Remove fan/vi scous fan dri ve assembl y from
water pump (Fi g. 18) (Refer to 7 - COOLI NG/EN-
GI NE/FAN DRI VE VI SCOUS CLUTCH - REMOV-
AL). Do not attempt to remove fan/vi scous fan dri ve
assembl y from vehi cl e at thi s ti me.
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
(4) I f water pump i s bei ng repl aced, do not unbol t
fan bl ade assembl y from thermal vi scous fan dri ve.
(5) Remove two fan shroud-to-radi ator screws, Di s-
connect the cool ant overfl ow hose.
(6) Remove upper fan shroud and fan bl ade/vi scous
fan dri ve assembl y from vehi cl e.
(7) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
(8) Remove accessory dri ve bel t (Fi g. 19) (Refer to
7 - COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(9) Remove l ower radi ator hose cl amp and remove
l ower hose at water pump.
(10) Remove seven water pump mounti ng bol ts
and one stud bol t.
PINS 8346
2 - FAN
Fig. 19 Automatic Belt Tensioner3.7L
1 - AUTOMATIC TENSIONER
7 - 30 ENGINE KJ
WATER PUMP (Continued)
CAUTION: Do not pry water pump at timing chain
case/cover. The machined surfaces may be dam-
aged resulting in leaks.
(11) Remove water pump and gasket. Di scard gas-
ket.
CLEANING
Cl ean the gasket mati ng surface. Use cauti on not
to damage the gasket seal i ng surface.
INSPECTION
I nspect the water pump assembl y for cracks i n the
housi ng, Water l eaks from shaft seal , Loose or rough
turni ng beari ng or I mpel l er rubbi ng ei ther the pump
body or ti mi ng chai n case/cover.
INSTALLATION
The water pump on 3.7L engi nes i s bol ted di rectl y
to the engi ne ti mi ng chai n case cover.
(1) Cl ean gasket mati ng surfaces.
(2) Usi ng a new gasket, posi ti on water pump and
i nstal l mounti ng bol ts as shown. (Fi g. 20). Ti ghten
water pump mounti ng bol ts to 54 Nm (40 ft. l bs.)
torque.
(3) Spi n water pump to be sure that pump i mpel -
l er does not rub agai nst ti mi ng chai n case/cover.
(4) Connect radi ator l ower hose to water pump.
(5) Rel ax tensi on from bel t tensi oner. I nstal l dri ve
bel t (Refer to 7 - COOLI NG/ACCESSORY DRI VE/
DRI VE BELTS - I NSTALLATI ON).
CAUTION: When installing the serpentine accessory
drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 21) for correct belt
routing. Or, refer to the Belt Routing Label located
in the engine compartment. The correct belt with
correct length must be used.
(6) Posi ti on upper fan shroud and fan bl ade/vi s-
cous fan dri ve assembl y.
(7) Be sure the upper and l ower porti ons of the fan
shroud are fi rml y connected. Al l ai r must fl ow
through the radi ator.
(8) I nstal l two fan shroud-to-radi ator screws.
(9) Be sure of at l east 25 mm (1.0 i nches) between
ti ps of fan bl ades and fan shroud.
(10) I nstal l fan bl ade/vi scous fan dri ve assembl y to
water pump shaft (Refer to 7 - COOLI NG/ENGI NE/
FAN DRI VE VI SCOUS CLUTCH - I NSTALLATI ON).
(12) Connect negati ve battery cabl e.
(13) Start and warm the engi ne. Check for l eaks.
Fig. 20 Water Pump Installation3.7L
1 - WATER PUMP
Fig. 21 Belt Routing 3.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
KJ ENGINE 7 - 31
WATER PUMP (Continued)
TRANSMISSION
TABLE OF CONTENTS
page
TRANS COOLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
TRANS COOLER
DESCRIPTION
An i nternal hi gh capaci ty/hi gh effi ci ency cool er i s
used on al l vehi cl es, these cool ers are an oi l -to-cool -
ant type, whi ch consi sts of pl ates mounted i n the
radi ator outl et tank.Because the i nternal oi l cool er i s
so effi ci ent, no auxi l i ary oi l cool er i s offered. The
cool er i s not servi ceabl e separatel y from the radi ator.
7 - 32 TRANSMISSION KJ
AUDIO
TABLE OF CONTENTS
page page
AUDIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - AUDIO . . . . . . . . . . 2
AMPLIFIER CHOKE AND RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - AMPLIFIER
CHOKE AND RELAY . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ANTENNA BODY & CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CD CHANGER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTRUMENT PANEL ANTENNA CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RADIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RADIO NOISE SUPPRESSION GROUND STRAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOTE SWITCHES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - REMOTE
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPEAKER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
AUDIO
DESCRIPTION
An audi o system i s standard factory-i nstal l ed
equi pment on thi s model . Several combi nati ons of
radi o recei vers and speaker systems are offered on
thi s model . The audi o system uses an i gni ti on
swi tched source of battery current so that the system
wi l l onl y operate when the i gni ti on swi tch i s i n the
RUN or ACCESSORY posi ti ons.
The audi o system i ncl udes the fol l owi ng compo-
nents:
Ampl i fi er choke and rel ay
Antenna
Compact di sc changer (i f equi pped)
Power ampl i fi er mounted to each front door
speaker (wi th premi um speaker system onl y)
Radi o noi se suppressi on components
Radi o recei ver
Remote radi o swi tches (i f equi pped)
Speakers
Certai n functi ons and features of the audi o system
rel y upon resources shared wi th other el ectroni c
modul es i n the vehi cl e over the Programmabl e Com-
muni cati on I nterface (PCI ) bus network. The data
bus network al l ows the shari ng of sensor i nforma-
ti on. For di agnosi s of these el ectroni c modul es or of
the data bus network, the use of a DRB scan tool and
the proper Di agnosti c Procedures manual are recom-
mended.
Refer to the appropri ate wi ri ng i nformati on for
compl ete standard and premi um audi o system ci rcui t
di agrams. The wi ri ng i nformati on i ncl udes proper
wi re and connector repai r procedures, further detai l s
on wi re harness routi ng and retenti on, as wel l as
pi n-out and l ocati on vi ews for the vari ous wi re har-
ness connectors, spl i ces, and grounds.
OPERATION
The audi o system components are desi gned to pro-
vi de audi o entertai nment and i nformati on through
the recepti on, tuni ng and ampl i fi cati on of l ocal l y
broadcast radi o si gnal s i n both the Ampl i tude Modu-
KJ AUDIO 8A - 1
l ati ng (AM) and Frequency Modul ati ng (FM) com-
merci al frequency ranges.
The audi o system components operate on battery
current recei ved through a fuse i n the Juncti on Bl ock
(JB) on a fused i gni ti on swi tch output (run-acc) ci r-
cui t so that the system wi l l onl y operate when the
i gni ti on swi tch i s i n the Run or Accessory posi ti ons.
On vehi cl es that are equi pped wi th the opti onal
remote radi o swi tches, the Body Control Modul e
(BCM) recei ves hard wi red resi stor mul ti pl exed
i nputs from the remote radi o swi tches. The program-
mi ng i n the BCM al l ows i t to process those i nputs
and send the proper messages to the radi o recei ver
over the Programmabl e Communi cati on I nterface
(PCI ) bus network to control the radi o vol ume up or
down, stati on seek up or down, preset stati on
advance, and mode advance functi ons.
Refer to the owners manual for more i nformati on
on the features, use and operati on of each of the
avai l abl e audi o systems.
DIAGNOSIS AND TESTING - AUDIO
Any diagnosis of the Audio system should
begin with the use of the DRB diagnostic tool.
For information on the use of the DRB, refer to
the appropriate Diagnostic Service Manual.
Refer to the appropri ate wi ri ng i nformati on. The
wi ri ng i nformati on i ncl udes wi ri ng di agrams, proper
wi re and connector repai r procedures, detai l s of wi re
harness routi ng and retenti on, connector pi n-out
i nformati on and l ocati on vi ews for the vari ous wi re
harness connectors, spl i ces and grounds.
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
AUDIO SYSTEM DIAGNOSIS TABLE
NO AUDIO 1. Fuse faulty. 1. Check radio fuse and Ignition-Off Draw (IOD)
fuse in Junction Block (JB). Replace fuses, if
required.
2. Radio connector faulty. 2. Check for loose or corroded radio connector.
Repair, if required.
3. Wiring faulty. 3. Check for shorted or open wires. Repair wiring,
if required.
4. Radio ground faulty. 4. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
5. Radio faulty. 5. Refer to appropriate Diagnostic Service
Manual.
6. Speakers faulty. 6. Replace speaker as necessary.
NO RADIO DISPLAY 1. Fuse faulty. 1. Check radio fuse and Ignition-Off Draw (IOD)
fuse in Junction Block (JB). Replace fuses, if
required.
3. Wiring faulty. 3. Check for battery voltage at radio connector.
Repair wiring, if required.
8A - 2 AUDIO KJ
AUDIO (Continued)
Manual.
CLOCK WILL NOT KEEP
SET TIME
1. Fuse faulty. 1. Check Ignition-Off Draw (IOD) fuse in the
Junction Block (JB). Replace fuse, if required.
3. Wiring faulty. 3. Check for battery voltage at radio connector.
Repair wiring, if required.
Manual.
POOR RADIO RECEPTION 1. Antenna faulty. 1. (Refer to 8 - ELECTRICAL/AUDIO/ANTENNA
BODY & CABLE - DIAGNOSIS AND TESTING).
3. Radio noise suppression
faulty.
3. Repair or replace ground strap as necessary.
Manual.
NO/POOR TAPE
OPERATION
1. Faulty tape. 1. Insert known good tape and test operation.
2. Foreign objects behind
tape door.
2. Remove foreign objects and test operation.
3. Dirty cassette tape head. 3. Clean head with Mopar Cassette Head
Cleaner.
4. Faulty tape deck. 4. Exchange or replace radio, if required.
NO COMPACT DISC
OPERATION
1. Faulty CD. 1. Insert known good CD and test operation.
2. Foreign material on CD. 2. Clean CD and test operation.
3. Condensation on CD or
optics.
3. Allow temperature of vehicle interior to stabilize
and test operation.
4. Faulty CD player. 4. Refer to appropriate Diagnostic Service
Manual.
AMPLIFIER CHOKE AND
RELAY
DESCRIPTION
Model s equi pped wi th the premi um speaker pack-
age have a ampl i fi er choke and rel ay. The ampl i fi er
choke and rel ay i s mounted to the l ower i nstrument
panel above the accel erator pedal .
The ampl i fi er choke and rel ay shoul d be checked i f
there i s no sound output from the speakers. The
ampl i fi er choke and rel ay can not be repai red or
adjusted and, i f faul ty or damaged, the uni t must be
repl aced.
OPERATION
The ampl i fi er choke and rel ay i s used to control
the suppl y of fused battery current to the front door
speaker-mounted dual ampl i fi ers. The speaker rel ay
i s energi zed by a fused 12 vol t output from the radi o
recei ver whenever the radi o i s turned on. For com-
pl ete ci rcui t di agrams, refer to the appropri ate wi r-
i ng i nformati on. The wi ri ng i nformati on i ncl udes
wi ri ng di agrams, proper wi re and connector repai r
procedures, detai l s of wi re harness routi ng and
retenti on, connector pi n-out i nformati on and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds.
KJ AUDIO 8A - 3
AUDIO (Continued)
DIAGNOSIS AND TESTING - AMPLIFIER
CHOKE AND RELAY
The ampl i fi er choke and rel ay i s used to swi tch
power to the i ndi vi dual speaker ampl i fi ers used wi th
the premi um speaker package. The ampl i fi er choke
and rel ay i s servi ced onl y as a uni t. I f al l of the
speakers are i noperati ve the ampl i fi er choke and
rel ay shoul d be i nspected. Before repl acement, make
the fol l owi ng i nspecti ons of the ampl i fi er choke and
rel ay ci rcui ts. For compl ete ci rcui t di agrams, refer to
the appropri ate wi ri ng i nformati on. The wi ri ng i nfor-
mati on i ncl udes wi ri ng di agrams, proper wi re and
connector repai r procedures, detai l s of wi re harness
routi ng and retenti on, connector pi n-out i nformati on
and l ocati on vi ews for the vari ous wi re harness con-
nectors, spl i ces and grounds.
(1) Check the fused B(+) fuse i n the juncti on bl ock. I f
OK, go to Step 2. I f not OK, repl ace the faul ty fuse.
(2) Check for battery vol tage at the fused B(+) fuse
i n the juncti on bl ock. I f OK, go to Step 3. I f not OK,
repai r the open fused B(+) ci rcui t to the battery as
requi red.
(3) Di sconnect the i nstrument panel wi re harness
connector from the ampl i fi er choke and rel ay. Check
for battery vol tage at the fused B(+) ci rcui t cavi ty of
the i nstrument panel wi re harness connector for the
ampl i fi er choke and rel ay. I f OK, go to Step 4. I f not
OK, repai r the open fused B(+) ci rcui t to the juncti on
bl ock fuse as requi red.
(4) Probe the ground ci rcui t cavi ty of the i nstru-
ment panel wi re harness connector for the ampl i fi er
choke and rel ay. Check for conti nui ty to a good
ground. There shoul d be conti nui ty. I f OK, go to Step
5. I f not OK, repai r the open ground ci rcui t to ground
as requi red.
(5) Turn the i gni ti on swi tch to the RUN posi ti on
and turn the radi o ON. Check for battery vol tage at
the radi o 12-vol t output ci rcui t cavi ty of the i nstru-
ment panel wi re harness connector for the ampl i fi er
choke and rel ay. I f OK, go to Step 6. I f not OK,
repai r the open radi o 12-vol t output ci rcui t to the
radi o as requi red.
(6) Turn the radi o and i gni ti on swi tches to the
OFF posi ti on. Reconnect the i nstrument panel wi re
harness connector to the ampl i fi er choke and rel ay.
Check for battery vol tage at the ampl i fi ed speaker
(+) ci rcui t cavi ty of the i nstrument panel wi re har-
ness connector for the ampl i fi er choke and rel ay.
There shoul d be zero vol ts. Turn the i gni ti on and
radi o swi tches to the ON posi ti on. There shoul d now
be battery vol tage. I f OK, repai r the open ampl i fi ed
speaker (+) ci rcui ts to the speaker-mounted ampl i fi -
ers as requi red. I f not OK, repl ace the faul ty ampl i -
fi er choke and rel ay.
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove knee bl ocker cover and knee bl ocker.
(3) Di sconnect the el ectri cal harness connector
from the ampl i fi er choke and rel ay (Fi g. 1).
(4) Remove mounti ng screws and ampl i fi er choke
and rel ay.
INSTALLATION
(1) I nstal l the ampl i fi er choke and rel ay.
(2) I nstal l the mounti ng screws.
(3) Connect the el ectri cal harness connector.
(4) I nstal l knee bl ocker cover and knee bl ocker.
(5) Connect the battery negati ve cabl e.
ANTENNA BODY & CABLE
DESCRIPTION
The antenna body and cabl e i s secured bel ow the
fender panel by the antenna cap nut through a
mounti ng hol e i n the si de of the ri ght front fender.
The pri mary coaxi al antenna cabl e i s then routed
beneath the fender sheet metal and through a entry
hol e i n the ri ght cowl si de panel i nto the i nteri or of
the vehi cl e. I nsi de the vehi cl e, the pri mary coaxi al
cabl e i s connected to a secondary i nstrument panel
antenna coaxi al cabl e wi th an i n-l i ne connector that
i s l ocated behi nd the ri ght ki ck panel . The secondary
coaxi al cabl e i s then routed behi nd the i nstrument
panel to the back of the radi o.
Fig. 1 RADIO CHOKE
1 - RADIO CHOKE
2 - MOUNTING SCREWS
8A - 4 AUDIO KJ
AMPLIFIER CHOKE AND RELAY (Continued)
OPERATION
The antenna body and cabl e connects the antenna
mast to the radi o. The radi o antenna i s an el ectro-
magneti c ci rcui t component used to capture radi o fre-
quency si gnal s that are broadcast by l ocal
commerci al radi o stati ons i n both the Ampl i tude
Modul ati ng (AM) and Frequency Modul ati ng (FM)
frequency ranges. These el ectromagneti c radi o fre-
quency si gnal s i nduce smal l el ectri cal modul ati ons
i nto the antenna as they move past the mast. The
antenna body transfers the weak el ectromagneti c
radi o waves i nduced i nto the ri gi d antenna mast i nto
the center conductor of the fl exi bl e pri mary antenna
coaxi al cabl e. The brai ded outer shi el d of the
antenna coaxi al cabl e i s grounded through both the
antenna body and the radi o chassi s, effecti vel y
shi el di ng the radi o waves as they are conducted to
the radi o. The radi o then tunes and ampl i fi es the
weak radi o si gnal s i nto stronger el ectri cal si gnal s i n
order to operate the audi o system speakers.
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE
The fol l owi ng four tests are used to di agnose the
antenna wi th an ohmmeter:
Test 1 - Mast to ground test
Test 2 - Ti p-of-mast to ti p-of-conductor test
Test 3 - Body ground to battery ground test
Test 4 - Body ground to antenna coaxi al cabl e
shi el d test.
INJURY.
The ohmmeter test l ead connecti ons for each test
are shown i n the i l l ustrati on (Fi g. 2).
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate an antenna cable problem. First,
test the primary antenna cable (integral to the
antenna body and cable) from the coaxial cable
connector behind the right side kick panel to the
antenna body. Then, test the secondary antenna
cable (instrument panel antenna cable) from the
coaxial cable connector behind the right side kick
panel to the coaxial cable connector at the radio.
TEST 1
Test 1 determi nes i f the antenna mast i s i nsul ated
from ground. Proceed as fol l ows:
(1) Di sconnect and i sol ate the antenna coaxi al
cabl e connector behi nd the ri ght si de ki ck panel .
(2) Touch one ohmmeter test l ead to the ti p of the
antenna mast. Touch the other test l ead to known
ground. Check the ohmmeter readi ng for conti nui ty.
(3) There shoul d be no conti nui ty. I f OK, go to Test
2. I f not OK, repl ace the faul ty antenna body and
cabl e.
TEST 2
Test 2 checks the antenna conductor components
for an open ci rcui t. Thi s test shoul d be performed
fi rst on the enti re antenna ci rcui t, from the antenna
mast to the center conductor of the coaxi al cabl e con-
nector at the radi o. I f an open ci rcui t i s detected,
each of the three antenna conductor components
(antenna mast, antenna body and cabl e, i nstrument
panel antenna cabl e) shoul d be i sol ated and tested
i ndi vi dual l y to l ocate the exact component that i s the
source of the open ci rcui t. To begi n thi s test, proceed
as fol l ows:
(1) Di sconnect the i nstrument panel antenna cabl e
coaxi al connector from the back of the radi o.
(2) Touch one ohmmeter test l ead to the ti p of the
antenna mast. Touch the other test l ead to the center
conductor pi n of the i nstrument panel antenna cabl e
coaxi al connector for the radi o. Check the ohmmeter
readi ng for conti nui ty.
Fig. 2 Antenna Tests - Typical
KJ AUDIO 8A - 5
ANTENNA BODY & CABLE (Continued)
(3) There shoul d be conti nui ty. The ohmmeter
shoul d regi ster onl y a fracti on of an ohm resi stance.
Hi gh or i nfi ni te resi stance i ndi cates a damaged or
open antenna conductor. I f OK, go to Test 3. I f not
OK, i sol ate and test each of the i ndi vi dual antenna
conductor components. Repl ace onl y the faul ty
antenna conductor component.
TEST 3
Test 3 checks the condi ti on of the vehi cl e body
ground connecti on. To begi n thi s test, proceed as fol -
l ows:
(1) Thi s test must be performed wi th the battery
posi ti ve cabl e di sconnected from the battery. Di scon-
nect and i sol ate both battery cabl es, negati ve cabl e
fi rst.
(2) Reconnect the battery negati ve cabl e.
(3) Touch one ohmmeter test l ead to a good cl ean
ground poi nt on the vehi cl e fender. Touch the other
test l ead to the battery negati ve termi nal post. Check
the ohmmeter readi ng for conti nui ty.
shoul d regi ster l ess than one ohm resi stance. Hi gh or
i nfi ni te resi stance i ndi cates a l oose, corroded, or
damaged connecti on between the battery negati ve
termi nal and the vehi cl e body. I f OK, go to Test 4. I f
not OK, check the battery negati ve cabl e connecti on
to the vehi cl e body and the radi o noi se suppressi on
ground strap connecti ons to the engi ne and the vehi -
cl e body for bei ng l oose or corroded. Cl ean or ti ghten
these connecti ons as requi red.
TEST 4
Test 4 checks the condi ti on of the connecti on
between the antenna coaxi al cabl e shi el d and the
vehi cl e body ground as fol l ows:
(1) Di sconnect and i sol ate the antenna coaxi al
cabl e connector behi nd the ri ght si de ki ck panel .
(2) Touch one ohmmeter test l ead to a good cl ean
ground poi nt on the vehi cl e fender. Touch the other
test l ead to the outer cri mp on the antenna coaxi al
cabl e connector. Check the ohmmeter readi ng for con-
ti nui ty.
shoul d regi ster l ess than one ohm resi stance. Hi gh or
i nfi ni te resi stance i ndi cates a l oose, corroded, or
damaged connecti on between the antenna body and
the vehi cl e body or between the antenna body and
the antenna coaxi al cabl e shi el d. I f not OK, cl ean the
antenna body to fender mati ng surfaces and ti ghten
the antenna cap nut to speci fi cati ons.
(4) Check the resi stance agai n wi th an ohmmeter.
I f the resi stance i s sti l l more then one ohm, repl ace
the faul ty antenna body and cabl e.
REMOVAL
cabl e.
(2) Remove the antenna mast.
(3) Remove cover (Fi g. 3).
(4) Remove mounti ng nut.
(5) Remove bezel adapter.
(6) Remove ri ght ki ck panel tri m.
(7) Di sconnect antenna body and cabl e from the
i nstrument panel cabl e. Attach a wi re or stri ng
(approxi matel y 2 feet i n l ength) to the cabl e to ai d i n
i nstal l ati on of the new cabl e.
(8) Remove the upper fender mounti ng bol ts.
Loosen the two fender mounti ng bol ts l ocated near
the upper door hi nge (Refer to 23 - BODY/EXTERI -
OR/FRONT FENDER - REMOVAL).
(9) Careful l y pul l fender out to access the antenna
body and cabl e. Pul l cabl e up through the openi ng
wi th wi re attached.
INSTALLATION
(1) Attached wi re to new cabl e. Pul l fender out and
i nsert cabl e i nto openi ng.
(2) Pul l cabl e through hol e i n ki ck panel area
usi ng the attached wi re.
(3) Connect antenna body cabl e to the i nstrument
panel cabl e.
(4) I nstal l ri ght ki ck panel tri m.
(5) I nstal l bezel adapter.
(6) I nstal l mounti ng nut. Ti ghten to 12 Nm (105
i n. l bs.).
(7) I nstal l cover.
Fig. 3 ANTENNA BODY AND CABLE
1 - ANTENNA MAST
2 - ANTENNA COVER
3 - ANTENNA BASE MOUNTING NUT
4 - ANTENNA BEZEL ADAPTER
5 - ANTENNA BODY AND CABLE
8A - 6 AUDIO KJ
(8) I nstal l antenna mast.
(9) Ti ghten fender mounti ng bol ts near door hi nge
area.
(10) I nstal l and ti ghten the upper fender mounti ng
bol ts (Refer to 23 - BODY/EXTERI OR/FRONT
FENDER - I NSTALLATI ON).
CD CHANGER
DESCRIPTION
A factory-i nstal l ed Compact Di sc (CD) changer fea-
turi ng a si x-CD magazi ne i s an avai l abl e opti on on
thi s model . The CD changer i s mounted i n the cargo
area of the passenger compartment on the ri ght rear
quarter panel .
The control s on the radi o recei ver operate the CD
changer through messages sent over the Programma-
bl e Communi cati ons I nterface (PCI ) data bus net-
work. For di agnosi s of the messagi ng functi ons of the
radi o recei ver and the CD changer, or of the PCI data
bus, a DRB scan tool and the proper Di agnosti c Pro-
cedures manual are requi red.
The CD changer can onl y be servi ced by an autho-
ri zed radi o repai r stati on. See the l atest Warranty
Pol i ci es and Procedures manual for a current l i sti ng
of authori zed radi o repai r stati ons. Refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, detai l s of wi re harness
OPERATION
The CD changer wi l l onl y operate when the i gni -
ti on swi tch i s i n the On or Accessory posi ti ons, and
the radi o i s turned on. The si x-CD magazi ne may be
ejected wi th the i gni ti on i n the Off posi ti on. For more
i nformati on on the features, l oadi ng procedures and
radi o control functi ons for the operati on of the CD
changer, refer to the owners manual .
REMOVAL
cabl e.
(2) Remove the ri ght rear quarter tri m panel .
(Refer to 23 - BODY/I NTERI OR/QUARTER TRI M
PANEL - REMOVAL).
(3) Di sconnect the el ectri cal wi re harness connec-
tor (Fi g. 4).
(4) Remove the mounti ng nuts.
(5) Remove the CD Changer from the vehi cl e.
INSTALLATION
(1) I nstal l the CD Changer to the vehi cl e.
(2) I nstal l the mounti ng nuts. Ti ghten to 11.8 Nm
(104 i n. l bs.).
(3) Connect the wi re harness connector.
(4) I nstal l the ri ght rear quarter tri m panel (Refer
to 23 - BODY/I NTERI OR/QUARTER TRI M PANEL -
I NSTALLATI ON).
INSTRUMENT PANEL
ANTENNA CABLE
REMOVAL
INJURY.
cabl e.
Fig. 4 CD CHANGER
1 - CD CHANGER
2 - WIRE HARNESS CONNECTOR
3 - MOUNTING NUT
KJ AUDIO 8A - 7
(2) Remove the i nstrument panel (Refer to 23 -
BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL ASSEMBLY - REMOVAL).
(3) Di sconnect the antenna cabl e from radi o by
pul l i ng the l ocki ng antenna connector away from
radi o (Fi g. 5).
(4) Di sengage each of the retai ners that secure the
cabl e to the i nstrument panel (Fi g. 6).
(5) Remove the cabl e from the i nstrument panel .
INSTALLATION
INJURY.
(1) Posi ti on the i nstrument panel antenna cabl e
onto the i nstrument panel .
(2) Engage each of the retai ners that secure the
cabl e to the back si de of the i nstrument panel .
(3) Connect cabl e to radi o.
(4) I nstal l i nstrument panel (Refer to 23 - BODY/
I NSTRUMENT PANEL/I NSTRUMENT PANEL
ASSEMBLY - I NSTALLATI ON).
RADIO
DESCRIPTION
Avai l abl e factory-i nstal l ed radi o recei vers for thi s
model i ncl ude an AM/FM/cassette wi th CD changer
control feature (RBB sal es code), an AM/FM/cassette/
CD/graphi c equal i zer wi th CD changer control fea-
ture (RBP sal es code), or an AM/FM/CD/ wi th CD
changer control feature (RBK sal es code). Al l factory-
i nstal l ed radi o recei vers can communi cate on the
Programmabl e Communi cati ons I nterface (PCI ) data
bus network. Al l factory-i nstal l ed recei vers are stereo
El ectroni cal l y Tuned Radi os (ETR) and i ncl ude an
el ectroni c di gi tal cl ock functi on.
These radi o recei vers can onl y be servi ced by an
authori zed radi o repai r stati on. See the l atest War-
ranty Pol i ci es and Procedures manual for a current
l i sti ng of authori zed radi o repai r stati ons.
OPERATION
The radi o recei ver operates on i gni ti on swi tched
battery current that i s avai l abl e onl y when the i gni -
ti on swi tch i s i n the On or Accessory posi ti ons. The
el ectroni c di gi tal cl ock functi on of the radi o operates
on fused battery current suppl i ed through the I OD
fuse, regardl ess of the i gni ti on swi tch posi ti on.
For more i nformati on on the features, setti ng pro-
cedures, and control functi ons for each of the avai l -
abl e factory-i nstal l ed radi o recei vers, refer to the
owners manual . For compl ete ci rcui t di agrams, refer
to the appropri ate wi ri ng i nformati on. The wi ri ng
i nformati on i ncl udes wi ri ng di agrams, proper wi re
and connector repai r procedures, detai l s of wi re har-
Fig. 5 ANTENNA TO RADIO
1 - RADIO
2 - LOCKING ANTENNA CONNECTOR
3 - INSTRUMENT PANEL ANTENNA CABLE
Fig. 6 INSTRUMENT PANEL ANTENNA CABLE
2 - ANTENNA BODY AND CABLE
8A - 8 AUDIO KJ
INSTRUMENT PANEL ANTENNA CABLE (Continued)
ness routi ng and retenti on, connector pi n-out i nfor-
mati on and l ocati on vi ews for the vari ous wi re
REMOVAL
cabl e.
(2) Remove the i nstrument panel center tri m
panel .
(3) Remove the radi o mounti ng screws (Fi g. 7).
(4) Di sconnect the antenna cabl e by pul l i ng the
l ocki ng antenna connector away from the radi o (Fi g.
8).
(5) Di sconnect the el ectri cal harness connector(s).
(6) Remove radi o from i nstrument panel .
INSTALLATION
(1) Connect the wi re harness connector(s).
(2) Connect the antenna cabl e.
(3) I nstal l the radi o to the i nstrument panel .
(4) I nstal l the radi o mounti ng screws.
(5) I nstal l the i nstrument panel center tri m panel .
RADIO NOISE SUPPRESSION
GROUND STRAP
DESCRIPTION
Radi o noi se suppressi on devi ces are factory-i n-
stal l ed standard equi pment on thi s vehi cl e. Radi o
Frequency I nterference (RFI ) and El ectroMagneti c
I nterference (EMI ) can be produced by any on-board
or external source of el ectromagneti c energy. These
el ectromagneti c energy sources can radi ate el ectro-
magneti c si gnal s through the ai r, or conduct them
through the vehi cl e el ectri cal system.
When the audi o system converts RFI or EMI to an
audi bl e acousti c wave form, i t i s referred to as radi o
noi se. Thi s undesi rabl e radi o noi se i s general l y man-
i fested i n the form of buzzi ng, hi ssi ng, poppi ng,
cl i cki ng, crackl i ng, and/or whi rri ng sounds. I n
most cases, RFI and EMI radi o noi se can be sup-
pressed usi ng a combi nati on of vehi cl e and compo-
nent groundi ng, fi l teri ng and shi el di ng techni ques.
Thi s vehi cl e i s equi pped wi th factory-i nstal l ed radi o
noi se suppressi on devi ces that were desi gned to mi n-
i mi ze exposure to typi cal sources of RFI and EMI ;
thereby, mi ni mi zi ng radi o noi se compl ai nts.
Factory-i nstal l ed radi o noi se suppressi on i s accom-
pl i shed pri mari l y through ci rcui try or devi ces that
are i ntegral to the factory-i nstal l ed radi os, audi o
power ampl i fi ers and other on-board el ectri cal com-
ponents such as generators, wi per motors, bl ower
motors, and fuel pumps that have been found to be
potenti al sources of RFI or EMI . External radi o noi se
suppressi on devi ces that are used on thi s vehi cl e to
control RFI or EMI , and can be servi ced, i ncl ude the
fol l owi ng:
Engine-to-body ground strap - Thi s l ength of
brai ded ground strap has an eyel et termi nal connec-
tor cri mped to each end. One end i s secured to the
engi ne cyl i nder head(s). The other i s secured to the
pl enum.
Resistor-type spark plugs - Thi s type of spark
pl ug has an i nternal resi stor connected i n seri es
between the spark pl ug termi nal and the center el ec-
trode to hel p reduce the producti on of el ectromag-
neti c radi ati on that can resul t i n radi o noi se.
Fig. 7 RADIO
Fig. 8 ANTENNA TO RADIO
1 - RADIO
2 - LOCKING ANTENNA CONNECTOR
KJ AUDIO 8A - 9
RADIO (Continued)
OPERATION
There are two common strategi es that can be used
to suppress Radi o Frequency I nterference (RFI ) and
El ectroMagneti c I nterference (EMI ) radi o noi se. The
fi rst suppressi on strategy i nvol ves preventi ng the
producti on of RFI and EMI el ectromagneti c si gnal s
at thei r sources. The second suppressi on strategy
i nvol ves preventi ng the recepti on of RFI and EMI
el ectromagneti c si gnal s by the audi o system compo-
nents.
The use of brai ded ground straps i n key l ocati ons
i s part of the RFI and EMI preventi on strategy.
These ground straps ensure adequate ground paths,
parti cul arl y for hi gh current components such as
many of those found i n the starti ng, chargi ng, i gni -
ti on, engi ne control and transmi ssi on control sys-
tems. An i nsuffi ci ent ground path for any of these
hi gh current components may resul t i n radi o noi se
caused by i nduced vol tages created as the hi gh cur-
rent seeks al ternati ve ground paths through compo-
nents or ci rcui ts i ntended for use by, or i n cl ose
proxi mi ty to the audi o system components or ci rcui ts.
Preventi ng the recepti on of RFI and EMI i s accom-
pl i shed by ensuri ng that the audi o system compo-
nents are correctl y i nstal l ed i n the vehi cl e. Loose,
corroded or i mproperl y sol dered wi re harness connec-
ti ons, i mproperl y routed wi ri ng and i nadequate audi o
system component groundi ng can al l contri bute to
the recepti on of RFI and EMI . A properl y grounded
antenna body and radi o chassi s, as wel l as a shi el ded
antenna coaxi al cabl e wi th cl ean and ti ght connec-
ti ons wi l l each hel p reduce the potenti al for recepti on
of RFI and EMI .
REMOVAL
2. 4L ENGINE
cabl e.
(2) Remove the retai ni ng bol t from the engi ne cyl -
i nder head (Fi g. 9).
(3) Remove the retai ni ng nut from the pl enum
(Fi g. 10).
Fig. 9 GROUND STRAP TO ENGINE - 2.4L
1 - GROUND STRAP
2 - BOLT
Fig. 10 GROUND STRAP TO PLENUM - 2.4L
1 - PLENUM
2 - RETAINING NUT
3 - GROUND STRAP
8A - 10 AUDIO KJ
RADIO NOISE SUPPRESSION GROUND STRAP (Continued)
3. 7L ENGINE
cabl e.
(2) Remove the retai ni ng bol ts from the engi ne cyl -
i nder heads (Fi g. 11).
(3) Remove the retai ni ng nut from the pl enum
(Fi g. 12).
INSTALLATION
2. 4L ENGINE
(1) I nstal l the retai ni ng nut and ground strap to
the pl enum. Ti ghten to 12 Nm (106 i n. l bs.).
(2) I nstal l the retai ni ng bol t and ground strap to
the engi ne cyl i nder head. Ti ghten to 12 Nm (106 i n.
l bs.).
3. 7L ENGINE
(1) I nstal l the retai ni ng nut and ground strap to
the pl enum. Ti ghten to 12 Nm (106 i n. l bs.).
(2) I nstal l the retai ni ng bol ts and ground strap to
the engi ne cyl i nder heads. Ti ghten to 12 Nm (106 i n.
l bs.).
REMOTE SWITCHES
DESCRIPTION
A remote radi o control swi tch opti on i s avai l abl e on
some model s. Two rocker-type swi tches are mounted
on the back (i nstrument panel si de) of the steeri ng
wheel spokes (Fi g. 13). The swi tch on the l eft spoke
i s the seek swi tch and has seek up, seek down, and
preset stati on advance functi ons. The swi tch on the
ri ght spoke i s the vol ume control swi tch and has vol -
ume up, and vol ume down functi ons. The swi tch on
the ri ght spoke al so i ncl udes a mode control that
al l ows the dri ver to sequenti al l y sel ect AM radi o, FM
radi o, cassette pl ayer, CD pl ayer or CD changer (i f
equi pped).
Fig. 11 GROUND STRAP TO ENGINE - 3.7L
1 - GROUND STRAP
2 - RETAINING BOLTS
Fig. 12 GROUND STRAP TO PLENUM - 3.7L
1 - PLENUM
2 - RETAINING NUT
3 - GROUND STRAP
Fig. 13 Remote Radio Switch Operational View
1 - PRESET SEEK
2 - SEEK UP
3 - VOLUME UP
4 - MODE
5 - VOLUME DOWN
6 - SEEK DOWN
KJ AUDIO 8A - 11
RADIO NOISE SUPPRESSION GROUND STRAP (Continued)
OPERATION
The si x swi tches i n the two remote radi o swi tch uni ts
are normal l y open, resi stor mul ti pl exed momentary
swi tches that are hard wi red to the Body Control Mod-
ul e (BCM) through the cl ockspri ng. The BCM sends a
fi ve vol t reference si gnal to both swi tch uni ts on one
ci rcui t, and senses the status of al l of the swi tches by
readi ng the vol tage drop on a second ci rcui t.
When the BCM senses an i nput (vol tage drop) from
any one of the remote radi o swi tches, i t sends the
proper swi tch status messages on the Programmabl e
Communi cati on I nterface (PCI ) data bus network to
the radi o recei ver. The el ectroni c ci rcui try wi thi n the
radi o recei ver i s programmed to respond to these
remote radi o swi tch status messages by adjusti ng the
radi o setti ngs as requested. For di agnosi s of the
BCM or the PCI data bus, the use of a DRB scan tool
and the proper Di agnosti c Procedures manual are
recommended.
For more i nformati on on the features and control
functi ons for each of the remote radi o swi tches, refer
to the owners manual .
SWITCHES
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on. The wi ri ng i nformati on
i ncl udes wi ri ng di agrams, proper wi re and connector
repai r procedures, detai l s of wi re harness routi ng
and retenti on, connector pi n-out i nformati on and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
INJURY.
cabl e. Remove the remote radi o swi tch(es) (Fi g. 14)
from the steeri ng wheel (Refer to 8 - ELECTRI CAL/
AUDI O/REMOTE SWI TCHES - REMOVAL).
(2) Use an ohmmeter to check the swi tch resi s-
tances as shown i n the Remote Radi o Swi tch Test
chart. I f the remote radi o swi tch resi stances check OK,
go to Step 3. I f not OK, repl ace the faul ty swi tch.
REMOTE RADIO SWITCH TEST TABLE
Switch Switch Position Resistance
Right
(White)
Volume Up 1.210 Kilohms 1%
Right
(White)
Volume Down 3.010 Kilohms 1%
Right
(White)
Mode Advance 0.0511 Kilohms 1%
Left
(Black)
Seek Up 0.261 Kilohms 1%
Left
(Black)
Seek Down 0.681 Kilohms 1%
Left
(Black)
Pre-Set Station
Advance
0.162 Kilohms 1%
(3) Reconnect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for 5 vol ts
at the radi o control mux ci rcui t cavi ti es of the steer-
i ng wheel wi re harness connectors for both remote
radi o swi tches. I f OK, go to Step 4. I f not OK, repai r
the open or shorted radi o control mux ci rcui t to the
Body Control Modul e (BCM) as requi red.
cabl e. Di sconnect the 22-way i nstrument panel wi re
harness connector from the BCM. Check for conti nu-
i ty between the remote radi o swi tch ground ci rcui t
cavi ti es of the steeri ng wheel wi re harness connec-
tors for both remote radi o swi tches and a good
Fig. 14 Remote Radio Switches
1 - BLACK (LEFT) SWITCH
2 - WHITE (RIGHT) SWITCH
8A - 12 AUDIO KJ
REMOTE SWITCHES (Continued)
ground. There shoul d be no conti nui ty. I f OK, go to
Step 5. I f not OK, repai r the shorted remote radi o
swi tch ground ci rcui t to the BCM as requi red.
(5) Check for conti nui ty between the remote radi o
swi tch ground ci rcui t cavi ti es of the steeri ng wheel
wi re harness connectors for both remote radi o
swi tches and the 22-way i nstrument panel wi re har-
ness connector for the BCM. There shoul d be conti -
nui ty. I f OK, refer to the proper Di agnosti c
Procedures manual to test the BCM and the PCI
data bus. I f not OK, repai r the open remote radi o
swi tch ground ci rcui t as requi red.
REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE AIRBAG SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE AIRBAG SYSTEM.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
cabl e.
(2) Remove the dri ver si de ai rbag modul e from the
vehi cl e (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - REMOVAL).
(3) Remove the crui se control swi tches (Fi g. 15).
(4) Unpl ug the wi re harness connector from the
remote radi o swi tch(es).
(5) Depress the tabs on each si de of each swi tch and
push the swi tch through the rear steeri ng wheel cover.
INSTALLATION
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE
COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG,
OR SERVICE. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE (GROUND) CABLE, THEN WAIT
TWO MINUTES FOR THE AIRBAG SYSTEM CAPACI-
SURE WAY TO DISABLE THE AIRBAG SYSTEM.
(1) I nstal l remote radi o swi tch to the steeri ng
wheel .
(2) Connect the wi re harness to the remote radi o
swi tch.
(3) I nstal l the crui se control swi tches.
(4) I nstal l the dri ver si de ai rbag modul e (Refer to
8 - ELECTRI CAL/RESTRAI NTS/DRI VER AI RBAG -
I NSTALLATI ON).
SPEAKER
DESCRIPTION
STANDARD
The standard equi pment speaker system i ncl udes
speakers i n si x l ocati ons. One 6.4 centi meter (2.50
i nch) di ameter speaker i s i nstal l ed on each end of the
i nstrument panel top pad. One 16.5 centi meter (6.5
i nch) ful l -range speaker i s l ocated i n each front door.
There i s al so one ful l -range 16.5 centi meter (6.5 i nch)
di ameter ful l -range speaker l ocated i n each rear door.
PREMIUM
The opti onal premi um speaker system features si x
Premi um model speakers i n si x l ocati ons. Each of the
standard speakers i s repl aced wi th Premi um model
speakers. One 6.4 centi meter (2.50 i nch) di ameter
Fig. 15 REMOTE SWITCH
1 - STEERING WHEEL
2 - SPEED CONTROL SWITCH
3 - SCREW
4 - DRIVER SIDE AIRBAG MODULE
5 - REMOTE RADIO SWITCH
6 - REAR TRIM COVER
KJ AUDIO 8A - 13
REMOTE SWITCHES (Continued)
speaker i s i nstal l ed on each end of the i nstrument
panel top pad. One 16.5 centi meter (6.5 i nch) Pre-
mi um woofer i s l ocated i n each front door. There i s
al so one ful l -range 16.5 centi meter (6.5 i nch) di ame-
ter Premi um ful l -range speaker l ocated i n each rear
door. The premi um speaker system al so i ncl udes a
power ampl i fi er mounted to each front door speaker.
The total avai l abl e power of the premi um speaker
system i s about 160 watts.
OPERATION
Two wi res connected to each speaker, one feed ci r-
cui t (+) and one return ci rcui t (), al l ow the audi o
output si gnal el ectri cal current to fl ow through the
voi ce coi l . For compl ete ci rcui t di agrams, refer to the
REMOVAL
FRONT DOOR
cabl e.
(2) Remove the front door tri m panel (Refer to 23 -
BODY/DOOR - FRONT/TRI M PANEL - REMOVAL).
(3) Remove the speaker mounti ng screws (Fi g. 16).
(4) Remove the speaker from the door and di scon-
nect the wi re harness connector.
INSTRUMENT PANEL
cabl e.
(2) Remove the A-pi l l ar tri m (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M - REMOVAL).
(3) Remove i nstrument panel top cover (Refer to
23 - BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL TOP COVER - REMOVAL).
(4) Remove speaker mounti ng screws (Fi g. 17).
(5) Remove speaker and di sconnect the wi re har-
ness connector.
Fig. 16 FRONT DOOR SPEAKER
1 - FRONT DOOR SPEAKER
2 - MOUNTING SCREW
Fig. 17 INSTRUMENT PANEL SPEAKER
1 - INSTRUMENT PANEL SPEAKER
2 - INSTRUMENT PANEL
8A - 14 AUDIO KJ
SPEAKER (Continued)
REAR DOOR
cabl e.
(2) Remove the rear door tri m panel (Refer to 23 -
BODY/DOORS - REAR/TRI M PANEL - REMOVAL).
(3) Remove the speaker mounti ng screws (Fi g. 18).
(4) Remove the speaker from the door and di scon-
nect the wi re harness connector.
INSTALLATION
FRONT DOOR
(1) Connect the wi re harness connector and i nstal l
the speaker to the door.
(2) I nstal l the speaker mounti ng screws. Ti ghten
to 2 Nm (20 i n. l bs.).
(3) I nstal l the front door tri m panel (Refer to 23 -
BODY/DOOR - FRONT/TRI M PANEL - I NSTALLA-
TI ON).
INSTRUMENT PANEL
(1) Connect wi re harness connector and i nstal l
speaker.
(2) I nstal l speaker mounti ng screws. Ti ghten to 2
Nm (20 i n. l bs.).
(3) I nstal l i nstrument panel top cover (Refer to 23
- BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL TOP COVER - I NSTALLATI ON).
(4) I nstal l the A-pi l l ar tri m (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M - I NSTALLATI ON).
REAR DOOR
(1) Connect the wi re harness connector and i nstal l
the speaker to the door.
(2) I nstal l the speaker mounti ng screws. Ti ghten
to 2 Nm (20 i n. l bs.).
(3) I nstal l the rear door tri m panel (Refer to 23 -
BODY/DOORS - REAR/TRI M PANEL - I NSTALLA-
TI ON).
Fig. 18 REAR DOOR SPEAKER
1 - REAR DOOR SPEAKER
2 - MOUNTING SCREW
KJ AUDIO 8A - 15
SPEAKER (Continued)
CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME WARNING SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - CHIME
WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 6
CHIME WARNING SYSTEM
DESCRIPTION
Fig. 1 Chime Warning System
1 - ELECTROMECHANICAL INSTRUMENT CLUSTER
KJ CHIME/BUZZER 8B - 1
A chi me warni ng system i s standard factory-i n-
stal l ed equi pment on thi s model . The chi me warni ng
system uses a si ngl e chi me tone generator that i s sol -
dered onto the el ectroni c ci rcui t board that i s i ntegral
to the El ectroMechani cal I nstrument Cl uster (EMI C)
to provi de an audi bl e i ndi cati on of vari ous vehi cl e
condi ti ons that may requi re the attenti on of the vehi -
cl e operator or occupants (Fi g. 1). The mi croproces-
sor-based EMI C uti l i zes el ectroni c chi me request
messages recei ved from other el ectroni c modul es i n
the vehi cl e over the Programmabl e Communi cati ons
I nterface (PCI ) data bus network al ong wi th hard
wi red i nputs to the cl uster mi croprocessor to moni tor
many sensors and swi tches throughout the vehi cl e.
I n response to those i nputs, the i ntegrated ci rcui try
and i nternal programmi ng of the EMI C al l ow i t to
control audi bl e outputs that are produced through i ts
on-board chi me tone generator.
The EMI C ci rcui try and i ts chi me tone generator
are capabl e of produci ng each of the four fol l owi ng
audi bl e outputs:
Fixed Duration Beep - A short, sharp, si ngl e
tacti l e beep-l i ke tone that i s about 150 mi l l i seconds
i n durati on.
Single Chime Tone - A si ngl e bong-l i ke chi me
tone.
Slow Rate Repetitive Chime - Repeated
chi me tones that are i ssued at a sl ow rate of about
50 bong-l i ke tones per mi nute.
Fast Rate Repetitive Chime - Repeated chi me
tones that are i ssued at a fast rate of about 180
bong-l i ke tones per mi nute.
Hard wi red ci rcui try connects the EMI C and the
vari ous chi me warni ng system swi tch and sensor
i nputs to thei r el ectroni c modul es and to each other
through the el ectri cal system of the vehi cl e. These
hard wi red ci rcui ts are i ntegral to numerous wi re
harnesses, whi ch are routed throughout the vehi cl e
and retai ned by many di fferent methods. These ci r-
cui ts may be connected to each other, to the vehi cl e
el ectri cal system and to the chi me warni ng system
through the use of a combi nati on of sol dered spl i ces,
spl i ce bl ock connectors, and many di fferent types of
wi re harness termi nal connectors and i nsul ators.
Refer to the appropri ate wi ri ng i nformati on. The wi r-
i ng i nformati on i ncl udes wi ri ng di agrams, proper
ness connectors, spl i ces and grounds.
The EMI C chi me warni ng system ci rcui try and
i ntegral chi me tone generator cannot be adjusted or
repai red. I f the EMI C or the chi me tone generator
are damaged or faul ty, the EMI C uni t must be
repl aced.
OPERATION
The chi me warni ng system i s desi gned to provi de
an audi bl e output as an i ndi cati on of vari ous condi -
ti ons that may requi re the attenti on or awareness of
the vehi cl e operator or occupants. The chi me warni ng
system components operate on battery current
recei ved through a fused B(+) fuse i n the Juncti on
Bl ock (JB) on a non-swi tched fused B(+) ci rcui t so
that the system may operate regardl ess of the i gni -
ti on swi tch posi ti on. However, the chi me warni ng
system al so moni tors the i gni ti on swi tch posi ti on so
that some chi me features wi l l onl y occur wi th i gni -
ti on swi tch i n the On posi ti on, whi l e others occur
regardl ess of the i gni ti on swi tch posi ti on.
The chi me warni ng system provi des an audi bl e
i ndi cati on to the vehi cl e operator or occupants under
the fol l owi ng condi ti ons:
Airbag Indicator Warning - The El ectroMe-
chani cal I nstrument Cl uster (EMI C) chi me tone gen-
erator wi l l generate one, short, bong-l i ke chi me
tone when the i gni ti on swi tch i s i n the On posi ti on,
and an el ectroni c message i s recei ved over the Pro-
grammabl e Communi cati ons I nterface (PCI ) data bus
from the Ai rbag Control Modul e (ACM) requesti ng
Ai rbag i ndi cator i l l umi nati on. Thi s warni ng wi l l
onl y occur fol l owi ng compl eti on of the Ai rbag i ndi -
cator bul b test, and wi l l onl y occur once duri ng an
i gni ti on cycl e. The ACM uses i nternal programmi ng,
hard wi red i nputs from the front Suppl emental
Restrai nt System (SRS) components and, on vehi cl es
so equi pped, el ectroni c messages recei ved over the
PCI data bus from each Si de I mpact Ai rbag Control
Modul e (SI ACM) to determi ne the proper Ai rbag
i ndi cator messages to send to the EMI C.
Anti-Lock Brake Indicator Warning - The
EMI C chi me tone generator wi l l generate one, short,
bong-l i ke chi me tone when the i gni ti on swi tch i s i n
the On posi ti on, and an el ectroni c message i s
recei ved over the PCI data bus from the Control l er
Anti -l ock Brake (CAB) requesti ng Anti l ock Brake
System (ABS) i ndi cator i l l umi nati on. Thi s warni ng
wi l l onl y occur fol l owi ng compl eti on of the ABS
i ndi cator bul b test, and wi l l onl y occur once duri ng
an i gni ti on cycl e. The CAB uses i nternal program-
mi ng, hard wi red i nputs from the Anti l ock Brake
System (ABS) components, and el ectroni c messages
recei ved over the PCI data bus from the Powertrai n
Control Modul e (PCM) to determi ne the proper
ABS i ndi cator messages to send to the EMI C.
Compass Mini-Trip Computer Reset - The
fi xed durati on beep-l i ke chi me tone when the i gni -
ti on swi tch i s i n the On posi ti on, and an el ectroni c
message i s recei ved over the PCI data bus from the
opti onal Compass Mi ni -Tri p Computer (CMTC)
requesti ng that the CMTC el apsed ti me, average fuel
8B - 2 CHIME/BUZZER KJ
CHIME WARNING SYSTEM (Continued)
economy, and/or tri p odometer data has been reset.
The CMTC uses i nternal programmi ng, hard wi red
i nputs from the U.S./Metri c and Reset swi tches, and
el ectroni c messages recei ved from the Body Control
Modul e (BCM) to determi ne the proper reset mes-
sages to send to the EMI C.
Door Ajar Warning - The EMI C chi me tone
generator wi l l generate a si ngl e bong-l i ke chi me
and el ectroni c messages are recei ved over the PCI
data bus from the Body Control Modul e (BCM) i ndi -
cati ng that the status of any door ajar i nput has
changed from cl osed to not cl osed, and from the PCM
i ndi cati ng that the vehi cl e i s movi ng. The BCM uses
i nternal programmi ng, and hard wi red i nputs from
the door ajar swi tches and the i gni ti on swi tch to
determi ne the proper door ajar swi tch messages to
send to the EMI C. The PCM uses i nternal program-
mi ng and a hard wi red vehi cl e speed pul se i nput
recei ved from the BCM to determi ne the proper vehi -
cl e di stance messages to send to the EMI C.
Electrical System Voltage Low or High
Warning - Each ti me the i gni ti on swi tch i s turned to
the On posi ti on, the EMI C chi me tone generator wi l l
generate a si ngl e bong-l i ke chi me tone the fi rst
ti me an el ectroni c message i s recei ved over the PCI
data bus from the PCM requesti ng Chargi ng i ndi -
cator i l l umi nati on. Thi s warni ng woul d i ndi cate that
the moni tored el ectri cal system vol tage i s ei ther too
l ow or too hi gh. Thi s warni ng wi l l onl y occur once
duri ng an i gni ti on cycl e. The PCM uses i nternal pro-
grammi ng and hard wi red i nputs from the el ectri cal
and chargi ng systems to determi ne the proper
Chargi ng i ndi cator messages to send to the EMI C.
Engine Coolant Temperature High Warning
- Each ti me the i gni ti on swi tch i s turned to the On
posi ti on, the EMI C chi me tone generator wi l l gener-
ate bong-l i ke chi me tones the fi rst ti me an el ec-
troni c message i s recei ved over the PCI data bus
from the PCM i ndi cati ng that the engi ne cool ant
temperature i s too hi gh. Thi s chi me wi l l sound for
fi ve consecuti ve si ngl e tones, unl ess an el ectroni c
message i s recei ved from the PCM i ndi cati ng that
the engi ne cool ant temperature i s not too hi gh, or
unl ess the i gni ti on swi tch i s turned to the Off posi -
ti on before the fi ve si ngl e tones have compl eted. The
PCM uses i nternal programmi ng and a hard wi red
i nput from the engi ne cool ant temperature sensor to
determi ne the proper engi ne cool ant temperature
messages to send to the EMI C.
Engine Oil Pressure Low Warning - Each
ti me the i gni ti on swi tch i s turned to the On posi ti on,
the EMI C chi me tone generator wi l l generate a si n-
gl e bong-l i ke chi me tone the fi rst ti me three
sequenti al sets of el ectroni c messages are recei ved
over the PCI data bus from the PCM i ndi cati ng that
the engi ne oi l pressure i s too l ow wi th the engi ne
runni ng. The PCM uses i nternal programmi ng and
hard wi red i nputs from the oi l pressure sensor and
the crankshaft posi ti on sensor to determi ne the
proper oi l pressure and engi ne speed messages to
send to the EMI C.
Fasten Seat Belt Warning - Each ti me the
i gni ti on swi tch i s turned to the On posi ti on, the
EMI C chi me tone generator wi l l generate repeti ti ve
bong-l i ke chi me tones at a sl ow rate the fi rst ti me
an el ectroni c message i s recei ved over the PCI data
bus from the ACM requesti ng Seatbel t i ndi cator
i l l umi nati on. The ACM uses i nternal programmi ng
and hard wi red i nputs from the dri ver si de front seat
bel t swi tch and the i gni ti on swi tch to determi ne that
the dri ver si de front seat bel t i s not fastened wi th
the i gni ti on swi tch i n the On posi ti on. These chi mes
wi l l conti nue to sound for a durati on of about si x sec-
onds each ti me the i gni ti on swi tch i s turned to the
On posi ti on, or unti l the dri ver si de front seat bel t i s
fastened, whi chever occurs fi rst. Thi s audi bl e warn-
i ng occurs i ndependent of the vi sual warni ng pro-
vi ded by the EMI C Seatbel t i ndi cator.
Gate Ajar Warning - The EMI C chi me tone
data bus from the BCM i ndi cati ng that the status of
the tai l gate ajar i nput has changed from cl osed to
not cl osed, and from the PCM i ndi cati ng that the
vehi cl e i s movi ng. The BCM uses i nternal program-
mi ng, and hard wi red i nputs from the tai l gate ajar
swi tch and the i gni ti on swi tch to determi ne the
proper tai l gate ajar swi tch messages to send to the
EMI C. The PCM uses i nternal programmi ng and a
hard wi red vehi cl e speed pul se i nput recei ved from
the BCM to determi ne the proper vehi cl e di stance
messages to send to the EMI C.
Glass Ajar Warning - The EMI C chi me tone
data bus from the BCM i ndi cati ng that the status of
the rear fl i p-up gl ass ajar i nput has changed from
cl osed to not cl osed, and from the PCM i ndi cati ng
that the vehi cl e i s movi ng. The BCM uses i nternal
programmi ng, and hard wi red i nputs from the fl i p-up
gl ass ajar swi tch and the i gni ti on swi tch to deter-
mi ne the proper fl i p-up gl ass ajar swi tch messages to
send to the EMI C. The PCM uses i nternal program-
mi ng and a hard wi red vehi cl e speed pul se i nput
recei ved from the BCM to determi ne the proper vehi -
cl e di stance messages to send to the EMI C.
Head/Park/Fog Lights-On Warning - The
EMI C chi me tone generator wi l l generate repeti ti ve
bong-l i ke chi me tones at a fast rate when the i gni -
ti on swi tch i s i n any posi ti on except On, and el ec-
troni c messages are recei ved over the PCI data bus
from the BCM i ndi cati ng that the exteri or l i ghts are
On wi th the i gni ti on swi tch i n any posi ti on except
On, and the status of the dri ver si de front door i s not
cl osed. The BCM uses i nternal programmi ng and
hard wi red i nputs from the l eft (l i ghti ng) control
stal k of the mul ti -functi on swi tch, the i gni ti on
swi tch, and the dri ver si de front door ajar swi tch to
determi ne the proper messages to send to the EMI C.
These chi mes wi l l conti nue to sound unti l the exte-
ri or l i ghti ng i s turned Off, unti l the i gni ti on swi tch i s
turned to the On posi ti on, or unti l the status of the
dri ver si de front door ajar i nput changes from not
cl osed to cl osed, whi chever occurs fi rst.
Key-In-Ignition Warning - The EMI C chi me
tone generator wi l l generate repeti ti ve bong-l i ke
chi me tones at a fast rate when the i gni ti on swi tch i s
i n any posi ti on except On, and el ectroni c messages
are recei ved over the PCI data bus from the BCM
i ndi cati ng that the key i s i n the i gni ti on l ock cyl i nder
wi th the i gni ti on swi tch i n any posi ti on except On,
and the dri ver si de front door i s not cl osed. The BCM
i nternal programmi ng and hard wi red i nputs from
the key-i n i gni ti on ci rcui try of the i gni ti on swi tch,
the i gni ti on swi tch, and the dri ver si de front door
ajar swi tch to determi ne the proper messages to send
to the EMI C. These chi mes wi l l conti nue to sound
unti l the key i s removed from the i gni ti on l ock cyl i n-
der, unti l the i gni ti on swi tch i s turned to the On
posi ti on, or unti l the status of the dri ver si de front
door ajar i nput changes from not cl osed to cl osed,
whi chever occurs fi rst.
Low Coolant Warning - On vehi cl es equi pped
wi th a di esel engi ne, the EMI C chi me tone generator
wi l l generate a si ngl e bong-l i ke chi me tone when
the i gni ti on swi tch i s fi rst turned to the On posi ti on
and a hard wi red i nput from the engi ne cool ant l evel
sensor to the EMI C i ndi cates that the cool ant l evel i s
l ow for more than about one-quarter second. Any
ti me after the i gni ti on swi tch i s fi rst turned to the
On posi ti on, the EMI C uses i nternal programmi ng to
check the status of the engi ne cool ant l evel sensor
i nputs about once every second, then adjusts an
i nternal counter up or down based upon the status of
thi s i nput. When the counter accumul ates thi rty
i nputs i ndi cati ng that the cool ant l evel i s l ow, a si n-
gl e chi me tone i s sounded. Thi s strategy i s i ntended
to reduce the effect that cool ant sl oshi ng wi thi n the
cool ant reservoi r can have on rel i abl e chi me warni ng
operati on. Thi s warni ng wi l l onl y occur once duri ng
an i gni ti on cycl e.
Low Fuel Warning - Each ti me the i gni ti on
swi tch i s turned to the On posi ti on, the EMI C chi me
tone generator wi l l generate a si ngl e bong-l i ke
chi me tone the fi rst ti me an el ectroni c message i s
recei ved over the PCI data bus from the PCM
requesti ng Low Fuel i ndi cator i l l umi nati on. The
chi me wi l l onl y occur a second ti me duri ng the same
i gni ti on cycl e i f another el ectroni c message has been
recei ved from the PCM i ndi cati ng that there i s an
i ncrease i n the fuel l evel equal to about 3 l i ters (0.8
gal l on), then a subsequent el ectroni c message from
the PCM requests Low Fuel i ndi cator i l l umi nati on.
Thi s strategy combi ned wi th fi l teri ng performed by
the i nternal programmi ng of the PCM on the fuel
tank sendi ng uni t i nput i s i ntended to reduce the
possi bi l i ty of fuel sl oshi ng wi thi n the fuel tank caus-
i ng mul ti pl e l ow fuel warni ng chi mes duri ng a gi ven
i gni ti on cycl e. The EMI C wi l l al so respond wi th the
l ow fuel warni ng chi me when el ectroni c fuel l evel
messages are recei ved from the PCM i ndi cati ng that
the hard wi red i nput to the PCM from the fuel tank
sendi ng uni t i s an open ci rcui t (greater than ful l ), or
a short ci rcui t (l ess than empty).
Low Washer Fluid Warning - The EMI C
chi me tone generator wi l l generate a si ngl e bong-
l i ke chi me tone when the i gni ti on swi tch i s turned
to the On posi ti on and a hard wi red i nput from the
washer fl ui d l evel swi tch to the EMI C i ndi cates the
washer fl ui d i s l ow for more than about one-quarter
second. Any ti me after the i gni ti on swi tch i s fi rst
turned to the On posi ti on, the EMI C uses i nternal
programmi ng to check the status of the washer fl ui d
l evel swi tch i nputs about once every second, then
adjusts an i nternal counter up or down based upon
the status of thi s i nput. When the counter accumu-
l ates thi rty i nputs i ndi cati ng that the washer fl ui d
l evel i s l ow, a si ngl e chi me tone i s sounded. Thi s
strategy i s i ntended to reduce the effect that fl ui d
sl oshi ng wi thi n the washer reservoi r can have on
rel i abl e chi me warni ng operati on. Thi s warni ng wi l l
onl y occur once duri ng an i gni ti on cycl e.
Overspeed Warning - The EMI C chi me tone
generator wi l l generate repeti ti ve bong-l i ke chi me
tones at a sl ow rate when the i gni ti on swi tch i s i n
the On posi ti on, and an el ectroni c message recei ved
over the PCI data bus from the PCM i ndi cates that
the vehi cl e speed i s over a programmed speed val ue.
The PCM uses i nternal programmi ng and di stance
pul se i nformati on recei ved over a hard wi red vehi cl e
speed pul se i nput from the BCM to determi ne the
proper vehi cl e speed messages to send to the EMI C.
The BCM uses an i nternal l y programmed el ectroni c
pi ni on factor and a hard wi red i nput from the rear
wheel speed sensor to cal cul ate the proper di stance
pul se i nformati on to send to the PCM. The el ectroni c
pi ni on factor represents the proper ti re si ze and axl e
rati o i nformati on for the vehi cl e. These chi mes wi l l
conti nue to sound unti l the vehi cl e speed messages
are bel ow the programmed speed val ue, or unti l the
i gni ti on swi tch i s turned to the Off posi ti on, whi ch-
ever occurs fi rst. The overspeed warni ng feature i s
onl y enabl ed on a BCM that has been programmed
wi th a Mi ddl e East Gul f Coast Country (GCC) coun-
try code.
No Airbag Indicator Message Warning - The
bong-l i ke chi me tone and turn on the Ai rbag i ndi -
cator when the i gni ti on swi tch i s i n the On posi ti on,
and a PCI data bus Ai rbag i ndi cator on or off mes-
sage i s not recei ved from the ACM for si x consecuti ve
seconds.
No Antilock Brake Indicator Message Warn-
ing - The EMI C chi me tone generator wi l l generate
one, short, bong-l i ke chi me tone and turn on the
ABS i ndi cator when the i gni ti on swi tch i s i n the On
posi ti on, and a PCI data bus ABS i ndi cator on or
off message i s not recei ved from the CAB for si x con-
secuti ve seconds.
No Fuel Level Message Warning - The EMI C
chi me tone generator wi l l generate one, short, bong-
l i ke chi me tone and turn on the Low Fuel i ndi ca-
tor when the i gni ti on swi tch i s i n the On posi ti on,
and a PCI data bus fuel l evel message i s not recei ved
from the PCM for twel ve consecuti ve seconds.
Remote Keyless Entry Transmitter Pro-
gramming - On vehi cl es so equi pped, the EMI C
chi me tone generator wi l l generate a si ngl e bong-
l i ke chi me tone when an el ectroni c message i s
recei ved over the PCI data bus from the BCM i ndi -
cati ng that a Remote Keyl ess Entry (RKE) transmi t-
ter has been successful l y programmed by the
customer i nto the RKE modul e memory.
Sentry Key Immobilizer System Transpon-
der Programming - On vehi cl es so equi pped, the
EMI C chi me tone generator wi l l generate a si ngl e
bong-l i ke chi me tone when an el ectroni c message i s
recei ved over PCI data bus message from the Sentry
Key I mmobi l i zer Modul e (SKI M) i ndi cati ng that the
Sentry Key I mmobi l i zer System (SKI S) has been
pl aced i n the Customer Learn programmi ng mode,
and agai n each ti me a new SKI S transponder has
been successful l y programmed by the customer.
Turn Signal Cancel Warning - The EMI C
chi me tone generator wi l l generate repeti ti ve bong-
l i ke chi me tones at a sl ow rate when the vehi cl e i s
dri ven for a di stance of about 3.2 ki l ometers (about
two mi l es) wi th a turn si gnal i ndi cator fl ashi ng. The
EMI C uses an el ectroni c message recei ved over the
PCI data bus from the PCM, and a hard wi red i nput
from the turn si gnal swi tch ci rcui try of the mul ti -
functi on swi tch to determi ne when to sound the turn
si gnal cancel warni ng. The PCM uses i nternal pro-
grammi ng and di stance pul se i nformati on recei ved
over a hard wi red vehi cl e speed pul se i nput from the
BCM to determi ne the proper vehi cl e speed messages
to send to the EMI C. The BCM uses an i nternal l y
programmed el ectroni c pi ni on factor and a hard
wi red i nput from the rear wheel speed sensor to cal -
cul ate the proper di stance pul se i nformati on to send
to the PCM. The el ectroni c pi ni on factor represents
the proper ti re si ze and axl e rati o i nformati on for the
vehi cl e. These chi mes wi l l conti nue to sound unti l
the turn si gnal i s turned Off, unti l the hazard warn-
i ng system i s turned On, or unti l the i gni ti on swi tch
i s turned to the Off posi ti on, whi chever occurs fi rst.
Water-In-Fuel Warning - On vehi cl es equi pped
wi th a di esel engi ne, each ti me the i gni ti on swi tch i s
turned to the On posi ti on, the EMI C chi me tone gen-
erator wi l l generate a si ngl e bong-l i ke chi me tone
the fi rst ti me an el ectroni c message i s recei ved over
the PCI data bus from the PCM requesti ng Water-
i n-Fuel i ndi cator i l l umi nati on. The PCM uses i nter-
nal programmi ng and a hard wi red i nput from the
water-i n-fuel sensor to determi ne the proper water-
i n-fuel messages to send to the EMI C. Thi s warni ng
wi l l onl y occur once duri ng an i gni ti on cycl e.
The EMI C provi des chi me servi ce for al l avai l abl e
features i n the chi me warni ng system. The EMI C
rel i es upon i ts i nternal programmi ng and hard wi red
i nputs from the turn si gnal (mul ti -functi on) swi tch,
the washer fl ui d l evel swi tch, and the engi ne cool ant
l evel sensor (di esel engi ne onl y) to provi de chi me ser-
vi ce for the turn si gnal cancel warni ng, the l ow
washer fl ui d warni ng, and the l ow cool ant warni ng
respecti vel y. The EMI C rel i es upon el ectroni c mes-
sage i nputs recei ved from other el ectroni c modul es
over the PCI data bus network to provi de chi me ser-
vi ce for al l of the remai ni ng chi me warni ng system
features. Upon recei vi ng the proper i nputs, the EMI C
acti vates the i ntegral chi me tone generator to pro-
vi de the audi bl e chi me warni ng to the vehi cl e opera-
tor. The i nternal programmi ng of the EMI C
determi nes the pri ori ty of each chi me request i nput
that i s recei ved, as wel l as the rate and durati on of
each chi me tone that i s to be generated. See the own-
ers manual i n the vehi cl e gl ove box for more i nfor-
mati on on the features provi ded by the chi me
warni ng system.
The hard wi red chi me warni ng system i nputs to
the EMI C, as wel l as other hard wi red ci rcui ts for
thi s system may be di agnosed and tested usi ng con-
venti onal di agnosti c tool s and procedures. However,
conventi onal di agnosti c methods may not prove con-
cl usi ve i n the di agnosi s of the EMI C, the PCI data
bus network, or the el ectroni c message i nputs used
by the EMI C to provi de chi me warni ng system ser-
vi ce. The most rel i abl e, effi ci ent, and accurate means
to di agnose the EMI C, the PCI data bus network,
and the el ectroni c message i nputs for the chi me
warni ng system requi res the use of a DRBI I I scan
tool . Refer to the appropri ate di agnosti c i nformati on.
DIAGNOSIS AND TESTING - CHIME WARNING
SYSTEM
the EMI C, as wel l as other hard wi red ci rcui ts for
thi s system may be di agnosed and tested usi ng con-
venti onal di agnosti c tool s and procedures. However,
conventi onal di agnosti c methods may not prove con-
cl usi ve i n the di agnosi s of the EMI C, the PCI data
bus network, or the el ectroni c message i nputs used
by the EMI C to provi de chi me warni ng system ser-
vi ce. The most rel i abl e, effi ci ent, and accurate means
to di agnose the EMI C, the PCI data bus network,
and the el ectroni c message i nputs for the chi me
warni ng system requi res the use of a DRBI I I scan
the El ectroMechani cal I nstrument Cl uster (EMI C),
as wel l as other hard wi red ci rcui ts for thi s system
may be di agnosed and tested usi ng conventi onal
di agnosti c tool s and procedures. However, conven-
ti onal di agnosti c methods may not prove concl usi ve
i n the di agnosi s of the EMI C, the Programmabl e
Communi cati ons I nterface (PCI ) data bus network, or
the el ectroni c message i nputs used by the EMI C to
provi de chi me warni ng system servi ce. The most rel i -
abl e, effi ci ent, and accurate means to di agnose the
EMI C, the PCI data bus network, and the el ectroni c
message i nputs for the chi me warni ng system
requi res the use of a DRBI I I scan tool . Refer to the
appropri ate di agnosti c i nformati on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG,
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . 1
BODY CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - BODY CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COMMUNICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONTROLLER ANTILOCK BRAKE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR . . . . 10
OPERATION - DATA LINK CONNECTOR . . . . . . 10
POWERTRAIN CONTROL MODULE
DESCRIPTION
DESCRIPTION - PCM . . . . . . . . . . . . . . . . . . 11
DESCRIPTION - MODES OF OPERATION . . . 11
DESCRIPTION - 5 VOLT SUPPLIES . . . . . . . 13
DESCRIPTION - IGNITION CIRCUIT SENSE . 13
DESCRIPTION - POWER GROUNDS . . . . . . 13
DESCRIPTION - SENSOR RETURN . . . . . . . 14
OPERATION
OPERATION - PCM . . . . . . . . . . . . . . . . . . . . 14
OPERATION - 5 VOLT SUPPLIES . . . . . . . . . 15
OPERATION - IGNITION CIRCUIT SENSE . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
STANDARD PROCEDURE - TCM QUICK
LEARN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HEATED SEAT MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING - HEATED SEAT
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
ELECTRONIC CONTROL
MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING
NOTE: Before replacing the PCM for a failed driver,
control circuit, or ground circuit, be sure to check
the related component/circuit integrity for failures
not detected due to a double fault in the circuit.
Most PCM driver/control circuit failures are caused
by internal component failures (i.e. relays and sole-
noids) and shorted circuits (i.e. pull-ups, drivers,
and switched circuits). These failures are difficult to
detect when a double fault has occurred and only
one DTC has been set.
When a PCM (JTEC) and the SKI M are repl aced
at the same ti me, perform the fol l owi ng steps i n
order:
(1) Program the new PCM (JTEC).
(2) Program the new SKI M.
(3) Repl ace al l i gni ti on keys and program them to
the new SKI M.
PROGRAMMING THE PCM (JTEC)
The SKI S Secret Key i s an I D code that i s uni que
to each SKI M. Thi s code i s programmed and stored
i n the SKI M, the PCM, and the i gni ti on key tran-
sponder chi p(s). When repl aci ng the PCM, i t i s nec-
essary to program the secret key i nto the new PCM
usi ng the DRBI I I scan tool . Perform the fol l owi ng
steps to program the secret key i nto the PCM.
(1) Turn the i gni ti on swi tch to the On posi ti on
(transmi ssi on i n Park/Neutral ).
(2) Use the DRBI I I and sel ect THEFT ALARM,
SKI M, then MI SCELLANEOUS.
(3) Sel ect PCM REPLACED (GAS ENGI NE).
(4) Enter secured access mode by enteri ng the
vehi cl e four-di gi t PI N.
(5) Sel ect ENTER to update PCM VI N.
KJ ELECTRONIC CONTROL MODULES 8E - 1
NOTE: If three attempts are made to enter secured
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lockout mode, turn the ignition switch to
the ON position for one hour, then enter the correct
PIN. (Ensure all accessories are turned off. Also
monitor the battery state and connect a battery
charger if necessary).
(6) Press ENTER to transfer the secret key (the
SKI M wi l l send the secret key to the PCM).
(7) Press PAGE BACK to get to the Sel ect System
menu and sel ect ENGI NE, MI SCELLANEOUS, and
SRI MEMORY CHECK.
(8) The DRBI I I wi l l ask, I s odometer readi ng
between XX and XX? Sel ect the YES or NO button
on the DRBI I I . I f NO i s sel ected, the DRBI I I wi l l
read, Enter Odometer Readi ng (From I .P. odome-
ter). Enter the odometer readi ng from the i nstru-
ment cl uster and press ENTER.
PROGRAMMING THE SKIM
(3) Sel ect PCM REPLACED (GAS ENGI NE).
(4) Program the vehi cl e four-di gi t PI N i nto SKI M.
(5) Sel ect COUNTRY CODE and enter the correct
country.
NOTE: Be sure to enter the correct country code. If
the incorrect country code is programmed into
SKIM, it cannot be changed and the SKIM must be
replaced.
(6) Sel ect YES to update VI N (the SKI M wi l l l earn
the VI N from the PCM).
(7) Press ENTER to transfer the secret key (the
PCM wi l l send the secret key to the SKI M).
(8) Program i gni ti on keys to the SKI M.
NOTE: If the PCM and the SKIM are replaced at the
same time, all vehicle ignition keys will need to be
replaced and programmed to the new SKIM.
PROGRAMMING IGNITION KEYS TO THE SKIM
(3) Sel ect PROGRAM I GNI TI ON KEYS.
(4) Enter secured access mode by enteri ng the
vehi cl e four-di gi t PI N.
NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM it (the
key) cannot be transferred to another vehicle.
(5) Obtai n i gni ti on keys to be programmed from
the customer (8 keys maxi mum).
(6) Usi ng the DRBI I I , erase al l i gni ti on keys by
sel ecti ng MI SCELLANEOUS, and ERASE ALL CUR-
RENT I GN. KEYS.
(7) Program al l of the i gni ti on keys.
I f i gni ti on key programmi ng i s unsuccessful , the
DRBI I I wi l l di spl ay one of the fol l owi ng messages:
Programming Not Attempted - The DRBI I I
attempts to read the programmed key status and
there are no keys programmed i nto SKI M memory.
Programming Key Failed (Possible Used
Key FromWrong Vehicle) - SKI M i s unabl e to pro-
gram an i gni ti on key transponder due to one of the
fol l owi ng:
The i gni ti on key transponder i s faul ty.
The i gni ti on key transponder i s or has been
al ready programmed to another vehi cl e.
8 Keys Already Learned, Programming Not
Done - The SKI M transponder I D memory i s ful l .
Learned Key In Ignition - The I D for the i gni -
ti on key transponder currentl y i n the i gni ti on l ock
cyl i nder i s al ready programmed i n SKI M memory.
BODY CONTROL MODULE
DESCRIPTION
A Body Control Modul e (BCM) i s conceal ed behi nd
the dri ver si de end of the i nstrument panel i n the
passenger compartment, where i t i s secured to the
fuse panel si de of the Juncti on Bl ock (JB) wi th four
screws (Fi g. 1). The JB i s the i nterface between the
body, the i nstrument panel , and the headl amp and
dash wi re harnesses. The JB al so contai ns the fuses
and rel ays used for the i nteri or el ectri cal system of
the vehi cl e. The BCM i s encl osed i n a mol ded pl asti c
housi ng wi th two i ntegral external connector recepta-
cl es that connect i t to the vehi cl e el ectri cal system
through two take outs wi th connectors from the
i nstrument panel wi re harness (Fi g. 2). The BCM
al so has an i ntegral i nterface connector conceal ed on
the back si de of the uni t that joi ns i t through a con-
nector receptacl e that i s i ntegral to the JB housi ng to
the ci rcui try wi thi n the JB. Thi s connector i s referred
to as the JB-BCM connector. The combi ned BCM and
JB are someti mes referred to as the Juncti on Bl ock
Modul e (JBM).
8E - 2 ELECTRONIC CONTROL MODULES KJ
ELECTRONIC CONTROL MODULES (Continued)
There are two di fferent versi ons of the BCM: base
and premi um. The base BCM i s a subset of the com-
ponents i n the premi um versi on. Basi cal l y, the base
versi on BCM does not support the fol l owi ng features:
Compass Mi ni -Tri p Computer (CMTC), fog l amps
(front and/or rear), Remote Keyl ess Entry (RKE),
remote radi o swi tches, or Vehi cl e Theft Securi ty Sys-
tem (VTSS). Both versi ons of the BCM uti l i ze i nte-
grated ci rcui try and i nformati on carri ed on the
bus network al ong wi th many hard wi red i nputs to
moni tor many sensor and swi tch i nputs throughout
the vehi cl e. I n response to those i nputs, the i nternal
ci rcui try and programmi ng of the BCM al l ow i t to
control and i ntegrate many el ectroni c functi ons and
features of the vehi cl e through both hard wi red out-
puts and the transmi ssi on of el ectroni c message out-
puts to other el ectroni c modul es i n the vehi cl e over
the PCI data bus. The el ectroni c functi ons and fea-
tures that the BCM supports or control s i ncl ude the
fol l owi ng:
A/C Select Switch Status - The BCM moni tors
an i nput from, and transmi ts the status of the A/C
swi tch on the heater-A/C control .
Ambient Temperature Data - The premi um
BCM moni tors and transmi ts the ambi ent tempera-
ture sensor i nput data.
Cargo Lamp Disable - The BCM moni tors an
i nput from the cargo l amp swi tch to provi de an i nte-
ri or l i ghti ng di sabl e feature.
Chimes - The chi me tone generator i s l ocated
on the El ectroMechani cal I nstrument Cl uster (EMI C)
ci rcui t board, but the EMI C goes to sl eep wi th the
i gni ti on swi tch i n the Off posi ti on. The BCM provi des
a wake-up output to the EMI C based upon i nputs
from the key-i n i gni ti on swi tch or the exteri or l i ght-
i ng swi tch, then sends el ectroni c chi me request mes-
sages to the EMI C for the headl amps-on warni ng
and key-i n i gni ti on warni ng.
Door Lock Inhibit - The BCM moni tors the
key-i n i gni ti on swi tch and the dri ver si de front door
ajar swi tch to provi de a door l ock i nhi bi t feature.
Exterior Lamp Load Shedding - The BCM
provi des a battery saver feature whi ch wi l l automat-
i cal l y turn off exteri or l amps that remai n on after a
ti med i nterval .
Exterior Lamp Status - The BCM moni tors
the status of the park l amp, l ow beam, hi gh beam or
Dayti me Runni ng Lamp (DRL - Canada onl y), front
fog l amp (opti onal ), and rear fog l amp (i n requi red
markets onl y) rel ays.
Exterior Lighting Control - The BCM pro-
vi des exteri or l amp control for standard head and
park l amps, as wel l as Dayti me Runni ng Lamps
(DRL - Canada onl y), front fog l amps (opti onal ), and
rear fog l amps (i n requi red markets onl y). Thi s
i ncl udes support for features i ncl udi ng opti cal horn
(al so known as fl ash-to-pass) and headl amp ti me
del ay.
Flip-Up Glass Control - The BCM moni tors
the tai l gate cyl i nder l ock swi tch, the tai l gate handl e
swi tch, the Remote Keyl ess Entry (RKE) modul e
i nputs and the rear wi per swi tch to provi de control
for the rear fl i p-up gl ass actuator.
Fig. 1 Body Control Module Location
1 - DRIVER DOOR
2 - INSTRUMENT PANEL END BRACKET
3 - JUNCTION BLOCK
4 - BODY CONTROL MODULE
Fig. 2 Body Control Module
1 - BODY CONTROL MODULE (FRONT VIEW)
2 - REMOTE KEYLESS ENTRY MODULE RECEPTACLE
3 - BCM-RKE CONNECTOR
4 - BODY CONTROL MODULE (BACK VIEW)
5 - JB-BCM CONNECTOR
6 - CONNECTOR RECEPTACLE (2)
BODY CONTROL MODULE (Continued)
Fog Lamp Control - The premi um BCM pro-
vi des fog l amp control for front fog l amps (opti onal ),
and rear fog l amps (i n requi red markets onl y).
Front Wiper System Status - The BCM moni -
tors the status of the front wi per motor park swi tch.
Fuel Economy and Distance to Empty Cal-
culations - The BCM cal cul ates and transmi ts the
fuel economy and Di stance To Empty (DTE) data.
Headlamp Time Delay - The BCM provi des a
headl amp ti me del ay feature wi th the i gni ti on swi tch
i n the Off posi ti on.
Heated Rear Glass Control - The BCM pro-
vi des control and ti mer functi ons for the heated rear
gl ass feature and transmi ts the system status.
Ignition On/Off Timer - The BCM moni tors
and transmi ts the el apsed i gni ti on On ti mer data
and moni tors the i gni ti on Off ti me.
Ignition Switch Position Status - The BCM
moni tors and transmi ts the status of the i gni ti on
swi tch.
Instrument Panel Dimming - The BCM mon-
i tors and transmi ts the sel ected i l l umi nati on i nten-
si ty l evel of the panel l amps di mmer swi tch.
Interior Lamp Load Shedding - The BCM
provi des a battery saver feature whi ch wi l l automat-
i cal l y turn off al l i nteri or l amps that remai n on after
a ti med i nterval .
Interior Lighting Control - The BCM moni -
tors i nputs from the i nteri or l i ghti ng swi tch, the door
ajar swi tches, the fl i p-up gl ass ajar swi tch, the tai l -
gate ajar swi tch, the cargo l amp swi tch, the readi ng
l amp swi tches, and the Remote Keyl ess Entry (RKE)
modul e to provi de courtesy l amp control . Thi s
i ncl udes support for ti med i l l umi nated entry wi th
theater-styl e fade-to-off and courtesy i l l umi nati on
defeat features.
Intermittent Wipe and Front Wiper System
Control - The BCM moni tors i nputs from the front
wi per and washer swi tch and the front wi per motor
park swi tch to provi de front wi per system control
through the wi per on/off and hi gh/l ow rel ays. Thi s
i ncl udes support for adjustabl e i ntermi ttent wi pe,
mi st wi pe (al so known as pul se wi pe), and wi pe-after-
wash features.
Key-In-Ignition Switch Status - The BCM
moni tors and transmi ts the status of the key-i n-i gni -
ti on swi tch.
Panic Mode - The BCM provi des support for
the Remote Keyl ess Entry (RKE) system pani c mode
feature.
Parade Mode - The BCM provi des a parade
mode (al so known as funeral mode) that al l ows the
i nteri or Vacuum Fl uorescent Di spl ays (VFD) to be
i l l umi nated at ful l i ntensi ty whi l e dri vi ng i n dayl i ght
wi th the exteri or l amps On.
Power Locks - The BCM moni tors i nputs from
the power l ock swi tches and the Remote Keyl ess
Entry (RKE) modul e (opti onal ) to provi de control of
the power l ock motors through outputs to the l ock,
unl ock, and dri ver unl ock (RKE onl y) rel ays. Thi s
i ncl udes support for rol l i ng door l ocks (al so known as
automati c door l ocks) and a door l ock i nhi bi t mode.
Programmable Features - The BCM provi des
support for several standard and opti onal program-
mabl e features, i ncl udi ng: rol l i ng door l ocks, head-
l amp ti me del ay i nterval , Remote Keyl ess Entry
(RKE) dri ver-door-onl y or unl ock-al l -doors, RKE opti -
cal chi rp, and RKE audi bl e chi rp.
Remote Keyless Entry - The premi um BCM
provi des the opti onal Remote Keyl ess Entry (RKE)
system features, i ncl udi ng support for the RKE Lock,
Unl ock (wi th opti onal dri ver-door-onl y unl ock, and
unl ock-al l -doors), rear fl i p-up gl ass control , Pani c,
audi bl e chi rp, opti cal chi rp, and i l l umi nated entry
modes, as wel l as the abi l i ty to be programmed to
recogni ze up to four RKE transmi tters.
Rolling Door Locks - The BCM provi des sup-
port for the power l ock system rol l i ng door l ocks fea-
ture (al so known as automati c door l ocks).
Tailgate and Flip-Up Glass Ajar Status - The
BCM moni tors and transmi ts the status of the tai l -
gate and rear fl i p-up gl ass ajar swi tches.
Remote Radio Switch Interface - The pre-
mi um BCM moni tors and transmi ts the status of the
opti onal remote radi o swi tches.
Self-Diagnostics - The BCM provi des support
for di agnosti cs through communi cati on wi th the
DRBI I I scan tool over the PCI data bus network.
Each anal og and di gi tal i nput can be veri fi ed, and
each output can be actuated through the use of thi s
di agnosti c protocol . The BCM al so stores Di agnosti c
Troubl e Codes (DTCs) to assi st i n troubl eshooti ng
thi s uni t.
Vacuum Fluorescent Display Synchroniza-
tion - The BCM transmi ts panel l amp i ntensi ty data
whi ch al l ows modul es wi th Vacuum Fl uorescent Di s-
pl ays (VFD) to coordi nate thei r i l l umi nati on i nten-
si ty.
Vehicle Speed System - The BCM moni tors a
vehi cl e speed i nput from the vehi cl e speed sensor
(wi thout Anti l ock Brake System [ABS]) or from the
Control l er Anti l ock Brake (CAB)(wi th ABS), cal cu-
l ates the vehi cl e speed based upon a programmed
axl e rati o/ti re si ze (el ectroni c pi ni on factor), and
transmi ts the vehi cl e speed i nformati on to the Pow-
ertrai n Control Modul e (PCM) on a hard wi red out-
put ci rcui t.
Vehicle Theft Security System - The pre-
mi um BCM moni tors i nputs from the door cyl i nder
l ock swi tches, the tai l gate cyl i nder l ock swi tch, the
door ajar swi tches, the tai l gate ajar swi tch, the
fl i p-up gl ass ajar swi tch, the hood ajar swi tch (i n
requi red markets onl y), and the Remote Keyl ess
Entry (RKE) modul e to control the features of the
opti onal Vehi cl e Theft Securi ty System (VTSS).
Hard wi red ci rcui try connects the BCM to the el ec-
tri cal system of the vehi cl e. These hard wi red ci rcui ts
are i ntegral to several wi re harnesses, whi ch are
routed throughout the vehi cl e and retai ned by many
di fferent methods. These ci rcui ts may be connected to
each other, to the vehi cl e el ectri cal system and to the
BCM through the use of a combi nati on of sol dered
spl i ces, spl i ce bl ock connectors, and many di fferent
types of wi re harness termi nal connectors and i nsu-
l ators. Refer to the appropri ate wi ri ng i nformati on.
The wi ri ng i nformati on i ncl udes wi ri ng di agrams,
proper wi re and connector repai r procedures, further
detai l s on wi re harness routi ng and retenti on, as wel l
as pi n-out and l ocati on vi ews for the vari ous wi re
Many of the el ectroni c features i n the vehi cl e con-
trol l ed or supported by the BCM are programmabl e
usi ng a customer programmi ng procedure or the
DRBI I I scan tool . I n addi ti on, the BCM software i s
Fl ash compati bl e, whi ch means i t can be repro-
grammed usi ng Fl ash reprogrammi ng procedures.
However, i f any of the BCM hardware components i s
damaged or faul ty, the enti re BCM uni t must be
repl aced.
OPERATION
The mi croprocessor-based Body Control Modul e
(BCM) moni tors many hard wi red swi tch and sensor
i nputs as wel l as those resources i t shares wi th other
el ectroni c modul es i n the vehi cl e through i ts commu-
ni cati on over the Programmabl e Communi cati ons
I nterface (PCI ) data bus network. The i nternal pro-
grammi ng and al l of these i nputs al l ow the BCM
mi croprocessor to determi ne the tasks i t needs to
perform and thei r pri ori ti es, as wel l as both the stan-
dard and opti onal features that i t shoul d provi de.
The BCM programmi ng then performs those tasks
and provi des those features through both PCI data
bus communi cati on wi th other el ectroni c modul es
and through hard wi red outputs through a number of
dri ver ci rcui ts, rel ays, and actuators. These outputs
al l ow the BCM the abi l i ty to control numerous acces-
sory systems i n the vehi cl e.
The BCM operates on battery current recei ved
through a fuse i n the Juncti on Bl ock (JB) on a non-
swi tched fused B(+) ci rcui t, through another fuse i n
the JB on a fused i gni ti on swi tch output (run-start)
ci rcui t, and through a thi rd fuse i n the JB on a fused
i gni ti on swi tch output (run-acc) ci rcui t. Thi s arrange-
ment al l ows the BCM to provi de some features
regardl ess of the i gni ti on swi tch posi ti on, whi l e other
features wi l l operate onl y wi th the i gni ti on swi tch i n
the On, Start, and/or Accessory posi ti ons. Al l of the
battery current ci rcui ts are connected to the BCM
through the JB/BCM connector. The BCM recei ves
ground through fi ve separate ci rcui ts. Three of these
ci rcui ts are connected to the BCM through a connec-
tor and take out of the i nstrument panel wi re har-
ness on three separate ground ci rcui ts, whi l e the
other two ci rcui ts are connected to the BCM through
the JB/BCM connector. Al l of these ci rcui ts are
grounded through a spl i ce bl ock l ocated i n the i nstru-
ment panel wi re harness wi th an eyel et termi nal con-
nector that i s secured by a nut to a ground stud on
the dri ver si de i nstrument panel end bracket near
the JB.
The BCM moni tors i ts own i nternal ci rcui try as
wel l as many of i ts i nput and output ci rcui ts, and
wi l l store a Di agnosti c Troubl e Code (DTC) i n el ec-
troni c memory for any fai l ure i t detects. These DTCs
can be retri eved and di agnosed usi ng a DRBI I I scan
HARD WI RED I NPUTS The hard wi red i nputs to
the BCM i ncl ude the fol l owi ng:
A/C on/off control
Ambient temperature sensor signal
Body control module flash enable
Door lock switch mux
Driver door ajar switch sense
Flip-up glass ajar switch sense
Flip-up glass release switch sense
Fog lamp switch sense
Front wiper park switch sense
Front wiper switch mux
Front washer pump driver
Fused B(+)
Fused ignition switch output (run-acc)
Fused ignition switch output (run-start)
Headlamp switch mux
High beam switch sense
Hood ajar switch sense - premium with
VTSS - in markets where required only
Key-in ignition switch sense
Left cylinder lock switch sense - premium
with VTSS only - omitted in some markets as
required
Panel lamps dimmer switch mux
Passenger doors ajar switch sense (input
from three ajar switches connected in parallel)
Radio control mux - premium with remote
radio switches only
Rear courtesy lamp control
Rear window defogger control
Rear wiper intermittent driver
Rear wiper on driver
Right cylinder lock switch sense - premium
with VTSS only - omitted in some markets as
required
RKE antenna (two circuits) - premium with
RKE only
Tailgate ajar switch sense
Tailgate cylinder lock switch sense
Vehicle speed sensor
addi ti onal detai l s.
HARD WI RED OUTPUTS The hard wi red outputs
of the BCM i ncl ude the fol l owi ng:
Courtesy lamp driver
Courtesy lamp load shed
Door lock relay control
Driver door unlock relay control - premium
with RKE only
Flip-up glass release motor driver
Front fog lamp relay control - premium
with front fog lamps only
Front wiper high/low relay control
Front wiper on/off relay control
Hazard lamp control
High beam relay control
Horn relay control - premium with RKE
only
Instrument cluster wake up signal
Low beam relay control
Park lamp relay control
Passenger door unlock relay control
Rear fog lamp relay control - premiumwith
rear fog lamps in markets where required only
Rear window defogger relay control
RKE supply - premium with RKE only
Tailgate lock driver
Tailgate unlock driver
Vehicle speed output
Vehicle speed sensor supply
VTSS indicator driver - premium with
VTSS only
GROUNDS The BCM recei ves ground through fi ve
separate ci rcui ts, and al so suppl i es a ground path to
several swi tches through the fol l owi ng hard wi red
ci rcui ts:
Ambient temperature sensor return
Door lock switch ground
Headlamp switch return
Radio control mux return
RKE ground - premium with RKE only
Tailgate switch ground
COMMUNI CATI ON Not i ncl udi ng the two RKE
antenna ci rcui ts (RKE antenna + and ), whi ch
merel y pass through the premi um BCM from the
RKE modul e to the external RKE antenna i n the
i nstrument panel wi re harness, the BCM has the fol -
l owi ng communi cati on ci rcui ts:
PCI bus
RKE program serial data - premium with
RKE only
RKE transmit serial data - premium with
RKE only
MESSAGI NG The BCM uses the fol l owi ng mes-
sages recei ved from other el ectroni c modul es over the
PCI data bus:
Battery Temperature (PCM)
Compass Mini-Trip Computer Button Sta-
tus (CMTC) - premium only
Coolant Temperature (PCM)
Distance Pulses (PCM)
Engine Speed (PCM)
Fuel Tank Level (PCM)
Fuel Used (PCM)
Intrusion Transceiver Module Commands
(ITM) - premium in markets where required
only
Manifold Absolute Pressure (PCM)
OK to Lock - Rolling Locks (PCM)
SKIS Status (SKIM)
Vehicle Identification Number (PCM)
Vehicle Speed (PCM)
The BCM provi des the fol l owi ng messages to other
el ectroni c modul es over the PCI data bus:
A/C Select Switch Status (PCM)
Country Code (EMIC, PCM, CMTC)
Distance to Empty (CMTC) - premium only
Door Ajar Status (EMIC)
Exterior Lighting Status (EMIC)
Flip-up Glass Ajar Status (EMIC)
Fuel Economy (Average and Instantaneous)
(CMTC) - premium only
Hood Ajar Status (ITM) - premium in mar-
kets where required only
Ignition On Timer (CMTC) - premium only
Intrusion Transceiver Module Commands
(ITM) - premium in markets where required
only
Key-In Ignition Switch Status (EMIC)
Outside Temperature (CMTC) - premium
only
Panel Lamp Intensity (CMTC, Radio)
Tailgate Ajar Status (EMIC)
Radio Mode (Radio) - premium only
Radio Preset Scan (Radio) - premium only
Radio Seek Down (Radio) - premium only
Radio Seek Up (Radio) - premium only
Radio Volume Down (Radio) - premium
only
Radio Volume Up (Radio) - premium only
Vacuum Fluorescent Display Synchroniza-
tion (CMTC, EMIC, Radio)
Vehicle Theft Security System Status (PCM,
ITM) - premium only
Refer to the appropri ate di agnosti c i nformati on for
DIAGNOSIS AND TESTING - BODY CONTROL
MODULE
The hard wi red i nputs to and outputs from the
Body Control Modul e (BCM), as wel l as other hard
wi red ci rcui ts for thi s modul e may be di agnosed and
tested usi ng conventi onal di agnosti c tool s and proce-
dures. However, conventi onal di agnosti c methods
may not prove concl usi ve i n the di agnosi s of the
BCM, the Programmabl e Communi cati ons I nterface
(PCI ) data bus network, or the el ectroni c messages
recei ved and transmi tted by the BCM over the PCI
data bus. The most rel i abl e, effi ci ent, and accurate
means to di agnose the BCM and the PCI data bus
network i nputs to and outputs from thi s modul e
PERSONAL INJURY.
REMOVAL
PERSONAL INJURY.
NOTE: Before replacing a Body Control Module
(BCM), use a DRBIII scan tool to retrieve the cur-
rent settings for the BCM programmable features
and the axle ratio/tire size (electronic pinion factor).
Refer to the appropriate diagnostic information.
These settings should be duplicated in the replace-
ment BCM using the DRBIII scan tool before
returning the vehicle to service.
cabl e.
(2) Remove the Juncti on Bl ock Modul e (JBM) from
the i nstrument panel end bracket on the dri ver si de
of the vehi cl e. (Refer to 8 - ELECTRI CAL/POWER
DI STRI BUTI ON/JUNCTI ON BLOCK - REMOVAL).
(3) Remove the four screws that secure the BCM
to the Juncti on Bl ock (JB) (Fi g. 3).
(4) Remove the BCM from the JB.
(5) I f the vehi cl e i s equi pped wi th the opti onal
Remote Keyl ess Entry (RKE) system, remove the
RKE modul e from the receptacl e on the BCM. (Refer
to 8 - ELECTRI CAL/POWER LOCKS/REMOTE KEY-
LESS ENTRY MODULE - REMOVAL).
INSTALLATION
PERSONAL INJURY.
NOTE: Before replacing a Body Control Module
(BCM), use a DRBIII scan tool to retrieve the cur-
rent settings for the BCM programmable features
and the axle ratio/tire size (electronic pinion factor).
These settings should be duplicated in the replace-
ment BCM using the DRBIII scan tool before
returning the vehicle to service.
(1) I f the vehi cl e i s equi pped wi th the opti onal
Remote Keyl ess Entry (RKE) system, rei nstal l the
RKE modul e i nto the receptacl e on the BCM. (Refer
to 8 - ELECTRI CAL/POWER LOCKS/REMOTE KEY-
LESS ENTRY MODULE - I NSTALLATI ON).
(2) Posi ti on the BCM onto the Juncti on Bl ock (JB)
(Fi g. 3).
(3) I nstal l and ti ghten the four screws that secure
the BCM to the JB. Ti ghten the screws to 2 Nm (18
i n. l bs.).
(4) Rei nstal l the Juncti on Bl ock Modul e (JBM)
onto the i nstrument panel end bracket on the dri ver
si de of the vehi cl e. (Refer to 8 - ELECTRI CAL/
POWER DI STRI BUTI ON/JUNCTI ON BLOCK -
I NSTALLATI ON).
COMMUNICATION
DESCRIPTION
The Dai ml erChrysl er Programmabl e Communi ca-
ti on I nterface (PCI ) data bus system i s a si ngl e wi re
mul ti pl ex system used for vehi cl e communi cati ons on
many Dai ml erChrysl er Corporati on vehi cl es. Mul ti -
pl exi ng i s a system that enabl es the transmi ssi on of
several messages over a si ngl e channel or ci rcui t. Al l
Dai ml erChrysl er vehi cl es use thi s pri nci pl e for com-
muni cati on between vari ous mi croprocessor-based
el ectroni c control modul es. The PCI data bus exceeds
the Soci ety of Automoti ve Engi neers (SAE) J1850
Standard for Cl ass B Mul ti pl exi ng.
Many of the el ectroni c control modul es i n a vehi cl e
requi re i nformati on from the same sensi ng devi ce. I n
the past, i f i nformati on from one sensi ng devi ce was
requi red by several control l ers, a wi re from each con-
trol l er needed to be connected i n paral l el to that sen-
sor. I n addi ti on, each control l er uti l i zi ng anal og
sensors requi red an Anal og/Di gi tal (A/D) converter i n
order to read these sensor i nputs. Mul ti pl exi ng
reduces wi re harness compl exi ty, sensor current
l oads and control l er hardware because each sensi ng
devi ce i s connected to onl y one control l er, whi ch
reads and di stri butes the sensor i nformati on to the
other control l ers over the data bus. Al so, because
each control l er on the data bus can access the con-
trol l er sensor i nputs to every other control l er on the
data bus, more functi on and feature capabi l i ti es are
possi bl e.
I n addi ti on to reduci ng wi re harness compl exi ty,
component sensor current l oads and control l er hard-
ware, mul ti pl exi ng offers a di agnosti c advantage. A
mul ti pl ex system al l ows the i nformati on fl owi ng
between control l ers to be moni tored usi ng a di agnos-
ti c scan tool . The Dai ml erChrysl er system al l ows an
el ectroni c control modul e to broadcast message data
out onto the bus where al l other el ectroni c control
modul es can hear the messages that are bei ng sent.
When a modul e hears a message on the data bus
that i t requi res, i t rel ays that message to i ts mi cro-
processor. Each modul e i gnores the messages on the
data bus that are bei ng sent to other el ectroni c con-
trol modul es.
OPERATION
Data exchange between modul es i s achi eved by
seri al transmi ssi on of encoded data over a si ngl e wi re
broadcast network. The wi re col ors used for the PCI
data bus ci rcui ts are yel l ow wi th a vi ol et tracer, or
vi ol et wi th a yel l ow tracer, dependi ng upon the appl i -
cati on. The PCI data bus messages are carri ed over
the bus i n the form of Vari abl e Pul se Wi dth Modu-
l ated (VPWM) si gnal s. The PCI data bus speed i s an
average 10.4 Ki l o-bi ts per second (Kbps). By compar-
Fig. 3 Body Control Module Remove/Install
1 - SCREW (4)
2 - RKE MODULE
4 - JUNCTION BLOCK
i son, the pri or two-wi re Chrysl er Col l i si on Detecti on
(CCD) data bus system i s desi gned to run at 7.8125
Kbps.
The vol tage network used to transmi t messages
requi res bi asi ng and termi nati on. Each modul e on
the PCI data bus system provi des i ts own bi asi ng
and termi nati on. Each modul e (al so referred to as a
node) termi nates the bus through a termi nati ng
resi stor and a termi nati ng capaci tor. There are two
types of nodes on the bus. The domi nant node termi -
nates the bus through a 1 KW resi stor and a 3300 pF
capaci tor. The Powertrai n Control Modul e (PCM) i s
the onl y domi nant node for the PCI data bus system.
A standard node termi nates the bus through an 11
KW resi stor and a 330 pF capaci tor.
The modul es bi as the bus when transmi tti ng a
message. The PCI bus uses l ow and hi gh vol tage l ev-
el s to generate si gnal s. Low vol tage i s around zero
vol ts and the hi gh vol tage i s about seven and one-
hal f vol ts. The l ow and hi gh vol tage l evel s are gener-
ated by means of vari abl e-pul se wi dth modul ati on to
form si gnal s of varyi ng l ength. The Vari abl e Pul se
Wi dth Modul ati on (VPWM) used i n PCI bus messag-
i ng i s a method i n whi ch both the state of the bus
and the wi dth of the pul se are used to encode bi t
i nformati on. A zero bi t i s defi ned as a short l ow
pul se or a l ong hi gh pul se. A one bi t i s defi ned as a
l ong l ow pul se or a short hi gh pul se. A l ow (passi ve)
state on the bus does not necessari l y mean a zero bi t.
I t al so depends upon pul se wi dth. I f the wi dth i s
short, i t stands for a zero bi t. I f the wi dth i s l ong, i t
stands for a one bi t. Si mi l arl y, a hi gh (acti ve) state
does not necessari l y mean a one bi t. Thi s too depends
upon pul se wi dth. I f the wi dth i s short, i t stands for
a one bi t. I f the wi dth i s l ong, i t stands for a zero bi t.
I n the case where there are successi ve zero or one
data bi ts, both the state of the bus and the wi dth of
the pul se are changed al ternatel y. Thi s encodi ng
scheme i s used for two reasons. Fi rst, thi s ensures
that onl y one symbol per transi ti on and one transi -
ti on per symbol exi sts. On each transi ti on, every
transmi tti ng modul e must decode the symbol on the
bus and begi n ti mi ng of the next symbol . Si nce ti m-
i ng of the next symbol begi ns wi th the l ast transi ti on
detected on the bus, al l of the modul es are re-syn-
chroni zed wi th each symbol . Thi s ensures that there
are no accumul ated ti mi ng errors duri ng PCI data
bus communi cati on.
The second reason for thi s encodi ng scheme i s to
guarantee that the zero bi t i s the domi nant bi t on
the bus. When two modul es are transmi tti ng si mul -
taneousl y on the bus, there must be some form of
arbi trati on to determi ne whi ch modul e wi l l gai n con-
trol . A data col l i si on occurs when two modul es are
transmi tti ng di fferent messages at the same ti me.
When a modul e i s transmi tti ng on the bus, i t i s read-
i ng the bus at the same ti me to ensure message
i ntegri ty. When a col l i si on i s detected, the modul e
that transmi tted the one bi t stops sendi ng messages
over the bus unti l the bus becomes i dl e.
Each modul e i s capabl e of transmi tti ng and recei v-
i ng data si mul taneousl y. The typi cal PCI bus mes-
sage has the fol l owi ng four components:
Message Header - One to three bytes i n l ength.
The header contai ns i nformati on i denti fyi ng the mes-
sage type and l ength, message pri ori ty, target mod-
ul e(s) and sendi ng modul e.
Data Byte(s) - Thi s i s the actual message that
i s bei ng sent.
Cyclic Redundancy Check (CRC) Byte - Thi s
byte i s used to detect errors duri ng a message trans-
mi ssi on.
In-Frame Response (IFR) byte(s) - I f a
response i s requi red from the target modul e(s), i t can
be sent duri ng thi s frame. Thi s functi on i s descri bed
i n greater detai l i n the fol l owi ng paragraph.
The I FR consi sts of one or more bytes, whi ch are
transmi tted duri ng a message. I f the sendi ng modul e
requi res i nformati on to be recei ved i mmedi atel y, the
target modul e(s) can send data over the bus duri ng
the ori gi nal message. Thi s al l ows the sendi ng modul e
to recei ve ti me-cri ti cal i nformati on wi thout havi ng to
wai t for the target modul e to access the bus. After
the I FR i s recei ved, the sendi ng modul e broadcasts
an End of Frame (EOF) message and rel eases control
of the bus.
The PCI data bus can be moni tored usi ng the
DRBI I I scan tool . I t i s possi bl e, however, for the bus
to pass al l DRBI I I tests and sti l l be faul ty i f the
vol tage parameters are al l wi thi n the speci fi ed range
and fal se messages are bei ng sent.
COMMUNICATION (Continued)
CONTROLLER ANTILOCK
BRAKE
REMOVAL
(1) I nstal l the prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the negati ve battery cabl e from the
battery.
(3) Pul l up on the CAB harness connector rel ease
(Fi g. 4)and remove connector.
(4) Remove the pump connector from the CAB.
(5) Remove the CAB mounti ng bol ts (Fi g. 5).
(6) Remove the CAB from the HCU (Fi g. 6).
INSTALLATION
(1) I nstal l CAB to the HCU (Fi g. 6).
(2) I nstal l mounti ng bol ts. Ti ghten to 2 Nm (16 i n.
l bs.).
(3) I nstal l the pump el ecti rcal connector to the
CAB (Fi g. 6).
(4) I nstal l the wi ri ng harness connector to the
CAB and push down on the rel ease to secure the con-
nector.
(5) I nstal l negati ve battery cabl e to the battery.
(6) Remove the pushrod from the vehi cl e.
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR
The data l i nk connector i s l ocated at the l ower
edge of the i nstrument panel near the steeri ng col -
umn (Fi g. 7).
OPERATION - DATA LINK CONNECTOR
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool or the Mopar Di agnosti c System
(MDS) wi th the Powertrai n Control Modul e (PCM).
Fig. 4 CAB HARNESS CONNECTOR RELEASE
1 - ABS MODULE
2 - ELECTRICAL CONNECTOR
Fig. 5 HCU/CAB MOUNTING
1 - HCU
2 - CAB
3 - HCU/CAB BRACKET
4 - MOUNTING NUTS AND STUDS
5 - MOTOR
Fig. 6 CONTROLLER AND HCU
1 - CONTROLLER ANTILOCK BRAKE MODULE
2 - HYDRAULIC CONTROL UNIT (H.C.U)
POWERTRAIN CONTROL
MODULE
DESCRIPTION
DESCRIPTION - PCM
The Powertrai n Control Modul e (PCM) i s l ocated
i n the engi ne compartment (Fi g. 8). The PCM i s
referred to as JTEC.
DESCRIPTION - MODES OF OPERATION
As i nput si gnal s to the Powertrai n Control Modul e
(PCM) change, the PCM adjusts i ts response to the
output devi ces. For exampl e, the PCM must cal cul ate
di fferent i njector pul se wi dth and i gni ti on ti mi ng for
i dl e than i t does for wi de open throttl e (WOT).
The PCM wi l l operate i n two di fferent modes:
Open Loop and Closed Loop.
Duri ng Open Loop modes, the PCM recei ves i nput
si gnal s and responds onl y accordi ng to preset PCM
programmi ng. I nput from the oxygen (O2S) sensors
i s not moni tored duri ng Open Loop modes.
Duri ng Cl osed Loop modes, the PCM wi l l moni tor
the oxygen (O2S) sensors i nput. Thi s i nput i ndi cates
to the PCM whether or not the cal cul ated i njector
pul se wi dth resul ts i n the i deal ai r-fuel rati o. Thi s
rati o i s 14.7 parts ai r-to-1 part fuel . By moni tori ng
the exhaust oxygen content through the O2S sensor,
the PCM can fi ne tune the i njector pul se wi dth. Thi s
i s done to achi eve opti mum fuel economy combi ned
wi th l ow emi ssi on engi ne performance.
The fuel i njecti on system has the fol l owi ng modes
of operati on:
I gni ti on swi tch ON
Engi ne start-up (crank)
Engi ne warm-up
I dl e
Crui se
Accel erati on
Decel erati on
Wi de open throttl e (WOT)
I gni ti on swi tch OFF
The i gni ti on swi tch On, engi ne start-up (crank),
engi ne warm-up, accel erati on, decel erati on and wi de
open throttl e modes are Open Loop modes. The i dl e
and crui se modes, (wi th the engi ne at operati ng tem-
perature) are Cl osed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
Thi s i s an Open Loop mode. When the fuel system
i s acti vated by the i gni ti on swi tch, the fol l owi ng
acti ons occur:
The PCM pre-posi ti ons the i dl e ai r control (I AC)
motor.
The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
The PCM moni tors the engi ne cool ant tempera-
ture sensor i nput. The PCM modi fi es fuel strategy
based on thi s i nput.
I ntake mani fol d ai r temperature sensor i nput i s
moni tored.
Throttl e posi ti on sensor (TPS) i s moni tored.
The auto shutdown (ASD) rel ay i s energi zed by
the PCM for approxi matel y three seconds.
Fig. 7 DATA LINK CONNECTOR LOCATION
Fig. 8 PCM LOCATION
DATA LINK CONNECTOR (Continued)
The fuel pump i s energi zed through the fuel
pump rel ay by the PCM. The fuel pump wi l l operate
for approxi matel y three seconds unl ess the engi ne i s
operati ng or the starter motor i s engaged.
The O2S sensor heater el ement i s energi zed vi a
the ASD or O2S heater rel ay. The O2S sensor i nput
i s not used by the PCM to cal i brate ai r-fuel rati o dur-
i ng thi s mode of operati on.
ENGINE START-UP MODE
Thi s i s an Open Loop mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
The PCM recei ves i nputs from:
Battery vol tage
Engi ne cool ant temperature sensor
Crankshaft posi ti on sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Camshaft posi ti on sensor si gnal
The PCM moni tors the crankshaft posi ti on sensor.
I f the PCM does not recei ve a crankshaft posi ti on
sensor si gnal wi thi n 3 seconds of cranki ng the
engi ne, i t wi l l shut down the fuel i njecti on system.
The fuel pump i s acti vated by the PCM through
the fuel pump rel ay.
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM determi nes the proper i gni ti on ti mi ng
accordi ng to i nput recei ved from the crankshaft posi -
ti on sensor.
ENGINE WARM-UP MODE
Thi s i s an Open Loop mode. Duri ng engi ne warm-
up, the PCM recei ves i nputs from:
Battery vol tage
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Based on these i nputs the fol l owi ng occurs:
on and off.
The PCM adjusts engi ne i dl e speed through the
i dl e ai r control (I AC) motor and adjusts i gni ti on ti m-
i ng.
The PCM operates the A/C compressor cl utch
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l owpres-
sure A/C swi tches. Refer to Heati ng and Ai r Condi -
ti oni ng for addi ti onal i nformati on.
When engi ne has reached operati ng tempera-
ture, the PCM wi l l begi n moni tori ng O2S sensor
i nput. The system wi l l then l eave the warm-up mode
and go i nto cl osed l oop operati on.
IDLE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At i dl e speed, the PCM
recei ves i nputs from:
Battery vol tage
Battery vol tage
trans. onl y)
Oxygen sensors
Based on these i nputs, the fol l owi ng occurs:
i njecti on sequence and i njector pul se wi dth by turn-
i ng the ground ci rcui t to each i ndi vi dual i njector on
and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o by varyi ng i njector pul se wi dth.
I t al so adjusts engi ne i dl e speed through the i dl e ai r
control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by i ncreasi ng
and decreasi ng spark advance.
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l owpres-
sure A/C swi tches. Refer to Heati ng and Ai r Condi -
ti oni ng for addi ti onal i nformati on.
CRUISE MODE
i s a Cl osed Loop mode. At crui si ng speed, the PCM
recei ves i nputs from:
POWERTRAIN CONTROL MODULE (Continued)
Battery vol tage
trans. onl y)
Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
ASD rel ay vi a the PCM. The PCM wi l l then adjust
the i njector pul se wi dth by turni ng the ground ci rcui t
to each i ndi vi dual i njector on and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o. I t al so adjusts engi ne i dl e
speed through the i dl e ai r control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l (s) on and off.
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
ACCELERATION MODE
Thi s i s an Open Loop mode. The PCM recogni zes
an abrupt i ncrease i n throttl e posi ti on or MAP pres-
sure as a demand for i ncreased engi ne output and
vehi cl e accel erati on. The PCM i ncreases i njector
pul se wi dth i n response to i ncreased throttl e openi ng.
DECELERATION MODE
i s an Open Loop mode. Duri ng hard decel erati on, the
PCM recei ves the fol l owi ng i nputs.
Battery vol tage
trans. onl y)
Vehi cl e speed
I f the vehi cl e i s under hard decel erati on wi th the
proper rpm and cl osed throttl e condi ti ons, the PCM
wi l l i gnore the oxygen sensor i nput si gnal . The PCM
wi l l enter a fuel cut-off strategy i n whi ch i t wi l l not
suppl y a ground to the i njectors. I f a hard decel era-
ti on does not exi st, the PCM wi l l determi ne the
proper i njector pul se wi dth and conti nue i njecti on.
Based on the above i nputs, the PCM wi l l adjust
engi ne i dl e speed through the i dl e ai r control (I AC)
motor.
ground path to the coi l on and off.
WIDE OPEN THROTTLE MODE
Thi s i s an Open Loop mode. Duri ng wi de open
throttl e operati on, the PCM recei ves the fol l owi ng
i nputs.
Battery vol tage
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
on and off. The PCM i gnores the oxygen sensor i nput
si gnal and provi des a predetermi ned amount of addi -
ti onal fuel . Thi s i s done by adjusti ng i njector pul se
wi dth.
ground path to the coi l (s) on and off.
IGNITION SWITCH OFF MODE
When i gni ti on swi tch i s turned to OFF posi ti on,
the PCM stops operati ng the i njectors, i gni ti on coi l ,
ASD rel ay and fuel pump rel ay.
DESCRIPTION - 5 VOLT SUPPLIES
Two di fferent Powertrai n Control Modul e (PCM)
fi ve vol t suppl y ci rcui ts are used; pri mary and sec-
ondary.
DESCRIPTION - IGNITION CIRCUIT SENSE
Thi s ci rcui t ti es the i gni ti on swi tch to the Power-
trai n Control Modul e (PCM).
DESCRIPTION - POWER GROUNDS
The Powertrai n Control Modul e (PCM) has 2 mai n
grounds. Both of these grounds are referred to as
power grounds. Al l of the hi gh-current, noi sy, el ectri -
cal devi ces are connected to these grounds as wel l as
al l of the sensor returns. The sensor return comes
i nto the sensor return ci rcui t, passes through noi se
suppressi on, and i s then connected to the power
ground.
The power ground i s used to control ground ci r-
cui ts for the fol l owi ng PCM l oads:
Generator fi el d wi ndi ng
Fuel i njectors
I gni ti on coi l (s)
Certai n rel ays/sol enoi ds
Certai n sensors
DESCRIPTION - SENSOR RETURN
The Sensor Return ci rcui ts are i nternal to the Pow-
ertrai n Control Modul e (PCM).
Sensor Return provi des a l ownoi se ground refer-
ence for al l engi ne control system sensors. Refer to
Power Grounds for more i nformati on.
OPERATION
OPERATION - PCM
The PCM operates the fuel system. The PCM i s a
pre-programmed, tri pl e mi croprocessor di gi tal com-
puter. I t regul ates i gni ti on ti mi ng, ai r-fuel rati o,
emi ssi on control devi ces, chargi ng system, certai n
transmi ssi on features, speed control , ai r condi ti oni ng
compressor cl utch engagement and i dl e speed. The
PCM can adapt i ts programmi ng to meet changi ng
operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as Powertrai n Control Modul e
(PCM) Outputs. The sensors and swi tches that pro-
vi de i nputs to the PCM are consi dered Powertrai n
Control Modul e (PCM) I nputs.
The PCM adjusts i gni ti on ti mi ng based upon
i nputs i t recei ves from sensors that react to: engi ne
rpm, mani fol d absol ute pressure, engi ne cool ant tem-
perature, throttl e posi ti on, transmi ssi on gear sel ec-
ti on (automati c transmi ssi on), vehi cl e speed, power
steeri ng pump pressure, and the brake swi tch.
The PCM adjusts i dl e speed based on i nputs i t
recei ves from sensors that react to: throttl e posi ti on,
vehi cl e speed, transmi ssi on gear sel ecti on, engi ne
cool ant temperature and from i nputs i t recei ves from
the ai r condi ti oni ng cl utch swi tch and brake swi tch.
Based on i nputs that i t recei ves, the PCM adjusts
i gni ti on coi l dwel l . The PCM al so adjusts the gener-
ator charge rate through control of the generator
fi el d and provi des speed control operati on.
NOTE: PCM Inputs:
A/C request (i f equi pped wi th factory A/C)
A/C sel ect (i f equi pped wi th factory A/C)
A/C pressure transducer
Auto shutdown (ASD) sense
Battery temperature
Battery vol tage
Brake swi tch
J1850 bus (+) ci rcui ts
J1850 bus (-) ci rcui ts
Data l i nk connecti on for DRB scan tool
Fuel l evel (through J1850 ci rcui try)
Generator (battery vol tage) output
I gni ti on ci rcui t sense (i gni ti on swi tch i n on/off/
crank/run posi ti on)
Knock sensors (2 on 3.7L engi ne)
Leak detecti on pump (swi tch) sense (i f equi pped)
Oi l pressure
Oxygen sensors
Park/neutral swi tch (auto. trans. onl y)
Power ground
Power steeri ng pressure swi tch
Sensor return
Si gnal ground
Speed control mul ti pl exed si ngl e wi re i nput
Throttl e posi ti on sensor
Transfer case swi tch (4WD range posi ti on)
Vehi cl e speed sensor
NOTE: PCM Outputs:
A/C cl utch rel ay
Auto shutdown (ASD) rel ay
J1850 bus (+/-) ci rcui ts for: speedometer, vol tme-
ter, fuel gauge, oi l pressure gauge/l amp, engi ne temp.
gauge and speed control warn. l amp
Cl utch pedal posi ti on swi tch overri de rel ay
Data l i nk connecti on for DRB scan tool
EGR val ve control sol enoi d (i f equi pped)
EVAP cani ster purge sol enoi d
Fi ve vol t sensor suppl y (pri mary)
Fi ve vol t sensor suppl y (secondary)
Fuel i njectors
Fuel pump rel ay
Generator fi el d dri ver (-)
Generator fi el d dri ver (+)
I dl e ai r control (I AC) motor
I gni ti on coi l (s)
Leak detecti on pump (i f equi pped)
Mal functi on i ndi cator l amp (Check engi ne l amp).
Dri ven through J1850 ci rcui ts.
Oxygen sensor heater rel ays
Oxygen sensors (pul se wi dth modul ated)
Radi ator cool i ng fan rel ay (pul se wi dth modu-
l ated)
Speed control vacuum sol enoi d
Speed control vent sol enoi d
Tachometer (i f equi pped). Dri ven through J1850
ci rcui ts.
Transmi ssi on convertor cl utch ci rcui t. Dri ven
through J1850 ci rcui ts.
OPERATION - 5 VOLT SUPPLIES
Pri mary 5vol t suppl y:
suppl i es the requi red 5 vol t power source to the
Crankshaft Posi ti on (CKP) sensor.
Camshaft Posi ti on (CMP) sensor.
suppl i es a reference vol tage for the Mani fol d
Absol ute Pressure (MAP) sensor.
suppl i es a reference vol tage for the Throttl e
Posi ti on Sensor (TPS) sensor.
Secondary 5vol t suppl y:
oi l pressure sensor.
suppl i es the requi red 5 vol t power source for the
Vehi cl e Speed Sensor (VSS) (i f equi pped).
suppl i es the 5 vol t power source to the transmi s-
si on pressure sensor (certai n automati c transmi s-
si ons).
OPERATION - IGNITION CIRCUIT SENSE
The i gni ti on ci rcui t sense i nput tel l s the PCM the
i gni ti on swi tch has energi zed the i gni ti on ci rcui t.
Battery vol tage i s al so suppl i ed to the PCM
through the i gni ti on swi tch when the i gni ti on i s i n
the RUN or START posi ti on. Thi s i s referred to as
the i gni ti on sense ci rcui t and i s used to wake up
the PCM. Vol tage on the i gni ti on i nput can be as l ow
as 6 vol ts and the PCM wi l l sti l l functi on. Vol tage i s
suppl i ed to thi s ci rcui t to power the PCMs 8-vol t reg-
ul ator and to al l ow the PCM to perform fuel , i gni ti on
and emi ssi ons control functi ons.
REMOVAL
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
The PCM i s l ocated i n the engi ne compartment
near the battery (Fi g. 9).
To avoi d possi bl e vol tage spi ke damage to the
PCM, i gni ti on key must be off, and negati ve battery
cabl e must be di sconnected before unpl uggi ng PCM
connectors.
(2) Remove cover over el ectri cal connectors. Cover
snaps onto PCM.
(3) Careful l y unpl ug the three 32way connectors
from PCM.
(4) Remove three PCM mounti ng bol ts and remove
PCM from vehi cl e.
INSTALLATION
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
(1) I nstal l PCM and 3 mounti ng bol ts to vehi cl e.
(2) Ti ghten bol ts. Refer to torque speci fi cati ons.
(3) Check pi n connectors i n the PCM and the three
32way connectors for corrosi on or damage. Al so, the
pi n hei ghts i n connectors shoul d al l be same. Repai r
as necessary before i nstal l i ng connectors.
(4) I nstal l three 32way connectors.
(5) I nstal l cover over el ectri cal connectors. Cover
snaps onto PCM.
(6) I nstal l battery cabl e.
(7) Use the DRB scan tool to reprogram new PCM
wi th vehi cl es ori gi nal I denti fi cati on Number (VI N)
and ori gi nal vehi cl e mi l eage.
SENTRY KEY IMMOBILIZER
MODULE
DESCRIPTION
The Sentry Key I mmobi l i zer Modul e (SKI M) i s the
pri mary component of the Sentry Key I mmobi l i zer
System (SKI S) (Fi g. 10). The SKI M i s l ocated on the
ri ght si de of the steeri ng col umn, bel ow the i gni ti on
Fig. 9 PCM REMOVE/INSTALL
1 - PCM
3 - 32-WAY CONNECTORS
l ock cyl i nder housi ng and i s conceal ed beneath the
steeri ng col umn shrouds. The mol ded bl ack pl asti c
housi ng for the SKI M has an i ntegral mol ded pl asti c
hal o-l i ke antenna ri ng that extends from one end.
When the SKI M i s properl y i nstal l ed on the steeri ng
col umn, the antenna ri ng i s ori ented around the ci r-
cumference of the i gni ti on l ock cyl i nder housi ng. A
si ngl e i ntegral connector receptacl e contai ni ng si x
termi nal pi ns i s l ocated on the opposi te end of the
SKI M housi ng from the antenna ri ng. A stamped
metal mounti ng bracket secured to the SKI M hous-
i ng has a U-shaped cl i p formati on that i s used to
secure the uni t to the ri ght l ower fl ange of the steer-
i ng col umn jacket.
The SKI M cannot be adjusted or repai red. I f faul ty
or damaged, the enti re SKI M uni t must be repl aced.
OPERATION
The Sentry Key I mmobi l i zer Modul e (SKI M) con-
tai ns a Radi o Frequency (RF) transcei ver and a
mi croprocessor. The SKI M transmi ts RF si gnal s to,
and recei ves RF si gnal s from the Sentry Key tran-
sponder through a tuned antenna encl osed wi thi n the
mol ded pl asti c antenna ri ng i ntegral to the SKI M
housi ng. I f thi s antenna ri ng i s not mounted properl y
around the i gni ti on l ock cyl i nder housi ng, communi -
cati on probl ems between the SKI M and the transpon-
der may ari se. These communi cati on probl ems wi l l
resul t i n Sentry Key transponder-rel ated faul ts. The
SKI M al so communi cates over the Programmabl e
Communi cati ons I nterface (PCI ) data bus wi th the
Powertrai n Control Modul e (PCM), the El ectroMe-
chani cal I nstrument Cl uster (EMI C) and/or the
DRBI I I scan tool .
The SKI M retai ns i n memory the I D numbers of
any Sentry Key transponder that i s programmed i nto
i t. A maxi mum of ei ght Sentry Key transponders can
be programmed i nto the SKI M. For added system
securi ty, each SKI M i s programmed wi th a uni que
Secret Key code. Thi s code i s stored i n memory, sent
over the PCI data bus to the PCM, and i s encoded to
the transponder of every Sentry Key that i s pro-
grammed i nto the SKI M. Therefore, the Secret Key
code i s a common el ement that i s found i n every com-
ponent of the Sentry Key I mmobi l i zer System (SKI S).
Another securi ty code, cal l ed a PI N, i s used to gai n
access to the SKI M Secured Access Mode. The
Secured Access Mode i s requi red duri ng servi ce to
perform the SKI S i ni ti al i zati on and Sentry Key tran-
sponder programmi ng procedures. The SKI M al so
stores the Vehi cl e I denti fi cati on Number (VI N) i n i ts
memory, whi ch i t l earns through a PCI data bus
message from the PCM duri ng SKI S i ni ti al i zati on.
I n the event that a SKI M repl acement i s requi red,
the Secret Key code can be transferred to the new
SKI M from the PCM usi ng the DRBI I I scan tool
and the SKI S i ni ti al i zati on procedure. Proper com-
pl eti on of the SKI S i ni ti al i zati on wi l l al l ow the exi st-
i ng Sentry Keys to be programmed i nto the new
SKI M so that new keys wi l l not be requi red. I n the
event that the ori gi nal Secret Key code cannot be
recovered, SKI M repl acement wi l l al so requi re new
Sentry Keys. The DRBI I I scan tool wi l l al ert the
techni ci an duri ng the SKI S i ni ti al i zati on procedure i f
new Sentry Keys are requi red.
When the i gni ti on swi tch i s turned to the On posi -
ti on, the SKI M transmi ts an RF si gnal to the tran-
sponder i n the i gni ti on key. The SKI M then wai ts for
an RF si gnal response from the transponder. I f the
response recei ved i denti fi es the key as val i d, the
SKI M sends a val i d key message to the PCM over
the PCI data bus. I f the response recei ved i denti fi es
the key as i nval i d, or i f no response i s recei ved from
the key transponder, the SKI M sends an i nval i d key
message to the PCM. The PCM wi l l enabl e or di sabl e
engi ne operati on based upon the status of the SKI M
messages. I t i s i mportant to note that the defaul t
condi ti on i n the PCM i s an i nval i d key; therefore, i f
no message i s recei ved from the SKI M by the PCM,
the engi ne wi l l be di sabl ed and the vehi cl e i mmobi -
l i zed after two seconds of runni ng.
The SKI M al so sends SKI S i ndi cator status mes-
sages to the EMI C over the PCI data bus to tel l the
EMI C how to operate the SKI S i ndi cator. Thi s i ndi -
cator status message tel l s the EMI C to turn the i ndi -
cator on for about three seconds each ti me the
i gni ti on swi tch i s turned to the On posi ti on as a bul b
test. After compl eti on of the bul b test, the SKI M
sends i ndi cator status messages to the EMI C to turn
the i ndi cator off, turn the i ndi cator on, or to fl ash the
Fig. 10 Sentry Key Immobilizer Module
1 - SKIM
2 - BRACKET
3 - CONNECTOR RECEPTACLE
4 - ANTENNA RING
SENTRY KEY IMMOBILIZER MODULE (Continued)
i ndi cator on and off. I f the SKI S i ndi cator fl ashes
upon i gni ti on On or stays on sol i d after the bul b test,
i t si gni fi es a SKI S faul t. I f the SKI M detects a sys-
tem mal functi on and/or the SKI S has become i noper-
ati ve, the SKI S i ndi cator wi l l stay on sol i d. I f the
SKI M detects an i nval i d key or i f a key transponder-
rel ated faul t exi sts, the SKI S i ndi cator wi l l fl ash. I f
the vehi cl e i s equi pped wi th the Customer Learn
transponder programmi ng feature, the SKI M wi l l
al so send messages to the EMI C to fl ash the SKI S
i ndi cator and to generate a si ngl e audi bl e chi me tone
whenever the Customer Learn programmi ng mode i s
bei ng uti l i zed. (Refer to 8 - ELECTRI CAL/VEHI CLE
THEFT SECURI TY - STANDARD PROCEDURE -
SENTRY KEY TRANSPONDER PROGRAMMI NG).
The SKI S performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on, and wi l l
store faul t i nformati on i n the form of Di agnosti c
Troubl e Codes (DTCs) i n SKI M memory i f a system
mal functi on i s detected. The SKI M can be di agnosed,
and any stored DTCs can be retri eved usi ng a
DRBI I I scan tool . Refer to the appropri ate di agnos-
ti c i nformati on.
REMOVAL
PERSONAL INJURY.
cabl e.
(2) I f the vehi cl e i s equi pped wi th the opti onal ti l t
steeri ng col umn, move the ti l t steeri ng col umn to the
ful l y l owered posi ti on and l eave the ti l t rel ease l ever
i n the rel eased (down) posi ti on.
(3) From bel ow the steeri ng col umn, remove the
two screws that secure the l ower shroud to the upper
shroud (Fi g. 11).
(4) Usi ng hand pressure, push gentl y i nward on
both si des of the upper shroud near the parti ng l i ne
between the upper and l ower shrouds to rel ease the
snap features that secure the two hal ves to each
other.
(5) Remove both the upper and l ower shrouds from
the steeri ng col umn.
connector for the SKI M from the modul e connector
receptacl e.
(7) The SKI M mounti ng bracket features a cl i p for-
mati on that secures the SKI M to the ri ght l ower
fl ange of the steeri ng col umn jacket. Pul l downward
on the connector end of the SKI M mounti ng bracket
to rel ease thi s cl i p from the steeri ng col umn jacket.
(8) Rotate the SKI M and i ts mounti ng bracket
downwards and then to the si de away from the steer-
i ng col umn to sl i de the SKI M antenna ri ng from
around the i gni ti on swi tch l ock cyl i nder housi ng. Li ft
the mul ti -functi on swi tch upward off of the upper
steeri ng col umn housi ng far enough to remove the
SKI M antenna ri ng formati on from between the i gni -
ti on key rel ease button and the mul ti -functi on swi tch
housi ng.
(9) Remove the SKI M from the steeri ng col umn.
Fig. 11 Sentry Key Immobilizer Module Remove/
Install
1 - UPPER SHROUD
2 - STEERING COLUMN
4 - SENTRY KEY IMMOBILIZER MODULE
5 - LOWER SHROUD
6 - SCREW (2)
7 - IGNITION LOCK CYLINDER HOUSING
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the Sentry Key I mmobi l i zer Modul e
(SKI M) to the ri ght si de of the steeri ng col umn (Fi g.
11). Li ft the mul ti -functi on swi tch upward off of the
upper steeri ng col umn housi ng far enough to i nsert
the SKI M antenna ri ng formati on between the i gni -
ti on key rel ease button and the mul ti -functi on swi tch
housi ng.
(2) Sl i de the SKI M antenna ri ng around the i gni -
ti on swi tch l ock cyl i nder housi ng, then rotate the
SKI M and i ts mounti ng bracket upwards and toward
(3) Al i gn the SKI M mounti ng bracket cl i p forma-
ti on wi th the ri ght l ower fl ange of the steeri ng col -
umn jacket and, usi ng hand pressure, push upward
fi rml y and evenl y on the connector end of the SKI M
mounti ng bracket to engage thi s cl i p wi th the steer-
i ng col umn jacket.
(4) Reconnect the i nstrument panel wi re harness
connector for the SKI M to the modul e connector
receptacl e.
(5) Posi ti on both the upper and l ower shrouds onto
(6) Al i gn the snap features on the l ower shroud
wi th the receptacl es on the upper shroud and appl y
hand pressure to snap them together.
(7) From bel ow the steeri ng col umn, i nstal l and
ti ghten the two screws that secure the l ower shroud
to the upper shroud. Ti ghten the screws to 2 Nm (18
i n. l bs.).
ful l y rai sed posi ti on and secure i t i n pl ace by movi ng
the ti l t rel ease l ever back to the l ocked (up) posi ti on.
NOTE: If the SKIM has been replaced with a new
unit, the Sentry Key Immobilizer System (SKIS)
MUST be initialized before the vehicle can be oper-
ated. (Refer to 8 - ELECTRICAL/VEHICLE THEFT
SECURITY - STANDARD PROCEDURE - SKIS INI-
TIALIZATION).
TRANSMISSION CONTROL
MODULE
DESCRIPTION
The Transmi ssi on Control Modul e (TCM) i s l ocated
i n the engi ne compartment on the ri ght (passenger)
si de and i s mounted to the i nner fender (Fi g. 12).
OPERATION
The Transmi ssi on Control Modul e (TCM) i s the
control l i ng uni t for al l el ectroni c operati ons of the
transmi ssi on. The TCM recei ves i nformati on regard-
i ng vehi cl e operati on from both di rect and i ndi rect
i nputs, and sel ects the operati onal mode of the trans-
mi ssi on. Di rect i nputs are hardwi red to, and used
speci fi cal l y by the TCM. I ndi rect i nputs ori gi nate
from other components/modul es, and are shared wi th
the TCM vi a the vehi cl e communi cati on bus.
Some exampl es of direct inputs to the TCM are:
Battery (B+) vol tage
I gni ti on ON vol tage
Transmi ssi on Control Rel ay (Swi tched B+)
Throttl e Posi ti on Sensor
Crankshaft Posi ti on Sensor
Transmi ssi on Range Sensor
Pressure Swi tches
Transmi ssi on Temperature Sensor
I nput Shaft Speed Sensor
Fig. 12 Transmission Control Module Location
1 - Transmission Control Module
Output Shaft Speed Sensor
Li ne Pressure Sensor
Some exampl es of indirect inputs to the TCM are:
Engi ne/Body I denti fi cati on
Mani fol d Pressure
Target I dl e
Torque Reducti on Confi rmati on
Engi ne Cool ant Temperature
Ambi ent/Battery Temperature
DRB Scan Tool Communi cati on
Based on the i nformati on recei ved from these var-
i ous i nputs, the TCM determi nes the appropri ate
shi ft schedul e and shi ft poi nts, dependi ng on the
present operati ng condi ti ons and dri ver demand.
Thi s i s possi bl e through the control of vari ous di rect
and i ndi rect outputs.
Some exampl es of TCM direct outputs are:
Transmi ssi on Control Rel ay
Sol enoi ds
Torque Reducti on Request
Some exampl es of TCM indirect outputs are:
Transmi ssi on Temperature (to PCM)
PRNDL Posi ti on (to BCM)
I n addi ti on to moni tori ng i nputs and control l i ng
outputs, the TCM has other i mportant responsi bi l i -
ti es and functi ons:
Stori ng and mai ntai ni ng Cl utch Vol ume I ndexes
(CVI )
Stori ng and sel ecti ng appropri ate Shi ft Sched-
ul es
System sel f-di agnosti cs
Di agnosti c capabi l i ti es (wi th DRB scan tool )
NOTE: If the TCM has been replaced, the Quick
Learn Procedure must be performed. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
BATTERY FEED
A fused, di rect battery feed to the TCM i s used for
conti nuous power. Thi s battery vol tage i s necessary
to retai n adapti ve l earn val ues i n the TCMs RAM
(Random Access Memory). When the battery (B+) i s
di sconnected, thi s memory i s l ost. When the battery
(B+) i s restored, thi s memory l oss i s detected by the
TCM and a Di agnosti c Troubl e Code (DTC) i s set.
CLUTCH VOLUME INDEXES (CVI)
An i mportant functi on of the TCM i s to moni tor
Cl utch Vol ume I ndexes (CVI ). CVI s represent the vol -
ume of fl ui d needed to compress a cl utch pack.
The TCM moni tors gear rati o changes by moni tor-
i ng the I nput and Output Speed Sensors. The I nput,
or Turbi ne Speed Sensor sends an el ectri cal si gnal to
the TCM that represents i nput shaft rpm. The Out-
put Speed Sensor provi des the TCM wi th output
shaft speed i nformati on.
By compari ng the two i nputs, the TCM can deter-
mi ne transmi ssi on gear posi ti on. Thi s i s i mportant to
the CVI cal cul ati on because the TCM determi nes
CVI s by moni tori ng how l ong i t takes for a gear
change to occur (Fi g. 13).
Gear rati os can be determi ned by usi ng the DRB
Scan Tool and readi ng the I nput/Output Speed Sen-
sor val ues i n the Moni tors di spl ay. Gear rati o can
be obtai ned by di vi di ng the I nput Speed Sensor val ue
by the Output Speed Sensor val ue.
For exampl e, i f the i nput shaft i s rotati ng at 1000
rpm and the output shaft i s rotati ng at 500 rpm,
then the TCM can determi ne that the gear rati o i s
2:1. I n di rect dri ve (3rd gear), the gear rati o changes
to 1:1. The gear rati o changes as cl utches are appl i ed
and rel eased. By moni tori ng the l ength of ti me i t
takes for the gear rati o to change fol l owi ng a shi ft
request, the TCM can determi ne the vol ume of fl ui d
used to appl y or rel ease a fri cti on el ement.
The vol ume of transmi ssi on fl ui d needed to appl y
the fri cti on el ements are conti nuousl y updated for
adapti ve control s. As fri cti on materi al wears, the vol -
ume of fl ui d need to appl y the el ement i ncreases.
Fig. 13 Example of CVI Calculation
1 - OUTPUT SPEED SENSOR
2 - OUTPUT SHAFT
3 - CLUTCH PACK
4 - SEPARATOR PLATE
5 - FRICTION DISCS
6 - INPUT SHAFT
7 - INPUT SPEED SENSOR
8 - PISTON AND SEAL
TRANSMISSION CONTROL MODULE (Continued)
Certai n mechani cal probl ems wi thi n the i nput
cl utch assembl y (broken return spri ngs, out of posi -
ti on snap ri ngs, excessi ve cl utch pack cl earance,
i mproper assembl y, etc.) can cause i nadequate or out-
of-range el ement vol umes. Al so, defecti ve I nput/Out-
put Speed Sensors and wi ri ng can cause these
condi ti ons. The fol l owi ng chart i denti fi es the appro-
pri ate cl utch vol umes and when they are moni tored/
updated:
CLUTCH VOLUMES
Clutch When Updated
Proper Clutch
Volume
L/R
2-1 or 3-1
downshift
45 to 134
2C
3-2 kickdown
shift
25 to 85
OD 2-3 upshift 30 to 100
CLUTCH VOLUMES
4C 3-4 upshift 30 to 85
UD
4-3 kickdown
shift
30 to 100
SHIFT SCHEDULES
As menti oned earl i er, the TCM has programmi ng
that al l ows i t to sel ect a vari ety of shi ft schedul es.
Shi ft schedul e sel ecti on i s dependent on the fol l ow-
i ng:
Shi ft l ever posi ti on
Throttl e posi ti on
Engi ne l oad
Fl ui d temperature
Software l evel
As dri vi ng condi ti ons change, the TCM appropri -
atel y adjusts the shi ft schedul e. Refer to the fol l ow-
i ng chart to determi ne the appropri ate operati on
expected, dependi ng on dri vi ng condi ti ons.
Schedule Condition Expected Operation
Extreme Cold Oil temperature below -16F -Park, Reverse, Neutral and 1st and
3rd gear only in D position, 2nd
gear only in Manual 2 or L
-No EMCC
Super Cold Oil temperature between -12F and
10F
- Delayed 2-3 upshift
- Early 4-3 coastdown shift
- High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
-Shifts at high throttle openings willl
be early.
- No EMCC
Cold Oil temperature between 10F and
36F
-Shift schedule is the same as
Super Cold except that the 2-3
upshifts are not delayed.
Warm Oil temperature between 40F and
80F
- Normal operation (upshift,
kickdowns, and coastdowns)
- No EMCC
Hot Oil temperature between 80F and
240F
- Normal operation (upshift,
kickdowns, and coastdowns)
- Normal EMCC operation
Schedule Condition Expected Operation
Overheat Oil temperature above 240F or
engine coolant temperature above
244F
- 3rd gear FEMCC from 30-48 mph
- 3rd gear PEMCC above 35 mph
- Above 25 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
STANDARD PROCEDURE - TCM QUICK LEARN
The qui ck l earn procedure requi res the use of the
DRB scan tool .
Thi s program al l ows the el ectroni c transmi ssi on
system to recal i brate i tsel f. Thi s wi l l provi de the
proper transmi ssi on operati on. The qui ck l earn pro-
cedure shoul d be performed i f any of the fol l owi ng
procedures are performed:
Transmi ssi on Assembl y Repl acement
Transmi ssi on Control Modul e Repl acement
Sol enoi d Pack Repl acement
Cl utch Pl ate and/or Seal Repl acement
Val ve Body Repl acement or Recondi ti on
To perform the Qui ck Learn Procedure, the fol l ow-
i ng condi ti ons must be met:
The brakes must be appl i ed
The engi ne speed must be above 500 rpm
The throttl e angl e (TPS) must be l ess than 3
degrees
The shi ft l ever posi ti on must stay i n PARK unti l
prompted to shi ft to overdri ve
The shi ft l ever posi ti on must stay i n overdri ve
after the Shi ft to Overdri ve prompt unti l the DRB
i ndi cates the procedure i s compl ete
The cal cul ated oi l temperature must be above
60 and bel ow 200
HEATED SEAT MODULE
DESCRIPTION
The heated seat modul e i s al so known as the Seat
Heat I nterface Modul e. The heated seat modul e (Fi g.
14) i s l ocated under the l eft front seat cushi on, where
i t i s secured to a mounti ng bracket vi a two push-pi n
retai ners. The heated seat modul e has a si ngl e con-
nector receptacl e that al l ows the modul e to be con-
nected to al l of the requi red i nputs and outputs
through the seat wi re harness.
The heated seat modul e i s an el ectroni c mi cropro-
cessor control l ed devi ce desi gned and programmed to
use i nputs from the heated seat rel ay, the two heated
seat swi tches and the two heated seat sensors to
operate and control the heated seat el ements i n both
front seats and the two heated seat i ndi cator l amp
Li ght-Emi tti ng Di odes (LEDs) i n each heated seat
swi tch. The heated seat modul e i s al so programmed
to perform sel f-di agnosi s of certai n heated seat sys-
tem functi ons and provi de feedback of that di agnosi s
through the heated seat swi tch i ndi cator l amps.
The heated seat modul e cannot be repai red. I f the
heated seat modul e i s damaged or faul ty, the enti re
modul e must be repl aced.
OPERATION
The heated seat modul e operates on fused battery
current recei ved from a fuse i n the juncti on bl ock.
The modul e i s grounded at al l ti mes. I nputs to the
modul e i ncl ude a resi stor mul ti pl exed heated seat
swi tch request ci rcui t for each of the two heated seat
swi tches and the heated seat sensor i nputs from the
seat cushi ons of each front seat. I n response to those
i nputs, the heated seat modul e control s battery cur-
rent to the heated seat el ements and sensors, and
Fig. 14 Heated Seat Module
1 - Mounting Tabs (Not Used On KJ)
2 - Heated Seat Module
3 - Connector Receptacle
control s the ground for the heated seat swi tch i ndi -
cator l amps (LEDs).
When a heated seat swi tch (Dri ver or Passenger) i s
depressed a si gnal i s recei ved by the heated seat
modul e, the modul e energi zes the proper i ndi cator
LED (Low or Hi gh) i n the swi tch by groundi ng the
i ndi cator l amp ci rcui t to i ndi cate that the heated seat
system i s operati ng. At the same ti me, the heated
seat modul e energi zes the sel ected heated seat sensor
ci rcui t and the sensor provi des the modul e wi th an
i nput i ndi cati ng the surface temperature of the
sel ected seat cushi on.
The Low heat set poi nt i s about 36 C (96.8 F),
and the Hi gh heat set poi nt i s about 42 C (107.6 F).
I f the seat cushi on surface temperature i nput i s
bel ow the temperature set poi nt for the sel ected tem-
perature setti ng, the heated seat modul e energi zes
an N-channel Fi el d Effect Transi stor (N-FET) wi thi n
the modul e whi ch energi zes the heated seat el ements
i n the sel ected seat cushi on and back. When the sen-
sor i nput to the modul e i ndi cates the correct temper-
ature set poi nt has been achi eved, the modul e
de-energi zes the N-FET whi ch de-energi zes the
heated seat el ements. The heated seat modul e wi l l
conti nue to cycl e the N-FET as needed to mai ntai n
the sel ected temperature set poi nt.
I f the heated seat modul e detects a heated seat
sensor val ue i nput that i s out of range or a shorted
or open heated seat el ement ci rcui t, i t wi l l noti fy the
vehi cl e operator or the repai r techni ci an of thi s con-
di ti on by fl ashi ng the Hi gh and/or Low i ndi cator
l amps i n the affected heated seat swi tch. Refer to
Diagnosis and Testing Heated Seat System i n
Heated Systems for fl ashi ng LED di agnosi s and test-
i ng procedures. Refer to Diagnosis and Testing
Heated Seat Module i n thi s secti on for heated seat
modul e di agnosi s and testi ng procedures. Al so refer
to the Body Di agnosti c Manual for addi ti onal di agno-
si s and testi ng procedures.
MODULE
I f a heated seat fai l s to heat and one or both of the
i ndi cator l amps on a heated seat swi tch fl ash, refer
to Heated Seat System Diagnosis and Testing i n
Heated Systems for fl ashi ng LED fai l ure i denti fi ca-
ti on. Refer to Wiring Diagrams i n for compl ete
heated seat system wi ri ng di agrams.
(1) Remove the heated seat modul e from i ts
mounti ng l ocati on (Refer to 8 - ELECTRI CAL/ELEC-
TRONI C CONTROL MODULES/MEMORY HEATED
SEAT/MI RROR MODULE - REMOVAL).
NOTE: ANY RESISTANCE VALUES (OHMS ) GIVEN
IN THE FOLLOWING TEXT ARE SUPPLIED USING
THE AUTOMATIC RANGE GENERATED BY A
FLUKE AUTOMOTIVE METER. IF ANOTHER TYPE
OF MEASURING DEVICE IS USED THE VALUES
GENERATED MAY NOT BE THE SAME AS THE
RESULTS SHOWN HERE, OR MAY HAVE TO BE
CONVERTED TO THE RANGE USED HERE.
RIGHT SEAT HEATER INOPERATIVE
(1) I f a heated seat heats but one or both i ndi cator
l amps (LEDs) on the heated seat swi tch fai l to i l l u-
mi nate, check the dri ver ci rcui t wi th the i noperati ve
LED for a short to ground. I f OK, repl ace the heated
seat swi tch. I f NOT OK repai r the short to ground as
requi red and than repl ace the heated seat swi tch.
NOTE: IF THE RIGHT SEAT CUSHION IS ALREADY
WARM THE FOLLOWING STEP WILL NOT PROVE
CONCLUSIVE.
(2) Back-probe the heated seat modul e wi re har-
ness connector (Fi g. 15), do not di sconnect. Check
cavi ty #3 for battery vol tage when the ri ght heated
seat swi tch i s turned ON, vol tage shoul d be
present, I f OK go to Step 3 I f NOT OK, test the ri ght
heated seat swi tch (Refer to 8 - ELECTRI CAL/
HEATED SEATS/PASSENGER HEATED SEAT
SWI TCH - DI AGNOSI S AND TESTI NG). I f the
swi tch tests OK, check for conti nui ty between the
swi tch and control modul e on the MUX ci rcui t, I f OK
repl ace the heated seat control modul e. I f NOT OK,
repai r the open or shorted MUX ci rcui t as requi red.
Fig. 15 Heated Seat Module Electrical Connector
HEATED SEAT MODULE (Continued)
NOTE: BE CERTAIN THE BATTERY IS FULLY
CHARGED BEFORE TESTING. FAILURE TO DO SO
CAN RESULT IN INCORRECT READINGS.
ness connector, do not di sconnect. Check cavi ty #10
for battery vol tage, whi l e observi ng the vol tmeter
depress the ri ght heated seat swi tch low setti ng
twi ce, vol tage shoul d toggl e between approx.12v and
8v, I f OK go to Step 4. I f NOT OK check for conti nu-
i ty between the swi tch and control modul e on the l ow
heat dri ver ci rcui t, I f OK repl ace the heated seat con-
trol modul e.
depress the ri ght heated seat swi tch high setti ng
i ty between the swi tch and control modul e on the
hi gh heat dri ver ci rcui t, I f OK repl ace the heated
seat control modul e.
ness connector, do not di sconnect. Check cavi ty #2 for
approx. 5v, vol tage shoul d be present, I f OK go to
Step 6. I f NOT OK repl ace the heated seat control
modul e.
a range i n vol tage from 1.72v (warm seat) 3.0v
(col d seat). I t shoul d be wi thi n thi s range, I f OK
repl ace the heated seat modul e. I f NOT OK test the
Heated Seat Sensor. I f NOT OK, repl ace the ri ght
heated seat el ement and sensor assembl y. I f the
heated seat sensor tests OK, check for conti nui ty
between the ri ght heated seat cushi on connector and
control modul e connector on the 5v suppl y ci rcui t, I f
NOT OK, repai r the open or shorted 5v suppl y ci rcui t
as requi red. I f OK check for conti nui ty between the
ri ght heated seat cushi on connector and control mod-
ul e connector on the temperature sensor i nput ci r-
cui t. I f NOT OK, repai r the open or shorted
temperature sensor i nput ci rcui t as requi red. I f OK
repl ace the heated seat control modul e.
LEFT SEAT HEATER INOPERATIVE
(1) I f a heated seat heats but one or both i ndi cator
l amps (LEDs) on the heated seat swi tch fai l to i l l u-
mi nate, check the dri ver ci rcui t wi th the i noperati ve
LED for a short to ground. I f OK, repl ace the heated
seat swi tch. I f NOT OK repai r the short to ground as
requi red and than repl ace the heated seat swi tch.
NOTE: IF THE LEFT SEAT CUSHION IS ALREADY
WARM THE FOLLOWING STEP WILL NOT PROVE
CONCLUSIVE.
battery vol tage when the l eft heated seat swi tch i s
turned ON, vol tage shoul d be present, I f OK go to
Step 3 I f NOT OK, test the l eft heated seat swi tch
(Refer to 8 - ELECTRI CAL/HEATED SEATS/
DRI VER HEATED SEAT SWI TCH - DI AGNOSI S
AND TESTI NG). I f the swi tch tests OK, check for
conti nui ty between the swi tch and control modul e on
the MUX ci rcui t, I f OK repl ace the heated seat con-
trol modul e. I f NOT OK, repai r the open or shorted
MUX ci rcui t as requi red.
depress the l eft heated seat swi tch low setti ng twi ce,
vol tage shoul d toggl e between approx.12v and 8v, I f
OK go to Step 4. I f NOT OK check for conti nui ty
between the swi tch and control modul e on the l ow
heat dri ver ci rcui t, I f OK repl ace the heated seat con-
trol modul e.
depress the l eft heated seat swi tch high setti ng
i ty between the swi tch and control modul e on the
hi gh heat dri ver ci rcui t, I f OK repl ace the heated
seat control modul e.
approx. 5v, 5 vol tage shoul d be present, I f OK go to
Step 6. I f NOT OK repl ace the heated seat control
modul e.
a range i n vol tage from 1.72v (warm seat) 3.0v
(col d seat). I t shoul d be wi thi n thi s range, I f OK
repl ace the heated seat control modul e. I f NOT OK,
test the Heated Seat Sensor. I f NOT OK, repl ace the
l eft heated seat el ement and sensor assembl y. I f the
heated seat sensor tests OK, check for conti nui ty
between the l eft heated seat cushi on connector and
control modul e connector on the 5v suppl y ci rcui t, I f
NOT OK, repai r the open or shorted 5v suppl y ci rcui t
as requi red. I f OK check for conti nui ty between the
l eft heated seat cushi on connector and control mod-
ul e connector on the temperature sensor i nput ci r-
cui t. I f NOT OK, repai r the open or shorted
temperature sensor i nput ci rcui t as requi red. I f OK
repl ace the heated seat control modul e.
BOTH SEATS INOPERATIVE
I f both seats (dri ver and passenger) fai l to heat
and the i ndi cator l amps on the heated seat swi tches
for both seats fai l to operate, test the heated seat
fuses i n the juncti on bl ock. I f the heated seat fuses
check OK, go to Step 1.
ness connector, do not di sconnect. Check for conti nu-
i ty between the ground ci rcui t cavi ty #13 of the
heated seat modul e connector and a good ground. I f
OK go to Step 2. I f NOT OK, repai r the open or
shorted ground ci rcui t as requi red.
and #6 for battery vol tage, vol tage shoul d be present,
I f OK go to Step 3. I f NOT OK repai r the open or
shorted fused B(+) ci rcui t as requi red.
approx. 5v, vol tage shoul d be present, repl ace the
heated seat control modul e wi th a known good mod-
ul e and veri fy system operati on.
REMOVAL
(1) Worki ng under the front seat cushi on (Fi g. 16),
remove the heated seat modul e from i ts mounti ng
bracket by gentl y pryi ng the modul e off of the two
mounti ng pushpi ns.
(2) Di sconnect the seat wi re harness connector
from the connector receptacl e on the si de of the
heated seat modul e.
(3) Remove the heated seat modul e from the vehi -
cl e.
INSTALLATION
(1) Connect the seat wi re harness connector to the
connector receptacl e on the si de of the heated seat
modul e.
(2) I nstal l the heated seat modul e on i ts mounti ng
bracket under the front seat.
(3) Veri fy heated seat system operati on.
Fig. 16 Heated Seat Module Location
1 - Front Seat Cushion
2 - Heated Seat Module
3 - Electrical Connector
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 22
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 32
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - BATTERY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 7
BATTERY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - BATTERY . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - HYDROMETER
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - LOAD TEST . . . . 12
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE - USING
MIDTRONICS ELECTRICAL TESTER. . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
BATTERY HOLDDOWN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
BATTERY CABLES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
THERMAL GUARD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
BATTERY TRAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
BATTERY SYSTEM
DESCRIPTION
A si ngl e 12-vol t battery system i s standard factory-
i nstal l ed equi pment on thi s model . Al l of the compo-
nents of the battery system are l ocated wi thi n the
engi ne compartment of the vehi cl e. The servi ce i nfor-
mati on for the battery system i n thi s vehi cl e covers
the fol l owi ng rel ated components, whi ch are covered
i n further detai l el sewhere i n thi s servi ce manual :
Battery - The storage battery provi des a rel i -
abl e means of stori ng a renewabl e source of el ectri cal
energy wi thi n the vehi cl e.
Battery Cable - The battery cabl es connect the
battery termi nal posts to the vehi cl e el ectri cal sys-
tem.
Battery Holddown - The battery hol ddown
hardware secures the battery i n the battery tray i n
the engi ne compartment.
KJ ENGINE SYSTEMS 8F - 1
Battery Thermal Guard - The battery thermal
guard i nsul ates the battery to protect i t from engi ne
compartment temperature extremes.
Battery Tray - The battery tray provi des a
secure mounti ng l ocati on i n the vehi cl e for the bat-
tery and an anchor poi nt for the battery hol ddown
hardware.
For battery system mai ntenance schedul es and
jump starti ng procedures, see the owners manual i n
the vehi cl e gl ove box. Opti onal l y, refer to Lubri cati on
and Mai ntenance for the proper battery jump start-
i ng procedures. Whi l e battery chargi ng can be consi d-
ered a mai ntenance procedure, the battery chargi ng
procedures and rel ated i nformati on are l ocated i n the
servi ce procedures secti on of thi s servi ce manual .
Thi s was done because the battery must be ful l y-
charged before any battery system di agnosi s or test-
i ng procedures can be performed. Refer to Standard
Procedures for the proper battery chargi ng proce-
dures.
OPERATION
The battery system i s desi gned to provi de a safe,
effi ci ent, rel i abl e and mobi l e means of del i veri ng and
stori ng el ectri cal energy. Thi s el ectri cal energy i s
requi red to operate the engi ne starti ng system, as
wel l as to operate many of the other vehi cl e acces-
sory systems for l i mi ted durati ons whi l e the engi ne
and/or the chargi ng system are not operati ng. The
battery system i s al so desi gned to provi de a reserve
of el ectri cal energy to suppl ement the chargi ng sys-
tem for short durati ons whi l e the engi ne i s runni ng
and the el ectri cal current demands of the vehi cl e
exceed the output of the chargi ng system. I n addi ti on
to del i veri ng, and stori ng el ectri cal energy for the
vehi cl e, the battery system serves as a capaci tor and
vol tage stabi l i zer for the vehi cl e el ectri cal system. I t
absorbs most abnormal or transi ent vol tages caused
by the swi tchi ng of any of the el ectri cal components
or ci rcui ts i n the vehi cl e.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starti ng, and chargi ng systems i n the
vehi cl e operate wi th one another and must be tested
as a compl ete system. I n order for the engi ne to start
and the battery to mai ntai n i ts charge properl y, al l of
the components that are used i n these systems must
perform wi thi n speci fi cati ons. I t i s i mportant that
the battery, starti ng, and chargi ng systems be thor-
oughl y tested and i nspected any ti me a battery needs
to be charged or repl aced. The cause of abnormal bat-
tery di scharge, overchargi ng or earl y battery fai l ure
must be di agnosed and corrected before a battery i s
repl aced and before a vehi cl e i s returned to servi ce.
The servi ce i nformati on for these systems has been
separated wi thi n thi s servi ce manual to make i t eas-
i er to l ocate the speci fi c i nformati on you are seeki ng.
However, when attempti ng to di agnose any of these
systems, i t i s i mportant that you keep thei r i nterde-
pendency i n mi nd.
The di agnosti c procedures used for the battery,
starti ng, and chargi ng systems i ncl ude the most
basi c conventi onal di agnosti c methods, to the more
sophi sti cated On-Board Di agnosti cs (OBD) bui l t i nto
the Powertrai n Control Modul e (PCM). Use of an
i nducti on-type mi l l i ampere ammeter, a vol t/ohmme-
ter, a battery charger, a carbon pi l e rheostat (l oad
tester) and a 12-vol t test l amp may be requi red. Al l
OBD-sensed systems are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for any fai l ure i t detects. Refer to
Chargi ng System for the proper chargi ng system on-
board di agnosti c test procedures.
MIDTRONICS ELECTRICAL SYSTEM TESTER
The Mi dtroni cs automoti ve battery and chargi ng
system tester i s desi gned to hel p the deal ershi p tech-
ni ci ans di agnose the cause of a defecti ve battery or
chargi ng system. Fol l ow the i nstructi on manual sup-
pl i ed wi th the tester to properl y di agnose a vehi cl e. I f
the i nstructi on manual i s not avai l abl e refer to the
standard procedure i n thi s secti on, whi ch i ncl udes
the di recti ons for usi ng the mi dtroni cs el ectri cal sys-
tem tester.
8F - 2 BATTERY SYSTEM KJ
BATTERY SYSTEM (Continued)
BATTERY SYSTEM DIAGNOSIS
THE BATTERY SEEMS WEAK OR
DEAD WHEN ATTEMPTING TO
START THE ENGINE.
1. The electrical system ignition-off
draw is excessive.
1. Refer to the IGNITION-OFF
DRAW TEST Standard Procedure
for the proper test procedures.
Repair the excessive ignition-off
draw, as required.
2. The charging system is faulty. 2. Determine if the charging system
is performing to specifications using
the Midtronics battery and charging
system tester. Refer to Charging
System for additional charging
system diagnosis and testing
procedures. Repair the faulty
charging system, as required.
3. The battery is discharged. 3. Determine the battery state-of-
charge using the Midtronics battery
and charging system tester. Refer to
the Standard Procedures in this
section for additional test
procedures. Charge the faulty
battery, as required.
4. The battery terminal connections
are loose or corroded.
4. Refer to Battery Cables for the
proper battery cable diagnosis and
testing procedures. Clean and
tighten the battery terminal
connections, as required.
5. The battery has an incorrect size
or rating for this vehicle.
5. Refer to Battery System
Specifications for the proper size
and rating. Replace an incorrect
6. The battery is faulty. 6. Determine the battery cranking
capacity using the Midtronics battery
and charging system tester. Refer to
the Standard Procedures in this
section for additional test
procedures. Replace the faulty
7. The starting system is faulty. 7. Determine if the starting system
is performing to specifications. Refer
to Starting System for the proper
starting system diagnosis and
testing procedures. Repair the faulty
starting system, as required.
8. The battery is physically
damaged.
8. Inspect the battery for loose
terminal posts or a cracked and
leaking case. Replace the damaged
KJ BATTERY SYSTEM 8F - 3
BATTERY SYSTEM DIAGNOSIS
THE BATTERY STATE OF
CHARGE CANNOT BE
MAINTAINED.
1. The battery has an incorrect size
or rating for this vehicle.
1. Refer to Battery System
Specifications for the proper
specifications. Replace an incorrect
2. The battery terminal connections
are loose or corroded.
2. Refer to Battery Cable for the
proper cable diagnosis and testing
procedures. Clean and tighten the
battery terminal connections, as
required.
3. The electrical system ignition-off
draw is excessive.
3. Refer to the IGNITION-OFF
DRAW TEST Standard Procedure
for the proper test procedures.
Repair the faulty electrical system,
as required.
4. The battery is faulty. 4. Test the battery using the
Midtronics battery and charging
system tester. Refer to Standard
Procedures for additional test
procedures. Replace the faulty
5. The starting system is faulty. 5. Determine if the starting system
is performing to specifications. Refer
to Starting System for the proper
starting system diagnosis and
testing procedures. Repair the faulty
starting system, as required.
6. The charging system is faulty. 6. Determine if the charging system
is performing to specifications using
the Midtronics battery and charging
system tester.. Refer to Charging
System for additional charging
system diagnosis and testing
procedures. Repair the faulty
charging system, as required.
7. Electrical loads exceed the
output of the charging system.
7. Inspect the vehicle for
aftermarket electrical equipment
which might cause excessive
electrical loads.
8. Slow driving or prolonged idling
with high-amperage draw systems
in use.
8. Advise the vehicle operator, as
required.
THE BATTERY WILL NOT ACCEPT
A CHARGE.
1. The battery is faulty. 1. Test the battery using the
Midtronics battery and charging
system tester.. Charge or replace
the faulty battery, as required.
ABNORMAL BATTERY DISCHARGING
Any of the fol l owi ng condi ti ons can resul t i n abnor-
mal battery di schargi ng:
A faul ty or i ncorrect chargi ng system compo-
nent. Refer to Chargi ng System for the proper charg-
i ng system di agnosi s and testi ng procedures.
A faul ty or i ncorrect battery. Refer to Standard
Procedures for the proper battery di agnosi s and test-
i ng procedures. Refer to Battery System Speci fi ca-
ti ons for the proper speci fi cati ons.
A faul ty ci rcui t or component causi ng excessi ve
i gni ti on-off draw.
El ectri cal l oads that exceed the output of the
chargi ng system. Thi s can be due to equi pment
i nstal l ed after manufacture, or repeated short tri p
use.
A faul ty or i ncorrect starti ng system component.
Refer to Starti ng System for the proper starti ng sys-
tem di agnosi s and testi ng procedures.
Corroded or l oose battery posts and termi nal
cl amps.
A l oose or worn generator dri ve bel t.
Sl ow dri vi ng speeds (heavy traffi c condi ti ons) or
prol onged i dl i ng, wi th hi gh-amperage draw systems
i n use.
CLEANING
The fol l owi ng i nformati on detai l s the recommended
cl eani ng procedures for the battery and rel ated com-
ponents. I n addi ti on to the mai ntenance schedul es
found i n thi s servi ce manual and the owners man-
ual , i t i s recommended that these procedures be per-
formed any ti me the battery or rel ated components
must be removed for vehi cl e servi ce.
(1) Cl ean the battery cabl e termi nal cl amps of al l
corrosi on. Remove any corrosi on usi ng a wi re brush
or a post and termi nal cl eani ng tool , and a sodi um
bi carbonate (baki ng soda) and warm water cl eani ng
sol uti on (Fi g. 1).
(2) Cl ean the battery tray and battery hol ddown
hardware of al l corrosi on. Remove any corrosi on
usi ng a wi re brush and a sodi um bi carbonate (baki ng
soda) and warm water cl eani ng sol uti on. Pai nt any
exposed bare metal .
(3) I f the removed battery i s to be rei nstal l ed,
cl ean the outsi de of the battery case and the top
cover wi th a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on usi ng a sti ff bri stl e
parts cl eani ng brush to remove any aci d fi l m (Fi g. 2).
Ri nse the battery wi th cl ean water. Ensure that the
cl eani ng sol uti on does not enter the battery cel l s
through the vent hol es. I f the battery i s bei ng
repl aced, refer to Battery System Speci fi cati ons for
the factory-i nstal l ed battery speci fi cati ons. Confi rm
that the repl acement battery i s the correct si ze and
has the correct rati ngs for the vehi cl e.
Fig. 1 Clean Battery Cable Terminal Clamp - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
Fig. 2 Clean Battery - Typical
1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY
(4) Cl ean the battery thermal guard wi th a sodi um
bi carbonate (baki ng soda) and warm water cl eani ng
sol uti on usi ng a sti ff bri stl e parts cl eani ng brush to
remove any aci d fi l m.
(5) Cl ean any corrosi on from the battery termi nal
posts wi th a wi re brush or a post and termi nal
cl eaner, and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on (Fi g. 3).
INSPECTION
The fol l owi ng i nformati on detai l s the recommended
i nspecti on procedures for the battery and rel ated
components. I n addi ti on to the mai ntenance sched-
ul es found i n thi s servi ce manual and the owners
manual , i t i s recommended that these procedures be
performed any ti me the battery or rel ated compo-
nents must be removed for vehi cl e servi ce.
(1) I nspect the battery cabl e termi nal cl amps for
damage. Repl ace any battery cabl e that has a dam-
aged or deformed termi nal cl amp.
(2) I nspect the battery tray and battery hol ddown
hardware for damage. Repl ace any damaged parts.
(3) Sl i de the thermal guard off of the battery case.
I nspect the battery case for cracks or other damage
that coul d resul t i n el ectrol yte l eaks. Al so, check the
battery termi nal posts for l ooseness. Batteri es wi th
damaged cases or l oose termi nal posts must be
repl aced.
(4) I nspect the battery thermal guard for tears,
cracks, deformati on or other damage. Repl ace any
battery thermal guard that has been damaged.
(5) I nspect the battery bui l t-i n test i ndi cator si ght
gl ass for an i ndi cati on of the battery condi ti on. I f the
battery i s di scharged, charge as requi red. Refer to
Standard Procedures for the proper battery bui l t-i n
i ndi cator test procedures. Al so refer to Standard Pro-
cedures for the proper battery chargi ng procedures.
SPECIFICATIONS
The battery Group Si ze number, the Col d Cranki ng
Amperage (CCA) rati ng, and the Reserve Capaci ty
(RC) rati ng or Ampere-Hours (AH) rati ng can be
found on the ori gi nal equi pment battery l abel . Be
certai n that a repl acement battery has the correct
Group Si ze number, as wel l as CCA, and RC or AH
rati ngs that equal or exceed the ori gi nal equi pment
speci fi cati on for the vehi cl e bei ng servi ced. Battery
si zes and rati ngs are di scussed i n more detai l bel ow.
Group Size - The outsi de di mensi ons and ter-
mi nal pl acement of the battery conform to standards
establ i shed by the Battery Counci l I nternati onal
(BCI ). Each battery i s assi gned a BCI Group Si ze
number to hel p i denti fy a correctl y-si zed repl ace-
ment.
Cold Cranking Amperage - The Col d Crank-
i ng Amperage (CCA) rati ng speci fi es how much cur-
rent (i n amperes) the battery can del i ver for thi rty
seconds at -18 C (0 F). Termi nal vol tage must not
fal l bel ow 7.2 vol ts duri ng or after the thi rty second
di scharge peri od. The CCA requi red i s general l y
hi gher as engi ne di spl acement i ncreases, dependi ng
al so upon the starter current draw requi rements.
Reserve Capacity - The Reserve Capaci ty (RC)
rati ng speci fi es the ti me (i n mi nutes) i t takes for bat-
tery termi nal vol tage to fal l bel ow 10.5 vol ts, at a
di scharge rate of 25 amperes. RC i s determi ned wi th
the battery ful l y-charged at 26.7 C (80 F). Thi s rat-
i ng esti mates how l ong the battery mi ght l ast after a
chargi ng system fai l ure, under mi ni mum el ectri cal
l oad.
Ampere-Hours - The Ampere-Hours (AH) rat-
i ng speci fi es the current (i n amperes) that a battery
can del i ver steadi l y for twenty hours, wi th the vol t-
age i n the battery not fal l i ng bel ow 10.5 vol ts. Thi s
rati ng i s al so someti mes i denti fi ed as the twenty-
hour di scharge rati ng.
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
BATTERY CLASSIFICATIONS & RATINGS
Part Number
BCI Group Size
Classification
Cold Cranking
Amperage
Reserve
Capacity
Ampere -
Hours
Load Test
Amperage
56041380AA 86 525 100 Minutes 60 250
SPECIAL TOOLS
BATTERY
DESCRIPTION
A l arge capaci ty, l ow-mai ntenance storage battery
(Fi g. 5) i s standard factory-i nstal l ed equi pment on
thi s model . Refer to Battery Speci fi cati ons for the
proper speci fi cati ons of the factory-i nstal l ed batteri es
avai l abl e on thi s model . Mal e post type termi nal s
made of a soft l ead materi al protrude from the top of
the mol ded pl asti c battery case to provi de the means
for connecti ng the battery to the vehi cl e el ectri cal
system. The battery posi ti ve termi nal post i s physi -
cal l y l arger i n di ameter than the negati ve termi nal
post to ensure proper battery connecti on. The l etters
POS and NEG are al so mol ded i nto the top of the
battery case adjacent to thei r respecti ve posi ti ve and
negati ve termi nal posts for i denti fi cati on confi rma-
ti on. Refer to Battery Cabl es for more i nformati on on
the battery cabl es that connect the battery to the
vehi cl e el ectri cal system.
The battery i s made up of si x i ndi vi dual cel l s that
are connected i n seri es. Each cel l contai ns posi ti vel y
charged pl ate groups that are connected wi th l ead
straps to the posi ti ve termi nal post, and negati vel y
charged pl ate groups that are connected wi th l ead
straps to the negati ve termi nal post. Each pl ate con-
si sts of a sti ff mesh framework or gri d coated wi th
l ead di oxi de (posi ti ve pl ate) or sponge l ead (negati ve
pl ate). I nsul ators or pl ate separators made of a non-
conducti ve materi al are i nserted between the posi ti ve
and negati ve pl ates to prevent them from contacti ng
or shorti ng agai nst one another. These di ssi mi l ar
metal pl ates are submerged i n a sul furi c aci d and
water sol uti on cal l ed an el ectrol yte.
The factory-i nstal l ed battery has a bui l t-i n test
i ndi cator (hydrometer). The col or vi si bl e i n the si ght
gl ass of the i ndi cator wi l l reveal the battery condi -
ti on. Refer to Standard Procedures for the proper
bui l t-i n i ndi cator test procedures. The factory-in-
stalled low-maintenance battery has removable
battery cell caps. Di sti l l ed water can be added to
thi s battery. The battery i s not seal ed and has vent
hol es i n the cel l caps. The chemi cal composi ti on of
the metal coated pl ates wi thi n the l ow-mai ntenance
Fig. 4 MIDTRONICS BATTERY AND CHARGING
SYSTEM TESTER - Micro420
Fig. 5 Low-Maintenance Battery - Typical
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - VENT
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - GREEN BALL
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - LOW-MAINTENANCE BATTERY
battery reduces battery gassi ng and water l oss, at
normal charge and di scharge rates. Therefore, the
battery shoul d not requi re addi ti onal water i n nor-
mal servi ce. I f the el ectrol yte l evel i n thi s battery
does become l ow, water must be added. However,
rapi d l oss of el ectrol yte can be caused by an over-
chargi ng condi ti on. Be certai n to di agnose the charg-
i ng system after repl eni shi ng the water i n the
battery for a l ow el ectrol yte condi ti on and before
returni ng the vehi cl e to servi ce. Refer to Chargi ng
System for the proper chargi ng system di agnosi s and
testi ng procedures.
The battery must be compl etel y charged and the
top, posts and termi nal cl amps shoul d be properl y
cl eaned and i nspected before di agnosti c procedures
are performed. Refer to Battery System Cl eani ng for
the proper cl eani ng procedures, and Battery System
I nspecti on for the proper battery i nspecti on proce-
dures. Refer to Standard Procedures for the proper
battery chargi ng procedures.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
WARNING: IF THE BATTERY IS EQUIPPED WITH
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
OF THE CELL CAPS ARE IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
The condi ti on of a battery i s determi ned by two cri -
teri a:
State-Of-Charge - Thi s can be determi ned by
checki ng the speci fi c gravi ty of the battery el ectrol yte
(bui l t-i n i ndi cator test or hydrometer test), or by
checki ng the battery vol tage (open-ci rcui t vol tage
test).
Cranking Capacity - Thi s can be determi ned
by performi ng a battery l oad test, whi ch measures
the abi l i ty of the battery to suppl y hi gh-amperage
current.
Fi rst, determi ne the battery state-of-charge. Thi s
can be done i n one of three ways. I f the battery has a
bui l t-i n test i ndi cator, perform the bui l t-i n i ndi cator
test to determi ne the state-of-charge. I f the battery
has no bui l t-i n test i ndi cator but does have remov-
abl e cel l caps, perform the hydrometer test to deter-
mi ne the state-of-charge. I f the battery cel l caps are
not removabl e, or a hydrometer i s not avai l abl e, per-
form the open-ci rcui t vol tage test to determi ne the
state-of-charge. Refer to open-ci rcui t vol tage test i n
the Standard Procedures secti on of thi s group.
Second, determi ne the battery cranki ng capaci ty by
performi ng a l oad test. The battery must be charged
before proceedi ng wi th a l oad test i f:
The battery bui l t-i n test i ndi cator has a bl ack or
dark col or vi si bl e.
The temperature corrected speci fi c gravi ty of the
battery el ectrol yte i s l ess than 1.235.
The battery open-ci rcui t vol tage i s l ess than 12.4
vol ts.
A battery that wi l l not accept a charge i s faul ty,
and must be repl aced. Further testi ng i s not
requi red. A ful l y-charged battery must be l oad tested
to determi ne i ts cranki ng capaci ty. A battery that i s
ful l y-charged, but does not pass the l oad test, i s
faul ty and must be repl aced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Standard
Procedures for the proper battery charging proce-
dures.
A battery i s ful l y-charged when:
Al l battery cel l s are gassi ng freel y duri ng charg-
i ng.
A green col or i s vi si bl e i n the si ght gl ass of the
battery bui l t-i n test i ndi cator.
Three corrected speci fi c gravi ty tests, taken at
one-hour i nterval s, i ndi cate no i ncrease i n the spe-
ci fi c gravi ty of the battery el ectrol yte.
Open-ci rcui t vol tage of the battery i s 12.4 vol ts
or greater.
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING
Battery chargi ng can be performed fast or sl ow, i t
terms of ti me. Slow battery chargi ng i s the best
means of restori ng a battery to ful l potenti al . Fast
BATTERY (Continued)
battery chargi ng shoul d onl y be performed when
absol utel y necessary due to ti me restrai nts. A battery
i s ful l y-charged when:
Al l of the battery cel l s are gassi ng freel y duri ng
battery chargi ng.
A green col or i s vi si bl e i n the si ght gl ass of the
battery bui l t-i n test i ndi cator.
Three hydrometer tests, taken at one-hour i nter-
val s, i ndi cate no i ncrease i n the temperature-cor-
rected speci fi c gravi ty of the battery el ectrol yte.
Open-ci rcui t vol tage of the battery i s 12.65 vol ts
or above.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1 C [30 F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
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.
NOTE: Models equipped with the diesel engine
option are equipped with two 12-volt batteries, con-
nected in parallel (positive-to-positive and negative-
to-negative). In order to ensure proper charging of
each battery, these batteries MUST be disconnected
from each other, as well as from the vehicle electri-
cal system, while being charged.
Some battery chargers are equi pped wi th pol ari ty-
sensi ng ci rcui try. Thi s ci rcui try protects the battery
charger and the battery from bei ng damaged i f they
are i mproperl y connected. I f the battery state-of-
charge i s too l ow for the pol ari ty-sensi ng ci rcui try to
detect, the battery charger wi l l not operate. Thi s
makes i t appear that the battery wi l l not accept
chargi ng current. See the i nstructi ons provi ded by
the manufacturer of the battery charger for detai l s
on how to bypass the pol ari ty-sensi ng ci rcui try.
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne the battery
cranki ng capaci ty. Refer to Standard Procedures for
the proper battery l oad test procedures. I f the battery
wi l l endure a l oad test, return the battery to servi ce.
I f the battery wi l l not endure a l oad test, i t i s faul ty
and must be repl aced.
Cl ean and i nspect the battery hol d downs, tray,
termi nal s, posts, and top before compl eti ng battery
servi ce. Refer to Battery System Cl eani ng for the
proper battery system cl eani ng procedures, and Bat-
tery System I nspecti on for the proper battery system
i nspecti on procedures.
CHARGING A COMPLETELY DISCHARGED
BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess thi s proce-
dure i s properl y fol l owed, a good battery may be
needl essl y repl aced.
(1) Measure the vol tage at the battery posts wi th a
vol tmeter, accurate to 1/10 (0.10) vol t (Fi g. 6). I f the
readi ng i s bel ow ten vol ts, the battery chargi ng cur-
rent wi l l be l ow. I t coul d take some ti me before the
battery accepts a current greater than a few mi l l i am-
peres. Such l ow current may not be detectabl e on the
ammeters bui l t i nto many battery chargers.
cabl e. Connect the battery charger l eads. Some bat-
tery chargers are equi pped wi th pol ari ty-sensi ng ci r-
cui try. Thi s ci rcui try protects the battery charger and
the battery from bei ng damaged i f they are i mprop-
erl y connected. I f the battery state-of-charge i s too
l ow for the pol ari ty-sensi ng ci rcui try to detect, the
battery charger wi l l not operate. Thi s makes i t
appear that the battery wi l l not accept chargi ng cur-
rent. See the i nstructi ons provi ded by the manufac-
Fig. 6 Voltmeter - Typical
BATTERY (Continued)
turer of the battery charger for detai l s on how to
bypass the pol ari ty-sensi ng ci rcui try.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. The amount of ti me
requi red for a battery to accept measurabl e chargi ng
current at vari ous vol tages i s shown i n the Charge
Rate Tabl e. I f the chargi ng current i s sti l l not mea-
surabl e at the end of the chargi ng ti me, the battery
i s faul ty and must be repl aced. I f the chargi ng cur-
rent i s measurabl e duri ng the chargi ng ti me, the bat-
tery may be good and the chargi ng shoul d be
compl eted i n the normal manner.
CHARGE RATE TABLE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
CHARGING TIME REQUIRED
The ti me requi red to charge a battery wi l l vary,
dependi ng upon the fol l owi ng factors:
Battery Capacity - A compl etel y di scharged
heavy-duty battery requi res twi ce the chargi ng ti me
of a smal l capaci ty battery.
Temperature - A l onger ti me wi l l be needed to
charge a battery at -18 C (0 F) than at 27 C (80
F). When a fast battery charger i s connected to a col d
battery, the current accepted by the battery wi l l be
very l ow at fi rst. As the battery warms, i t wi l l accept
a hi gher chargi ng current rate (amperage).
Charger Capacity - A battery charger that
suppl i es onl y fi ve amperes wi l l requi re a l onger
chargi ng ti me. A battery charger that suppl i es
twenty amperes or more wi l l requi re a shorter charg-
i ng ti me.
State-Of-Charge - A compl etel y di scharged bat-
tery requi res more chargi ng ti me than a parti al l y
di scharged battery. El ectrol yte i s nearl y pure water
i n a compl etel y di scharged battery. At fi rst, the
chargi ng current (amperage) wi l l be l ow. As the bat-
tery charges, the speci fi c gravi ty of the el ectrol yte
wi l l gradual l y ri se.
The Battery Chargi ng Ti me Tabl e gi ves an i ndi ca-
ti on of the ti me requi red to charge a typi cal battery
at room temperature based upon the battery state-of-
charge and the charger capaci ty.
BATTERY CHARGING TIME TABLE
Charging
Amperage
5 Amps
10
Amps
20 Amps
Open Circuit
Voltage
Hours Charging @ 21C (70
F)
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST
An i ndi cator (hydrometer) bui l t i nto the top of the
battery case provi des vi sual i nformati on for battery
testi ng (Fi g. 7). Li ke a hydrometer, the bui l t-i n i ndi -
cator measures the speci fi c gravi ty of the battery
el ectrol yte. The speci fi c gravi ty of the el ectrol yte
reveal s the battery state-of-charge; however, i t wi l l
not reveal the cranki ng capaci ty of the battery. A l oad
test must be performed to determi ne the battery
the proper battery l oad test procedures.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. I n order to
obtai n correct i ndi cati ons from the bui l t-i n i ndi cator,
i t i s i mportant that the battery be l evel and have a
cl ean si ght gl ass. Addi ti onal l i ght may be requi red to
vi ew the i ndi cator. Do not use open flame as a
source of additional light.
Fig. 7 Built-In Indicator
1 - SIGHT GLASS
2 - BATTERY TOP
3 - GREEN BALL
4 - PLASTIC ROD
BATTERY (Continued)
To read the bui l t-i n i ndi cator, l ook i nto the si ght
gl ass and note the col or of the i ndi cati on (Fi g. 8). The
battery condi ti on that each col or i ndi cates i s
descri bed i n the fol l owi ng l i st:
Green - I ndi cates 75% to 100% battery state-of-
charge. The battery i s adequatel y charged for further
testi ng or return to servi ce. I f the starter wi l l not
crank for a mi ni mum of fi fteen seconds wi th a ful l y-
charged battery, the battery must be l oad tested.
Refer to Standard Procedures for the proper battery
l oad test procedures.
Black or Dark - I ndi cates 0% to 75% battery
state-of-charge. The battery i s i nadequatel y charged
and must be charged unti l a green i ndi cati on i s vi si -
bl e i n the si ght gl ass (12.4 vol ts or more), before the
battery i s tested further or returned to servi ce. Refer
to Standard Procedures for the proper battery charg-
i ng procedures. Al so refer to Di agnosi s and Testi ng
for more i nformati on on the possi bl e causes of the
di scharged battery condi ti on.
Clear or Bright - I ndi cates a l ow battery el ec-
trol yte l evel . The el ectrol yte l evel i n the battery i s
bel ow the bui l t-i n i ndi cator. A mai ntenance-free bat-
tery wi th non-removabl e cel l caps must be repl aced i f
the el ectrol yte l evel i s l ow. Water must be added to a
l ow-mai ntenance battery wi th removabl e cel l caps
before i t i s charged. Refer to Standard Procedures for
the proper battery fi l l i ng procedures. A l ow el ectro-
l yte l evel may be caused by an overchargi ng condi -
ti on. Refer to Chargi ng System for the proper
chargi ng system di agnosi s and testi ng procedures.
STANDARD PROCEDURE - HYDROMETER TEST
The hydrometer test reveal s the battery state-of-
charge by measuri ng the speci fi c gravi ty of the el ec-
trol yte. This test cannot be performed on
maintenance-free batteries with non-removable
cell caps. I f the battery has non-removabl e cel l caps,
refer to Di agnosi s and Testi ng for al ternate methods
of determi ni ng the battery state-of-charge.
Speci fi c gravi ty i s a compari son of the densi ty of
the battery el ectrol yte to the densi ty of pure water.
Pure water has a speci fi c gravi ty of 1.000, and sul fu-
ri c aci d has a speci fi c gravi ty of 1.835. Sul furi c aci d
makes up approxi matel y 35% of the battery el ectro-
l yte by wei ght, or 24% by vol ume. I n a ful l y-charged
battery the el ectrol yte wi l l have a temperature-cor-
rected speci fi c gravi ty of 1.260 to 1.290. However, a
speci fi c gravi ty of 1.235 or above i s sati sfactory for
the battery to be l oad tested and/or returned to ser-
vi ce.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. Then
remove the battery cel l caps and check the el ectrol yte
l evel . Add di sti l l ed water i f the el ectrol yte l evel i s
bel ow the top of the battery pl ates. Refer to Battery
System Cl eani ng for the proper battery i nspecti on
procedures.
See the i nstructi ons provi ded by the manufacturer
of the hydrometer for recommendati ons on the cor-
rect use of the hydrometer that you are usi ng.
Remove onl y enough el ectrol yte from the battery cel l
so that the fl oat i s off the bottom of the hydrometer
barrel wi th pressure on the bul b rel eased. To read
the hydrometer correctl y, hol d i t wi th the top surface
of the el ectrol yte at eye l evel (Fi g. 9).
CAUTION: Exercise care when inserting the tip of
the hydrometer into a battery cell to avoid damag-
ing the plate separators. Damaged plate separators
can cause early battery failure.
Hydrometer fl oats are general l y cal i brated to i ndi -
cate the speci fi c gravi ty correctl y onl y at 26.7 C.
When testi ng the speci fi c gravi ty at any other tem-
perature, a correcti on factor i s requi red. The correc-
ti on factor i s approxi matel y a speci fi c gravi ty val ue
of 0.004, whi ch may al so be i denti fi ed as four poi nts
of speci fi c gravi ty. For each 5.5 C above 26.7 C, add
four poi nts. For each 5.5 C bel ow 26.7 C, subtract
four poi nts. Al ways correct the speci fi c gravi ty for
temperature vari ati on.
EXAMPLE: A battery i s tested at -12.2 C and has
a speci fi c gravi ty of 1.240. Determi ne the actual spe-
ci fi c gravi ty as fol l ows:
(1) Determi ne the number of degrees above or
bel ow 26.7 C: 26.7 C +-12.2 C =14.5 C below
the 26.7 C specification
(2) Di vi de the resul t from Step 1 by 5.5 C: 14.5
C 5.5 C =2.64
(3) Mul ti pl y the resul t from Step 2 by the temper-
ature correcti on factor (0.004): 2.64 X 0.004 =0.01
(4) The temperature at testi ng was bel ow 26.7 C;
therefore, the temperature correcti on factor i s sub-
tracted: 1.240 - 0.01 =1.23
(5) The corrected speci fi c gravi ty of the battery cel l
i n thi s exampl e i s 1.23.
Fig. 8 Built-In Indicator Sight Glass Chart
BATTERY (Continued)
Test the speci fi c gravi ty of the el ectrol yte i n each
battery cel l . I f the speci fi c gravi ty of al l cel l s i s above
1.235, but the vari ati on between cel l s i s more than
fi fty poi nts (0.050), the battery shoul d be repl aced. I f
the speci fi c gravi ty of one or more cel l s i s l ess than
1.235, charge the battery at a rate of approxi matel y
fi ve amperes. Conti nue chargi ng the battery unti l
three consecuti ve speci fi c gravi ty tests, taken at one-
hour i nterval s, are constant. I f the cel l speci fi c grav-
i ty vari ati on i s more than fi fty poi nts (0.050) at the
end of the charge peri od, repl ace the battery.
When the speci fi c gravi ty of al l cel l s i s above 1.235,
and the cel l vari ati on i s l ess than fi fty poi nts (0.050),
the battery may be l oad tested to determi ne i ts
the proper battery l oad test procedures.
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-ci rcui t vol tage (no l oad) test wi l l
show the approxi mate state-of-charge of a battery.
Thi s test can be used i n pl ace of the hydrometer test
when a hydrometer i s not avai l abl e, or for mai nte-
nance-free batteri es wi th non-removabl e cel l caps.
Before proceedi ng wi th thi s test, compl etel y charge
the battery (Refer to 8 - ELECTRI CAL/BATTERY
SYSTEM/BATTERY - STANDARD PROCEDURE).
(1) Before measuri ng the open-ci rcui t vol tage, the
surface charge must be removed from the battery.
Turn on the headl amps for fi fteen seconds, then
al l ow up to fi ve mi nutes for the battery vol tage to
stabi l i ze.
(2) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst.
(3) Usi ng a vol tmeter connected to the battery
posts (see the i nstructi ons provi ded by the manufac-
turer of the vol tmeter), measure the open-ci rcui t vol t-
age (Fi g. 10).
See the Open-Ci rcui t Vol tage Tabl e. Thi s vol tage
readi ng wi l l i ndi cate the battery state-of-charge, but
wi l l not reveal i ts cranki ng capaci ty. I f a battery has
an open-ci rcui t vol tage readi ng of 12.4 vol ts or
greater, i t may be l oad tested to reveal i ts cranki ng
capaci ty (Refer to 8 - ELECTRI CAL/BATTERY SYS-
TEM/BATTERY - STANDARD PROCEDURE).
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
STANDARD PROCEDURE - LOAD TEST
A battery l oad test wi l l veri fy the battery cranki ng
capaci ty. The test i s based on the Col d Cranki ng
Amperage (CCA) rati ng of the battery. To determi ne
the battery CCA rati ng, see the l abel affi xed to the
battery case or refer to Battery Speci fi cati ons for the
proper factory-i nstal l ed speci fi cati ons.
Before proceedi ng wi th thi s test, compl etel y charge
the battery (Refer to 8 - ELECTRI CAL/BATTERY
SYSTEM/BATTERY - STANDARD PROCEDURE).
Fig. 9 Hydrometer - Typical
1 - BULB
2 - SURFACE COHESION
3 - SPECIFIC GRAVITY READING
4 - TEMPERATURE READING
5 - HYDROMETER BARREL
6 - FLOAT
Fig. 10 Testing Open-Circuit Voltage - Typical
BATTERY (Continued)
(1) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst. The battery top and posts shoul d be
cl ean (Refer to 8 - ELECTRI CAL/BATTERY SYSTEM
- CLEANI NG).
(2) Connect a sui tabl e vol t-ammeter-l oad tester
(Fi g. 11) to the battery posts (Fi g. 12). See the
i nstructi ons provi ded by the manufacturer of the
tester you are usi ng. Check the open-ci rcui t vol tage
(no l oad) of the battery (Refer to 8 - ELECTRI CAL/
BATTERY SYSTEM/BATTERY - STANDARD PRO-
CEDURE). The battery open-ci rcui t vol tage must be
12.4 vol ts or greater.
(3) Rotate the l oad control knob (carbon pi l e rheo-
stat) to appl y a 300 ampere l oad to the battery for
fi fteen seconds, then return the control knob to the
Off posi ti on (Fi g. 13). Thi s wi l l remove the surface
charge from the battery.
(4) Al l ow the battery to stabi l i ze to open-ci rcui t
vol tage. I t may take up to fi ve mi nutes for the bat-
tery vol tage to stabi l i ze.
(5) Rotate the l oad control knob to mai ntai n a l oad
equal to 50% of the CCA rati ng of the battery (Fi g.
14). After fi fteen seconds, record the l oaded vol tage
readi ng, then return the l oad control knob to the Off
posi ti on.
(6) The vol tage drop wi l l vary wi th the battery
temperature at the ti me of the l oad test. The battery
temperature can be esti mated by usi ng the ambi ent
temperature duri ng the past several hours. I f the
battery has been charged, boosted, or l oaded a few
mi nutes pri or to the test, the battery wi l l be some-
what warmer. See the Load Test Temperature Tabl e
for the proper l oaded vol tage readi ng.
Fig. 11 Volt-Ammeter-Load Tester - Typical
Fig. 12 Volt-Ammeter-Load
1 - INDUCTION AMMETER CLAMP
2 - NEGATIVE CLAMP
3 - POSITIVE CLAMP
Fig. 13 Remove Surface Charge from Battery
Fig. 14 Load 50% CCA Rating - Note Voltage -
Typical
BATTERY (Continued)
LOAD TEST TEMPERATURE TABLE
Minimum Voltage
Temperature
F C
9.6 volts 70and above 21and above
9.5 volts 60 16
9.4 volts 50 10
9.3 volts 40 4
9.1 volts 30 -1
8.9 volts 20 -7
8.7 volts 10 -12
8.5 volts 0 -18
(7) I f the vol tmeter readi ng fal l s bel ow 9.6 vol ts, at
a mi ni mum battery temperature of 21 C (70 F), the
battery i s faul ty and must be repl aced.
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term I gni ti on-Off Draw (I OD) i denti fi es a nor-
mal condi ti on where power i s bei ng drai ned from the
battery wi th the i gni ti on swi tch i n the Off posi ti on. A
normal vehi cl e el ectri cal system wi l l draw from fi ve
to thi rty-fi ve mi l l i amperes (0.005 to 0.035 ampere)
wi th the i gni ti on swi tch i n the Off posi ti on, and al l
non-i gni ti on control l ed ci rcui ts i n proper worki ng
order. Up to thi rty-fi ve mi l l i amperes are needed to
enabl e the memory functi ons for the Powertrai n Con-
trol Modul e (PCM), di gi tal cl ock, el ectroni cal l y tuned
radi o, and other modul es whi ch may vary wi th the
vehi cl e equi pment.
A vehi cl e that has not been operated for approxi -
matel y twenty days, may di scharge the battery to an
i nadequate l evel . When a vehi cl e wi l l not be used for
twenty days or more (stored), remove the I OD fuse
from the Power Di stri buti on Center (PDC). Thi s wi l l
reduce battery di schargi ng.
Excessi ve I OD can be caused by:
El ectri cal i tems l eft on.
Faul ty or i mproperl y adjusted swi tches.
Faul ty or shorted el ectroni c modul es and compo-
nents.
An i nternal l y shorted generator.
I ntermi ttent shorts i n the wi ri ng.
I f the I OD i s over thi rty-fi ve mi l l i amperes, the
probl em must be found and corrected before repl ac-
i ng a battery. I n most cases, the battery can be
charged and returned to servi ce after the excessi ve
I OD condi ti on has been corrected.
(1) Veri fy that al l el ectri cal accessori es are off.
Turn off al l l amps, remove the i gni ti on key, and cl ose
al l doors. I f the vehi cl e i s equi pped wi th an i l l umi -
nated entry system or an el ectroni cal l y tuned radi o,
al l ow the el ectroni c ti mer functi on of these systems
to automati cal l y shut off (ti me out). Thi s may take
up to three mi nutes. See the El ectroni c Modul e I gni -
ti on-Off Draw Tabl e for more i nformati on.
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE
Module
Time Out?
(If Yes, Interval And Wake-Up Input)
IOD
IOD After Time
Out
Radio No
1 to 3
milliamperes
N/A
Audio Power
Amplifier
No
up to 1
milliampere
N/A
Body Control Module
(BCM)
No
4.75
milliamperes
(max.)
N/A
Powertrain Control
Module (PCM)
No 0.95 milliampere N/A
ElectroMechanical
Instrument Cluster
(EMIC)
No 0.44 milliampere N/A
Combination Flasher No 0.08 milliampere N/A
Automatic
Transmission
Controller (EATX)
Yes, 20 minutes 120 milliampere 0.70 ma
BATTERY (Continued)
(2) Determi ne that the underhood l amp i s operat-
i ng properl y, then di sconnect the l amp wi re harness
connector or remove the l amp bul b.
(3) Di sconnect the battery negati ve cabl e.
(4) Set an el ectroni c di gi tal mul ti -meter to i ts
hi ghest amperage scal e. Connect the mul ti -meter
between the di sconnected battery negati ve cabl e ter-
mi nal cl amp and the battery negati ve termi nal post.
Make sure that the doors remai n cl osed so that the
i l l umi nated entry system i s not acti vated. The mul ti -
meter amperage readi ng may remai n hi gh for up to
three mi nutes, or may not gi ve any readi ng at al l
whi l e set i n the hi ghest amperage scal e, dependi ng
upon the el ectri cal equi pment i n the vehi cl e. The
mul ti -meter l eads must be securel y cl amped to the
battery negati ve cabl e termi nal cl amp and the bat-
tery negati ve termi nal post. I f conti nui ty between the
battery negati ve termi nal post and the negati ve cabl e
termi nal cl amp i s l ost duri ng any part of the I OD
test, the el ectroni c ti mer functi on wi l l be acti vated
and al l of the tests wi l l have to be repeated.
(5) After about three mi nutes, the hi gh-amperage
I OD readi ng on the mul ti -meter shoul d become very
l ow or nonexi stent, dependi ng upon the el ectri cal
equi pment i n the vehi cl e. I f the amperage readi ng
remai ns hi gh, remove and repl ace each fuse or ci rcui t
breaker i n the Power Di stri buti on Center (PDC) and
then i n the Juncti on Bl ock (JB), one at a ti me unti l
the amperage readi ng becomes very l ow, or nonexi st-
ent. Refer to the appropri ate wi ri ng i nformati on i n
thi s servi ce manual for compl ete PDC and JB fuse,
ci rcui t breaker, and ci rcui t i denti fi cati on. Thi s wi l l
i sol ate each ci rcui t and i denti fy the ci rcui t that i s the
source of the hi gh-amperage I OD. I f the amperage
readi ng remai ns hi gh after removi ng and repl aci ng
each fuse and ci rcui t breaker, di sconnect the wi re
harness from the generator. I f the amperage readi ng
now becomes very l ow or nonexi stent, refer to Charg-
i ng System for the proper chargi ng system di agnosi s
and testi ng procedures. After the hi gh-amperage I OD
has been corrected, swi tch the mul ti -meter to pro-
gressi vel y l ower amperage scal es and, i f necessary,
repeat the fuse and ci rcui t breaker remove-and-re-
pl ace process to i denti fy and correct al l sources of
excessi ve I OD. I t i s now safe to sel ect the l owest mi l -
l i ampere scal e of the mul ti -meter to check the l ow-
amperage I OD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the mul ti -meter readi ng. The l ow-am-
perage I OD shoul d not exceed thi rty-fi ve mi l l i am-
peres (0.035 ampere). I f the current draw exceeds
thi rty-fi ve mi l l i amperes, i sol ate each ci rcui t usi ng the
fuse and ci rcui t breaker remove-and-repl ace process
i n Step 5. The mul ti -meter readi ng wi l l drop to
wi thi n the acceptabl e l i mi t when the source of the
excessi ve current draw i s di sconnected. Repai r thi s
ci rcui t as requi red; whether a wi ri ng short, i ncorrect
swi tch adjustment, or a component fai l ure i s at faul t.
STANDARD PROCEDURE - USING
MIDTRONICS ELECTRICAL TESTER
Al ways use the Mi dtroni cs I nstructi on Manual that
was suppl i ed wi th the tester as a reference. I f the
I nstructi on Manual i s not avai l abl e the fol l owi ng pro-
cedure can be used:
WARNING: ALWAYS WEAR APPROPRIATE EYE
PROTECTION AND USE EXTREME CAUTION WHEN
WORKING WITH BATTERIES.
BATTERY TESTING
(1) I f testi ng the battery OUT-OF-VEHI CLE, cl ean
the battery termi nal s wi th a wi re brush before test-
i ng. I f the battery i s equi pped wi th si de post termi -
nal s, i nstal l and ti ghten the suppl i ed l ead termi nal
stud adapters. Do not use steel bol ts. Fai l ure to prop-
erl y i nstal l the stud adapters, or usi ng stud adapters
that are di rty or worn-out may resul t i n fal se test
readi ngs.
(2) I f testi ng the battery I N-THE-VEHI CLE, make
certai n al l of the vehi cl e accessory l oads are OFF,
i ncl udi ng the i gni ti on. The preferred test position
is at the battery terminal. I f the battery i s not
accessi bl e, you may test usi ng both the posi ti ve and
Fig. 15 MIDTRONICS BATTERY AND CHARGING
SYSTEM TESTER - Micro420
BATTERY (Continued)
negati ve jumper posts. Sel ect TESTI NG AT JUMPER
POST when connecti ng to that l ocati on.
(3) Connect the tester to the battery or jumper
posts, the red cl amp to posi ti ve (+) and the bl ack
cl amp to negati ve ().
NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
battery test. Failure to disconnect may result in
false battery test readings.
NOTE: When testing the battery in a PT Cruiser,
always test at the battery terminals
(4) Usi ng the ARROW key sel ect in or out of vehi -
cl e testi ng and press ENTER to make a sel ecti on.
(5) I f not sel ected, choose the Col d Cranki ng Amp
(CCA) battery rati ng. Or sel ect the appropri ate bat-
tery rati ng for your area (see menu). The tester wi l l
then run i ts sel f programmed test of the battery and
di spl ay the resul ts. Refer to the test resul t tabl e
noted bel ow.
CAUTION: If REPLACE BATTERY is the result of the
test, this may mean a poor connection between the
vehicles cables and battery exists. After discon-
necting the vehicles battery cables from the bat-
tery, retest the battery using the OUT-OF-VEHICLE
test before replacing.
(6) Whi l e vi ewi ng the battery test resul t, press the
CODE button and the tester wi l l prompt you for the
l ast 4 di gi ts of the VI N. Use the UP/DOWN arrow
buttons to scrol l to the correct character; then press
ENTER to sel ect and move to the next di gi t. Then
press the ENTER button to vi ew the SERVI CE
CODE. Pressi ng the CODE button a second ti me wi l l
return you to the test resul ts.
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
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post (Fi g. 16).
(4) Loosen the battery posi ti ve cabl e termi nal
(5) Di sconnect the battery posi ti ve cabl e termi nal
cl amp from the battery posi ti ve termi nal post. I f nec-
essary, use a battery termi nal pul l er to remove the
termi nal cl amp from the battery post.
(6) Remove the battery hol ddowns from the bat-
tery. Refer to Battery Hol ddown for the proper bat-
tery hol ddown removal procedures.
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
(7) Remove the battery and the battery thermal
guard from the battery tray as a uni t.
(8) Remove the battery thermal guard from the
battery case. Refer to Thermal Guard for the proper
battery thermal guard removal procedures.
INSTALLATION
(1) Cl ean and i nspect al l of the battery system
components. Refer to Battery System Cl eani ng for
the proper cl eani ng procedures, and refer to Battery
System I nspecti on for the proper i nspecti on proce-
dures.
Fig. 16 Remove Battery Cable Terminal Clamp -
Typical
1 - BATTERY
2 - BATTERY TERMINAL PULLER
BATTERY (Continued)
(2) Rei nstal l the battery thermal guard onto the
battery case. Refer to Thermal Guard for the proper
battery thermal guard i nstal l ati on procedures.
(3) Posi ti on the battery and the battery thermal
guard onto the battery tray as a uni t. Ensure that
the battery posi ti ve and negati ve termi nal posts are
correctl y posi ti oned. The battery cabl e termi nal
cl amps must reach the correct battery termi nal post
wi thout stretchi ng the cabl es (Fi g. 17).
(4) Rei nstal l the battery hol ddowns onto the bat-
tery. Refer to Battery Hol ddown for the proper i nstal -
l ati on procedure.
CAUTION: Be certain that the battery cable terminal
clamps are connected to the correct battery termi-
nal posts. Reversed battery polarity may damage
electrical components of the vehicle.
(5) Cl ean the battery cabl e termi nal cl amps and
the battery termi nal posts. Refer to Battery System
Cl eani ng for cl eani ng procedure.
(6) Reconnect the battery posi ti ve cabl e termi nal
cl amp to the battery posi ti ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 45 i n. l bs.
(7) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 45 i n. l bs.
(8) Appl y a thi n coati ng of petrol eum jel l y or chas-
si s grease to the exposed surfaces of the battery cabl e
termi nal cl amps and the battery termi nal posts.
BATTERY HOLDDOWN
DESCRIPTION
The battery hol ddown hardware i ncl udes a pl asti c
hol ddown bracket and retai ni ng bol t. The battery
hol ddown bracket meshes wi th the battery tray to
secure the battery to the battery tray.
When i nstal l i ng a battery i nto the battery tray, i t
i s i mportant that the hol ddown hardware i s properl y
i nstal l ed and that the fastener i s ti ghtened to the
proper speci fi cati ons. I mproper hol ddown fastener
ti ghtness, whether too l oose or too ti ght, can resul t i n
damage to the battery, the vehi cl e, or both. Refer to
Battery Hol ddown for the proper i nstal l ati on proce-
dure, i ncl udi ng the proper hol ddown fastener torque
speci fi cati ons.
OPERATION
The battery hol ddown secures the battery i n the
battery tray. Thi s hol ddown i s desi gned to prevent
battery movement duri ng the most extreme vehi cl e
operati on condi ti ons. Peri odi c removal and l ubri ca-
ti on of the battery hol ddown hardware i s recom-
mended to prevent hardware sei zure at a l ater date.
CAUTION: Never operate a vehicle without a battery
holddown device properly installed. Damage to the
vehicle, components and battery could result.
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post.
(4) Remove the battery hol d down bracket retai n-
i ng bol t from the threaded i nsert i n the battery tray
assembl y.
INSTALLATION
(1) Cl ean and i nspect the battery hol d down hard-
ware. Refer to Battery Cl eani ng for the proper bat-
tery system component cl eani ng procedures, and
Battery I nspecti on for the proper battery system
component i nspecti on procedures.
(2) Posi ti on the battery hol d down bracket onto the
battery tray.
Fig. 17 Battery Cables - Typical
1 - RADIATOR CROSSMEMBER
2 - WHEELHOUSE INNER PANEL
3 - NEGATIVE CABLE
4 - POSITIVE CABLE
5 - BATTERY
BATTERY (Continued)
(3) I nstal l and ti ghten the battery hol d down
bracket retai ni ng bol t. Ti ghten the bol t to 4 Nm (20
i n. l bs.).
(4) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 8.4 Nm (75
i n. l bs.).
BATTERY CABLES
DESCRIPTION
The battery cabl es (Fi g. 18) are l arge gauge,
stranded copper wi res sheathed wi thi n a heavy pl as-
ti c or syntheti c rubber i nsul ati ng jacket. The wi re
used i n the battery cabl es combi nes excel l ent fl exi bi l -
i ty and rel i abi l i ty wi th hi gh el ectri cal current carry-
i ng capaci ty. The battery cabl es feature a cl ampi ng
type femal e battery termi nal made of soft l ead that i s
di e cast onto one end of the battery cabl e wi re. A
square headed pi nch-bol t and hex nut are i nstal l ed
at the open end of the femal e battery termi nal cl amp.
Large eyel et type termi nal s are cri mped onto the
opposi te end of the battery cabl e wi re and then sol -
der-di pped. The battery posi ti ve cabl e wi res have a
red i nsul ati ng jacket to provi de vi sual i denti fi cati on
and feature a l arger femal e battery termi nal cl amp
to al l ow connecti on to the l arger battery posi ti ve ter-
mi nal post. The battery negati ve cabl e wi res have a
bl ack i nsul ati ng jacket and a smal l er femal e battery
termi nal cl amp.
The battery cabl es cannot be repai red and, i f dam-
aged or faul ty they must be repl aced. Both the bat-
tery posi ti ve and negati ve cabl es are avai l abl e for
servi ce repl acement onl y as a uni t wi th the battery
wi re harness, whi ch may i ncl ude porti ons of the wi r-
i ng ci rcui ts for the generator and other components
on some model s. Refer to the appropri ate wi ri ng
i nformati on i n thi s servi ce manual for the l ocati on of
the proper battery cabl e wi re harness di agrams. The
wi ri ng i nformati on al so i ncl udes proper wi re and con-
nector repai r procedures, further detai l s on wi re har-
ness routi ng and retenti on, as wel l as pi n-out and
OPERATION
The battery cabl es connect the battery termi nal
posts to the vehi cl e el ectri cal system. These cabl es
al so provi de a path back to the battery for el ectri cal
current generated by the chargi ng system for restor-
i ng the vol tage potenti al of the battery. The femal e
battery termi nal cl amps on the ends of the battery
cabl e wi res provi de a strong and rel i abl e connecti on
of the battery cabl e to the battery termi nal posts.
The termi nal pi nch bol ts al l ow the femal e termi nal
cl amps to be ti ghtened around the mal e termi nal
posts on the top of the battery. The eyel et termi nal s
secured to the opposi te ends of the battery cabl e
wi res from the femal e battery termi nal cl amps pro-
vi de secure and rel i abl e connecti on of the battery
cabl es to the vehi cl e el ectri cal system.
The battery posi ti ve cabl e termi nal cl amp i s di e
cast onto the ends of two wi res. One wi re has an eye-
l et termi nal that connects the battery posi ti ve cabl e
to the B(+) termi nal studs of the Power Di stri buti on
Center (PDC), and the other wi re has an eyel et ter-
mi nal that connects the battery posi ti ve cabl e to the
B(+) termi nal stud of the engi ne starter motor sol e-
noi d. The battery negati ve cabl e termi nal cl amp i s
al so di e cast onto the ends of two wi res. One wi re
has an eyel et termi nal that connects the battery neg-
ati ve cabl e to the vehi cl e powertrai n through a stud
on the l eft si de of the engi ne cyl i nder bl ock. The
other wi re has an eyel et termi nal that connects the
battery negati ve cabl e to the vehi cl e body through a
ground stud on the l eft wheel house, near the bat-
tery.
Fig. 18 Battery Cables - Typical
1 - Battery
2 - Radiator Crossmember
3 - Terminal Clamps
4 - Fender Inner Shield
5 - Negative Cable
6 - Positive Cable
BATTERY HOLDDOWN (Continued)
DIAGNOSIS AND TESTING - BATTERY CABLES
A vol tage drop test wi l l determi ne i f there i s exces-
si ve resi stance i n the battery cabl e termi nal connec-
ti ons or the battery cabl e. I f excessi ve resi stance i s
found i n the battery cabl e connecti ons, the connec-
ti on poi nt shoul d be di sassembl ed, cl eaned of al l cor-
rosi on or forei gn materi al , then reassembl ed.
Fol l owi ng reassembl y, check the vol tage drop for the
battery cabl e connecti on and the battery cabl e agai n
to confi rm repai r.
When performi ng the vol tage drop test, i t i s i mpor-
tant to remember that the vol tage drop i s gi vi ng an
i ndi cati on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached. EXAM-
PLE: When testi ng the resi stance of the battery pos-
i ti ve cabl e, touch the vol tmeter l eads to the battery
posi ti ve cabl e termi nal cl amp and to the battery pos-
i ti ve cabl e eyel et termi nal at the starter sol enoi d
B(+) termi nal stud. I f you probe the battery posi ti ve
termi nal post and the battery posi ti ve cabl e eyel et
termi nal at the starter sol enoi d B(+) termi nal stud,
you are readi ng the combi ned vol tage drop i n the
battery posi ti ve cabl e termi nal cl amp-to-termi nal
post connecti on and the battery posi ti ve cabl e.
VOLTAGE DROP TEST
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng thi s
test, be certai n that the fol l owi ng procedures are
accompl i shed:
The battery i s ful l y-charged and l oad tested.
Refer to Standard Procedures for the proper battery
chargi ng and l oad test procedures.
Ful l y engage the parki ng brake.
I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and bl ock the cl utch pedal i n the
ful l y depressed posi ti on.
Veri fy that al l l amps and accessori es are turned
off.
To prevent the engi ne from starti ng, remove the
Automati c Shut Down (ASD) rel ay. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC), i n
the engi ne compartment. See the fuse and rel ay l ay-
out l abel affi xed to the undersi de of the PDC cover
for ASD rel ay i denti fi cati on and l ocati on.
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e termi nal cl amp (Fi g. 19). Rotate and hol d the
i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f vol tage i s detected, correct the poor con-
necti on between the battery negati ve cabl e termi nal
cl amp and the battery negati ve termi nal post.
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
termi nal cl amp (Fi g. 20). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor connecti on
between the battery posi ti ve cabl e termi nal cl amp
and the battery posi ti ve termi nal post.
(3) Connect the vol tmeter to measure between the
battery posi ti ve cabl e termi nal cl amp and the starter
sol enoi d B(+) termi nal stud (Fi g. 21). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery posi ti ve cabl e eyel et termi nal con-
Fig. 19 TEST BATTERY NEGATIVE CONNECTION
RESISTANCE - TYPICAL
1 - VOLTMETER
2 - BATTERY
Fig. 20 TEST BATTERY POSITIVE CONNECTION
1 - VOLTMETER
2 - BATTERY
BATTERY CABLES (Continued)
necti on at the starter sol enoi d B(+) termi nal stud.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
(4) Connect the vol tmeter to measure between the
battery negati ve cabl e termi nal cl amp and a good
cl ean ground on the engi ne bl ock (Fi g. 22). Rotate
and hol d the i gni ti on swi tch i n the Start posi ti on.
Observe the vol tmeter. I f the readi ng i s above 0.2
vol t, cl ean and ti ghten the battery negati ve cabl e
eyel et termi nal connecti on to the engi ne bl ock.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery negati ve cabl e.
THERMAL GUARD
DESCRIPTION
A fl exi bl e pl asti c bubbl e-wrap styl e thermal guard
(Fi g. 23) sl i des over the battery case to encl ose the
si des of the battery. The thermal guard consi sts of a
heavy bl ack pl asti c outer ski n and two l i ghter pl i es of
pl asti c that have been formed i nto a sheet wi th hun-
dreds of smal l ai r pockets entrapped between them.
The resul ti ng materi al i s very si mi l ar to the bubbl e-
wrap used to protect i tems i n many parcel packagi ng
and shi ppi ng appl i cati ons.
OPERATION
The thermal guard protects the battery from
engi ne compartment temperature extremes. The tem-
perature of the battery can affect battery perfor-
mance. The ai r trapped between the pl asti c pl i es of
the thermal guard create a dead ai r space, whi ch
hel ps to i nsul ate the si des of the battery case from
the ai r temperature found i n the surroundi ng engi ne
compartment.
REMOVAL
(1) Remove the battery and the battery thermal
guard from the battery tray as a uni t. Refer to Bat-
tery Removal for the proper battery removal proce-
dures.
(2) Careful l y and evenl y sl i de the battery thermal
guard up off of the battery case (Fi g. 24).
INSTALLATION
(1) Cl ean and i nspect the battery thermal guard.
Refer to Battery System Cl eani ng for the proper
cl eani ng procedures, and refer to Battery System
I nspecti on for the proper i nspecti on procedures.
Fig. 21 TEST BATTERY POSITIVE CABLE
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
Fig. 22 TEST GROUND CIRCUIT RESISTANCE -
TYPICAL
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
Fig. 23 Battery Thermal guard
1 - THERMAL GUARD
2 - BATTERY
BATTERY CABLES (Continued)
(2) Careful l y and evenl y sl i de the battery thermal
guard down over the battery case.
(3) I nstal l the battery and the battery thermal
guard i nto the battery tray as a uni t. Refer to Bat-
tery I nstal l ati on for the proper battery i nstal l ati on
procedures.
BATTERY TRAY
DESCRIPTION
The battery i s pl aced i n a mol ded pl asti c tray
l ocated i n the l eft front corner of the engi ne compart-
ment (Fi g. 25). The battery hol d down hardware i s
contai ned wi thi n the battery tray. A hol e i n the bot-
tom of the battery tray i s fi tted wi th a battery tem-
perature sensor. Refer to Chargi ng System for more
i nformati on on the battery temperature sensor. Refer
to Battery Hol d down for more i nformati on on hol d
down hardware.
OPERATION
The battery tray provi des a secure mounti ng l oca-
ti on and supports the battery. On some vehi cl es, the
battery tray al so provi des the anchor poi nt/s for the
battery hol ddown hardware. The battery tray and
the battery hol ddown hardware combi ne to secure
and stabi l i ze the battery i n the engi ne compartment,
whi ch prevents battery movement duri ng vehi cl e
operati on. Unrestrai ned battery movement duri ng
vehi cl e operati on coul d resul t i n damage to the vehi -
cl e, the battery, or both.
REMOVAL
(1) Remove the battery from the battery tray
(Refer to 8 - ELECTRI CAL/BATTERY SYSTEM/BAT-
TERY - REMOVAL).
(2) Unl atch and remove the PDC from the battery
tray.
(3) Remove the battery temperature sensor from
the battery tray (Refer to 8 - ELECTRI CAL/CHARG-
I NG/BATTERY TEMPERATURE SENSOR -
REMOVAL).
(4) Remove the three nuts that secure the battery
tray to the wel d studs on the front extensi on of the
l eft front wheel house i nner panel (Fi g. 25).
(5) Remove the battery tray from the vehi cl e.
INSTALLATION
(1) Cl ean and i nspect the battery tray (Refer to 8 -
ELECTRI CAL/BATTERY SYSTEM - CLEANI NG).
(2) Posi ti on the battery tray onto the wel d studs
on the front extensi on of the l eft front wheel house
i nner panel .
(3) I nstal l the battery temperature sensor onto the
battery tray (Refer to 8 - ELECTRI CAL/CHARGI NG/
BATTERY TEMPERATURE SENSOR - I NSTALLA-
TI ON).
(4) I nstal l and ti ghten the three nuts that secure
the battery tray to the wel d studs on the front exten-
si on of the l eft front wheel house i nner panel . Ti ghten
the nuts to 5 Nm (45 i n. l bs.).
(5) I nstal l the PDC on the battery tray.
(6) I nstal l the battery onto the battery tray (Refer
to 8 - ELECTRI CAL/BATTERY SYSTEM/BATTERY -
I NSTALLATI ON).
Fig. 24 Battery thermal guard
1 - THERMAL GUARD
2 - BATTERY
Fig. 25 Battery Tray Location
1 - Battery Tray
2 - Battery Tray Retaining Nuts
THERMAL GUARD (Continued)
CHARGING SYSTEM
TABLE OF CONTENTS
page page
CHARGING SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING - CHARGING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
TORQUE - EXCEPT DIESEL . . . . . . . . . . . . . 23
GENERATOR RATINGS - GAS ENGINES . . . 23
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 24
BATTERY TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
GENERATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
GENERATOR DECOUPLER PULLEY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - GENERATOR
DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
VOLTAGE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CHARGING SYSTEM
DESCRIPTION
The chargi ng system consi sts of:
Generator
El ectroni c Vol tage Regul ator (EVR) ci rcui try
wi thi n the Powertrai n Control Modul e (PCM)
I gni ti on swi tch
Battery (refer to 8, Battery for i nformati on)
Battery temperature sensor
Generator Lamp (i f equi pped)
Check Gauges Lamp (i f equi pped)
Wi ri ng harness and connecti ons (refer to 8, Wi r-
i ng for i nformati on)
OPERATION
The chargi ng system i s turned on and off wi th the
i gni ti on swi tch. The system i s on when the engi ne i s
runni ng and the ASD rel ay i s energi zed. When the
ASD rel ay i s on, vol tage i s suppl i ed to the ASD rel ay
sense ci rcui t at the PCM. Thi s vol tage i s connected
through the PCM and suppl i ed to one of the genera-
tor fi el d termi nal s (Gen. Source +) at the back of the
generator.
The amount of DC current produced by the gener-
ator i s control l ed by the EVR (fi el d control ) ci rcui try
contai ned wi thi n the PCM. Thi s ci rcui try i s con-
nected i n seri es wi th the second rotor fi el d termi nal
and ground.
A battery temperature sensor, l ocated i n the bat-
tery tray housi ng, i s used to sense battery tempera-
ture. Thi s temperature data, al ong wi th data from
moni tored l i ne vol tage, i s used by the PCM to vary
the battery chargi ng rate. Thi s i s done by cycl i ng the
ground path to control the strength of the rotor mag-
neti c fi el d. The PCM then compensates and regul ates
generator current output accordi ngl y.
Al l vehi cl es are equi pped wi th On-Board Di agnos-
ti cs (OBD). Al l OBD-sensed systems, i ncl udi ng EVR
(fi el d control ) ci rcui try, are moni tored by the PCM.
Each moni tored ci rcui t i s assi gned a Di agnosti c Trou-
bl e Code (DTC). The PCM wi l l store a DTC i n el ec-
troni c memory for certai n fai l ures i t detects. Refer to
Di agnosti c Troubl e Codes i n; Powertrai n Control
Modul e; El ectroni c Control Modul es for more DTC
i nformati on.
The Check Gauges Lamp (i f equi pped) moni tors:
charging system voltage, engi ne cool ant tempera-
ture and engi ne oi l pressure. I f an extreme condi ti on
i s i ndi cated, the l amp wi l l be i l l umi nated. Thi s i s
done as remi nder to check the three gauges. The si g-
nal to acti vate the l amp i s sent vi a the CCD bus ci r-
cui ts. The l amp i s l ocated on the i nstrument panel .
Refer to 8, I nstrument Cl uster for addi ti onal i nfor-
mati on.
DIAGNOSIS AND TESTING - CHARGING
SYSTEM
The fol l owi ng procedures may be used to di agnose
the chargi ng system i f:
the check gauges l amp (i f equi pped) i s i l l umi -
nated wi th the engi ne runni ng
8F - 22 CHARGING SYSTEM KJ
the vol tmeter (i f equi pped) does not regi ster
properl y
an undercharged or overcharged battery condi -
ti on occurs.
Remember that an undercharged battery i s often
caused by:
accessori es bei ng l eft on wi th the engi ne not
runni ng
a faul ty or i mproperl y adjusted swi tch that
al l ows a l amp to stay on. Refer to I gni ti on-Off Draw
Test i n 8, Battery for more i nformati on.
INSPECTION
The Powertrai n Control Modul e (PCM) moni tors
cri ti cal i nput and output ci rcui ts of the chargi ng sys-
tem, maki ng sure they are operati onal . A Di agnosti c
Troubl e Code (DTC) i s assi gned to each i nput and
output ci rcui t moni tored by the On-Board Di agnosti c
(OBD) system. Some chargi ng system ci rcui ts are
checked conti nuousl y, and some are checked onl y
under certai n condi ti ons.
Refer to Di agnosti c Troubl e Codes i n; Powertrai n
Control Modul e; El ectroni c Control Modul es for more
DTC i nformati on. Thi s wi l l i ncl ude a compl ete l i st of
DTCs i ncl udi ng DTCs for the chargi ng system.
To perform a compl ete test of the chargi ng system,
refer to the appropri ate Powertrai n Di agnosti c Proce-
dures servi ce manual and the DRB scan tool . Per-
form the fol l owi ng i nspecti ons before attachi ng the
scan tool .
(1) I nspect the battery condi ti on. Refer to 8, Bat-
tery for procedures.
(2) I nspect condi ti on of battery cabl e termi nal s,
battery posts, connecti ons at engi ne bl ock, starter
sol enoi d and rel ay. They shoul d be cl ean and ti ght.
Repai r as requi red.
(3) I nspect al l fuses i n both the fusebl ock and
Power Di stri buti on Center (PDC) for ti ghtness i n
receptacl es. They shoul d be properl y i nstal l ed and
ti ght. Repai r or repl ace as requi red.
(4) I nspect generator mounti ng bol ts for ti ghtness.
Repl ace or ti ghten bol ts i f requi red. Refer to the Gen-
erator Removal /I nstal l ati on secti on of thi s group for
torque speci fi cati ons.
(5) I nspect generator dri ve bel t condi ti on and ten-
si on. Ti ghten or repl ace bel t as requi red. Refer to
Bel t Tensi on Speci fi cati ons i n 7, Cool i ng System.
(6) I nspect automati c bel t tensi oner (i f equi pped).
Refer to 7, Cool i ng System for i nformati on.
(7) I nspect generator el ectri cal connecti ons at gen-
erator fi el d, battery output, and ground termi nal (i f
equi pped). Al so check generator ground wi re connec-
ti on at engi ne (i f equi pped). They shoul d al l be cl ean
and ti ght. Repai r as requi red.
SPECIFICATIONS
TORQUE - EXCEPT DIESEL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Generator Horizontal Mounting Bolts - 3.7L 57 42 -
Generator Vertical Mounting Bolt - 3.7L 40 29 -
Generator Mounting Bolts - 2.4L 57 42 -
B+ Terminal Nut at Top of Generator 13 - 115
Generator Decoupler 110 81 -
GENERATOR RATINGS - GAS ENGINES
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 56044530AB 124 2.4L 88
DENSO 56044532AB 136 2.4L 96
DENSO 56041693AA 136 3.7L 96
DENSO 56029914AA 160 3.7L 112
KJ CHARGING SYSTEM 8F - 23
CHARGING SYSTEM (Continued)
SPECIAL TOOLS
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
The Battery Temperature Sensor (BTS) i s attached
to the battery tray l ocated under the battery.
OPERATION
The BTS i s used to determi ne the battery temper-
ature and control battery chargi ng rate. Thi s temper-
ature data, al ong wi th data from moni tored l i ne
vol tage, i s used by the PCM to vary the battery
chargi ng rate. System vol tage wi l l be hi gher at col der
temperatures and i s gradual l y reduced at warmer
temperatures.
The PCM sends 5 vol ts to the sensor and i s
grounded through the sensor return l i ne. As temper-
ature i ncreases, resi stance i n the sensor decreases
and the detecti on vol tage at the PCM i ncreases.
The BTS i s al so used for OBD I I di agnosti cs. Cer-
tai n faul ts and OBD I I moni tors are ei ther enabl ed
or di sabl ed, dependi ng upon BTS i nput (for exampl e,
di sabl e purge and enabl e Leak Detecti on Pump
(LDP) and O2 sensor heater tests). Most OBD I I
moni tors are di sabl ed bel ow 20 degrees F.
REMOVAL
The battery temperature sensor i s l ocated under
the vehi cl e battery (Fi g. 1) and i s attached to a
mounti ng hol e on battery tray.
(1) Remove battery. Refer to 8, Battery for proce-
dures.
(2) Di sconnect sensor pi gtai l harness from engi ne
wi re harness el ectri cal connector.
(3) Pry sensor strai ght up from battery tray
mounti ng hol e.
INSTALLATION
The battery temperature sensor i s l ocated under
vehi cl e battery and i s attached to a mounti ng hol e on
battery tray.
(1) Feed pi gtai l harness through hol e i n top of bat-
tery tray and press sensor i nto top of battery tray.
(2) Connect pi gtai l harness.
(3) I nstal l battery. Refer to 8, Battery for proce-
dures.
GENERATOR DECOUPLER TOOL #8433
GENERATOR DECOUPLER TOOL #8823
Fig. 1 BATTERY TEMPERATURE SENSOR
1 - BATTERY TEMPERATURE SENSOR
2 - BATTERY TRAY
CHARGING SYSTEM (Continued)
GENERATOR
DESCRIPTION
The generator i s bel t-dri ven by the engi ne usi ng a
serpenti ne type dri ve bel t. I t i s servi ced onl y as a
compl ete assembl y. I f the generator fai l s for any rea-
son, the enti re assembl y must be repl aced.
OPERATION
As the energi zed rotor begi ns to rotate wi thi n the
generator, the spi nni ng magneti c fi el d i nduces a cur-
rent i nto the wi ndi ngs of the stator coi l . Once the
generator begi ns produci ng suffi ci ent current, i t al so
provi des the current needed to energi ze the rotor.
The stator wi ndi ng connecti ons del i ver the i nduced
AC current to 3 posi ti ve and 3 negati ve di odes for
recti fi cati on. From the di odes, recti fi ed DC current i s
del i vered to the vehi cl e el ectri cal system through the
generator battery termi nal .
Al though the generators appear the same exter-
nal l y, di fferent generators wi th di fferent output rat-
i ngs are used on thi s vehi cl e. Be certai n that the
repl acement generator has the same output rati ng
and part number as the ori gi nal uni t. Refer to Spec-
i fi cati ons and see Generator Rati ngs for amperage
rati ngs and part numbers.
Noi se emi tti ng from the generator may be caused
by: worn, l oose or defecti ve beari ngs; a l oose or defec-
ti ve dri ve pul l ey; i ncorrect, worn, damaged or mi sad-
justed fan dri ve bel t; l oose mounti ng bol ts; a
mi sal i gned dri ve pul l ey or a defecti ve stator or di ode.
REMOVAL
Gasoline Powered Engines
CAUTION: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.
(1) Di sconnect and i sol ate negati ve battery cabl e
at battery.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Cooling
System.
(2) Remove generator dri ve bel t. Refer to 7, Cool -
i ng System for procedures.
(3) Unsnap pl asti c protecti ve cover (Fi g. 2) from
B+ mounti ng stud.
(4) Remove B+ termi nal mounti ng nut (Fi g. 2) at
top of generator.
(5) Di sconnect fi el d wi re el ectri cal connector at
rear of generator (Fi g. 2) by pushi ng on connector
tab.
(6) 2.4L Engi ne: Remove 2 generator mounti ng
bol ts (Fi g. 3).
(7) 3.7L Engi ne: Remove 1 verti cal generator
mounti ng bol t and 2 hori zontal mounti ng bol ts (Fi g.
4).
(8) Remove generator from vehi cl e.
Fig. 2 GENERATOR ELECTRICAL CONNECTORS -
TYPICAL
1 - PROTECTIVE CAP
2 - B+ NUT
3 - B+ TERMINAL
4 - FIELD ELECTRICAL CONNECTOR
INSTALLATION
Gasoline Powered Engines
(1) 2.4L Engi ne: Posi ti on generator to engi ne and
i nstal l 2 mounti ng bol ts. Refer to torque speci fi ca-
ti ons.
(2) 3.7L Engi ne: Posi ti on generator to engi ne and
i nstal l 3 mounti ng bol ts. Ti ghten 2 hori zontal mount-
i ng bol ts to speci fi ed torque. Ti ghten 1 verti cl e
mounti ng bol t to speci fi ed torque. Refer to torque
speci fi cati ons.
(3) Snap fi el d wi re connector i nto rear of genera-
tor.
(4) I nstal l B+ termi nal and nut to generator
mounti ng stud. Refer to torque speci fi cati ons.
(5) Snap pl asti c protecti ve cover to B+ termi nal .
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in 7, Cool-
ing System.
(6) I nstal l dri ve bel t Refer to 7, Cool i ng System for
bel t routi ng, bel t adjustment and bol t ti ghteni ng pro-
cedures.
(7) I nstal l negati ve battery cabl e to battery.
GENERATOR DECOUPLER
PULLEY
DESCRIPTION
The generator decoupler is used only with
certain engines. The decoupl er i s used i n pl ace of
the standard generator dri ve pul l ey (Fi g. 5).
Fig. 3 GENERATOR - 2.4L
2 - GENERTOR
Fig. 4 GENERATOR - 3.7L
1 - GENERATOR
2 - VERTICAL MOUNTING BOLT
3 - HORIZONTAL MOUNTING BOLTS
GENERATOR (Continued)
OPERATION
certain engines. The decoupl er (Fi g. 5). i s a one-
way cl utch desi gned to hel p reduce bel t tensi on fl uc-
tuati on, vi brati on, reduce fati gue l oads, i mprove bel t
l i fe, reduce hubl oads on components, and reduce
noi se. Dry operati on i s used (no grease or l ubri cants).
The decoupl er i s not temperature sensi ti ve and al so
has a l ow sensi ti vi ty to el ectri cal l oad. The decoupl er
i s a non-servi ceabl e i tem and i s to be repl aced as an
assembl y.
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER
Does not drive generator (generator not charging) Internal failure Replace decoupler
Noise coming from decoupler Internal failure Replace decoupler
REMOVAL
certain engines.
Two di fferent type generator decoupl er pul l eys are
used. One can be i denti fi ed by the use of machi ned
spl i nes (Fi g. 6). The other can be i denti fi ed by a hex
openi ng (Fi g. 7) and wi l l not use spl i nes.
Di fferent speci al tool s are requi red to servi ce each
di fferent decoupl er. Refer to fol l owi ng procedure.
INA Decoupler
(1) Di sconnect negati ve battery cabl e.
(2) Remove generator and accessory dri ve bel t.
Refer to Generator Removal .
(3) Posi ti on Speci al Tool #8823 (VM.1048) i nto
decoupl er (Fi g. 8).
(4) Determi ne i f end of generator shaft i s hex
shaped (Fi g. 9) or i s spl i ned (Fi g. 10). I f hex i s used,
i nsert a 10MM deep socket i nto tool #8823 (VM.1048)
(Fi g. 11). I f spl i ned, i nsert a 5/16 6-poi nt hex dri ver,
or a 10MM 12-poi nt tri pl e square dri ver i nto tool
#8823 (VM.1048) (Fi g. 12).
(5) The generator shaft uses conventi onal ri ght-
hand threads to attach decoupl er. To break decoupl er
l oose from generator threads, rotate end of tool cl ock-
wi se (Fi g. 11) or, (Fi g. 12).
(6) After breaki ng l oose wi th tool , unthread decou-
pl er by hand from generator.
Fig. 5 GENERATOR DECOUPLER PULLEY
(TYPICAL)
Fig. 6 GENERATOR DECOUPLER PULLEY (INA)
1 - GENERATOR
2 - DECOUPLER (INA)
3 - MACHINED SPLINES
GENERATOR DECOUPLER PULLEY (Continued)
Fig. 7 GENERATOR DECOUPLER PULLEY (LITENS)
1 - DECOUPLER (LITENS)
2 - HEX OPENING
Fig. 8 #8823 (VM.1048) TOOL AND INA DECOUPLER
1 - INA DECOUPLER
2 - TOOL #8823 (VM.1048)
Fig. 9 END OF GENERATOR SHAFT (HEX)
1 - GENERATOR SHAFT
2 - HEX
Fig. 10 END OF GENERATOR SHAFT (SPLINED)
1 - GENERATOR SHAFT
2 - SPLINES
Litens Decoupler
(2) Remove generator and accessory dri ve bel t.
Refer to Generator Removal .
(3) Posi ti on Speci al Tool #8433 (Fi g. 13) i nto
decoupl er. Al i gn to hex end of generator shaft.
(4) The generator shaft uses conventi onal ri ght-
hand threads to attach decoupl er. To break decoupl er
l oose from generator threads, rotate end of tool cl ock-
wi se (Fi g. 14).
(5) After breaki ng l oose wi th tool , unthread decou-
pl er by hand from generator.
Fig. 11 DECOUPLER REMOVAL (INA-HEX)
1 - DEEP 10 MM SOCKET
2 - TOOL #8823 (VM.1048)
Fig. 12 DECOUPLER REMOVAL (INA-SPLINED)
1 - DRIVER
2 - TOOL #8823 (VM.1048)
3 - 17 MM WRENCH
Fig. 13 # 8433 TOOL AND LITENS DECOUPLER
Fig. 14 DECOUPLER REMOVAL (LITENS)
INSTALLATION
INA Decoupler
(1) Thread decoupl er pul l ey onto generator shaft
by hand (ri ght-hand threads).
(2) Posi ti on Speci al Tool #8823 (VM.1048) i nto
decoupl er (Fi g. 8).
(3) Determi ne i f end of generator shaft i s hex
shaped (Fi g. 9) or i s spl i ned (Fi g. 10). I f hex i s used,
i nsert a 10MM deep socket i nto tool #8823 (VM.1048)
(Fi g. 15). I f spl i ned, i nsert a 5/16 6-poi nt hex dri ver,
or a 10MM 12-poi nt tri pl e square dri ver i nto tool
#8823 (VM.1048) (Fi g. 16).
(4) Do not use an adjustable, ratcheting click
type torque wrench. Most click type
wrenches will only allow torque to be applied
in a clockwise rotation. Use a dial-type or
beam-type wrench. Ti ghten i n counter-cl ockwi se
rotati on (Fi g. 15) or, (Fi g. 16). Refer to torque speci -
fi cati ons.
(5) I nstal l accessory dri ve bel t, and generator.
Refer to Generator I nstal l ati on.
Litens Decoupler
(1) Thread decoupl er pul l ey onto generator shaft
by hand (ri ght-hand threads).
(2) Posi ti on Speci al Tool 8433 (Fi g. 13) i nto decou-
pl er. Al i gn tool to hex end of generator shaft.
(3) Do not use an adjustable, ratcheting click
type torque wrench. Most click type
wrenches will only allow torque to be applied
in a clockwise rotation. Use a dial-type or
beam-type wrench. Ti ghten i n counter-cl ockwi se
rotati on (Fi g. 17). Refer to torque speci fi cati ons.
(4) I nstal l accessory dri ve bel t, and generator.
Refer to Generator I nstal l ati on.
Fig. 15 DECOUPLER INSTALLATION (INA-HEX)
1 - 10MM DEEP SOCKET
2 - TOOL # 8823 (VM.1048)
Fig. 16 DECOUPLER INSTALLATION (INA SPLINED)
1 - DRIVER
2 - TOOL # 8823 (VM.1048)
Fig. 17 DECOUPLER INSTALLATION (Litens)
VOLTAGE REGULATOR
DESCRIPTION
The El ectroni c Vol tage Regul ator (EVR) i s not a
separate component. I t i s actual l y a vol tage regul at-
i ng ci rcui t l ocated wi thi n the Powertrai n Control
Modul e (PCM). The EVR i s not servi ced separatel y. I f
repl acement i s necessary, the PCM must be repl aced.
OPERATION
The amount of DC current produced by the gener-
ator i s control l ed by EVR ci rcui try contai ned wi thi n
the Powertrai n Control Modul e (PCM). Thi s ci rcui try
i s connected i n seri es wi th the generators second
rotor fi el d termi nal and i ts ground.
Vol tage i s regul ated by cycl i ng the ground path to
control the strength of the rotor magneti c fi el d. The
EVR ci rcui try moni tors system l i ne vol tage (B+) and
battery temperature (refer to Battery Temperature
Sensor for more i nformati on). I t then determi nes a
target chargi ng vol tage. I f sensed battery vol tage i s
0.5 vol ts or l ower than the target vol tage, the PCM
grounds the fi el d wi ndi ng unti l sensed battery vol t-
age i s 0.5 vol ts above target vol tage. A ci rcui t i n the
PCM cycl es the ground si de of the generator fi el d up
to 100 ti mes per second (100Hz), but has the capabi l -
i ty to ground the fi el d control wi re 100% of the ti me
(ful l fi el d) to achi eve the target vol tage. I f the charg-
i ng rate cannot be moni tored (l i mp-i n), a duty cycl e
of 25% i s used by the PCM i n order to have some
generator output. Al so refer to Chargi ng Operati on
for addi ti onal i nformati on.
STARTING SYSTEM
TABLE OF CONTENTS
page page
STARTING SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSIS AND TESTING - STARTING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSPECTION - STARTING SYSTEM . . . . . . . . . 37
SPECIFICATIONS
TORQUE - GAS POWERED . . . . . . . . . . . . . 38
STARTER MOTOR - GAS POWERED . . . . . . 39
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
STARTER MOTOR RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DIAGNOSIS AND TESTING -
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
STARTING SYSTEM
DESCRIPTION
The starti ng system consi sts of:
Starter rel ay
Starter motor (i ncl udi ng an i ntegral starter sol e-
noi d)
Other components to be consi dered as part of start-
i ng system are:
Battery
Battery cabl es
I gni ti on swi tch and key l ock cyl i nder
Cl utch pedal posi ti on swi tch (manual transmi s-
si on)
Park/neutral posi ti on swi tch (automati c trans-
mi ssi on)
Wi re harnesses and connecti ons.
The Battery, Starti ng, and Chargi ng systems oper-
ate i n conjuncti on wi th one another, and must be
tested as a compl ete system. For correct operati on of
starti ng/chargi ng systems, al l components used i n
these 3 systems must perform wi thi n speci fi cati ons.
When attempti ng to di agnose any of these systems, i t
i s i mportant that you keep thei r i nterdependency i n
mi nd.
The di agnosti c procedures used i n each of these
groups i ncl ude the most basi c conventi onal di agnosti c
methods, to the more sophi sti cated On-Board Di ag-
nosti cs (OBD) bui l t i nto the Powertrai n Control Mod-
ul e (PCM). Use of an i nducti on-type mi l l i ampere
ammeter, vol t/ohmmeter, battery charger, carbon pi l e
rheostat (l oad tester), and 12-vol t test l amp may be
requi red.
Certai n starti ng system components are moni tored
by the PCM and may produce a Di agnosti c Troubl e
Code (DTC). Refer to Emi ssi on Control . See Di agnos-
ti c Troubl e Codes for addi ti onal i nformati on and a
l i st of codes.
OPERATION
The starti ng system components form two separate
ci rcui ts. A hi gh-amperage feed ci rcui t that feeds the
starter motor between 150 and 350 amperes (700
amperes - di esel engi ne), and a l ow-amperage control
ci rcui t that operates on l ess than 20 amperes. The
hi gh-amperage feed ci rcui t components i ncl ude the
battery, the battery cabl es, the contact di sc porti on of
the starter sol enoi d, and the starter motor. The l ow-
amperage control ci rcui t components i ncl ude the i gni -
ti on swi tch, the cl utch pedal posi ti on swi tch (manual
transmi ssi on), the park/neutral posi ti on swi tch (auto-
mati c transmi ssi on), the starter rel ay, the el ectro-
magneti c wi ndi ngs of the starter sol enoi d, and the
connecti ng wi re harness components.
I f the vehi cl e i s equi pped wi th a manual transmi s-
si on, i t has a cl utch pedal posi ti on swi tch i nstal l ed i n
seri es between the i gni ti on swi tch and the coi l bat-
tery termi nal of the starter rel ay. Thi s normal l y open
swi tch prevents the starter rel ay from bei ng ener-
gi zed when the i gni ti on swi tch i s turned to the
momentary Start posi ti on, unl ess the cl utch pedal i s
depressed. Thi s feature prevents starter motor oper-
ati on whi l e the cl utch di sc and the fl ywheel are
engaged. The starter rel ay coi l ground termi nal i s
al ways grounded on vehi cl es wi th a manual trans-
mi ssi on.
8F - 32 STARTING SYSTEM KJ
I f the vehi cl e i s equi pped wi th an automati c trans-
mi ssi on, battery vol tage i s suppl i ed through the l ow-
amperage control ci rcui t to the coi l battery termi nal
of the starter rel ay when the i gni ti on swi tch i s
turned to the momentary Start posi ti on. The park/
neutral posi ti on swi tch i s i nstal l ed i n seri es between
the starter rel ay coi l ground termi nal and ground.
Thi s normal l y open swi tch prevents the starter rel ay
from bei ng energi zed and the starter motor from
operati ng unl ess the automati c transmi ssi on gear
sel ector i s i n the Neutral or Park posi ti ons.
When the starter rel ay coi l i s energi zed, the nor-
mal l y open rel ay contacts cl ose. The rel ay contacts
connect the rel ay common feed termi nal to the rel ay
normal l y open termi nal . The cl osed rel ay contacts
energi ze the starter sol enoi d coi l wi ndi ngs.
The energi zed sol enoi d pul l -i n coi l pul l s i n the sol e-
noi d pl unger. The sol enoi d pl unger pul l s the shi ft
l ever i n the starter motor. Thi s engages the starter
overrunni ng cl utch and pi ni on gear wi th the starter
ri ng gear on the manual transmi ssi on fl ywheel or on
the automati c transmi ssi on torque converter or
torque converter dri ve pl ate.
As the sol enoi d pl unger reaches the end of i ts
travel , the sol enoi d contact di sc compl etes the hi gh-
amperage starter feed ci rcui t and energi zes the sol e-
noi d pl unger hol d-i n coi l . Current now fl ows between
the sol enoi d battery termi nal and the starter motor,
energi zi ng the starter.
Once the engi ne starts, the overrunni ng cl utch pro-
tects the starter motor from damage by al l owi ng the
starter pi ni on gear to spi n faster than the pi ni on
shaft. When the dri ver rel eases the i gni ti on swi tch to
the On posi ti on, the starter rel ay coi l i s de-energi zed.
Thi s causes the rel ay contacts to open. When the
rel ay contacts open, the starter sol enoi d pl unger
hol d-i n coi l i s de-energi zed.
When the sol enoi d pl unger hol d-i n coi l i s de-ener-
gi zed, the sol enoi d pl unger return spri ng returns the
pl unger to i ts rel axed posi ti on. Thi s causes the con-
tact di sc to open the starter feed ci rcui t, and the shi ft
l ever to di sengage the overrunni ng cl utch and pi ni on
gear from the starter ri ng gear.
DIAGNOSIS AND TESTING - STARTING
SYSTEM
The battery, starti ng, and chargi ng systems oper-
ate i n conjuncti on wi th one another, and must be
tested as a compl ete system. For correct starti ng/
chargi ng system operati on, al l of the components
i nvol ved i n these 3 systems must perform wi thi n
speci fi cati ons.
Starting System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO
OPERATE.
1. Battery discharged or
faulty.
1. Refer to Battery. Charge or replace battery, if required.
2. Starting circuit wiring
faulty.
2. Refer to 8, Wiring Diagrams. Test and repair starter
feed and/or control circuits, if required.
3. Starter relay faulty. 3. Refer to Starter Relay in Diagnosis and Testing.
Replace starter relay if required.
4. Ignition switch faulty. 4. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch if required.
5. Clutch pedal position
switch faulty.
5. Refer to Clutch Pedal Position Switch.
6. Park/Neutral position
switch faulty or
misadjusted.
6. Refer to Park/Neutral Position Switch. Replace
park/neutral position switch if required.
7. Starter solenoid faulty. 7. Refer to Starter Motor. Replace starter motor assembly
if required.
8. Starter motor faulty. 8. If all other starting system components and circuits test
OK, replace starter motor.
KJ STARTING SYSTEM 8F - 33
STARTING SYSTEM (Continued)
Starting System Diagnosis
STARTER ENGAGES,
FAILS TO TURN
ENGINE.
1. Battery discharged or
faulty.
1. Refer to Battery. Charge or replace battery if required.
2. Starting circuit wiring
faulty.
2. Refer to 8, Wiring Diagrams. Test and repair starter
feed and/or control circuits if required.
OK, replace starter motor assembly.
4. Engine seized. 4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of 9, Engine.
STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.
1. Starter ring gear faulty. 1. Refer to Starter Motor Removal and Installation.
Remove starter motor to inspect starter ring gear.
Replace starter ring gear if required.
OK, replace starter motor assembly.
STARTER DOES NOT
DISENGAGE.
1. Starter motor
improperly installed.
1. Refer to Starter Motor Removal and Installation.
Tighten starter mounting hardware to correct torque
specifications.
2. Starter relay faulty. 2. Refer to Starter Relay Diagnosis and Testing. Replace
starter relay if required.
3. Ignition switch faulty. 3. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch if required.
OK, replace starter motor.
INSPECTION
For compl ete starter wi ri ng ci rcui t di agrams, refer
to 8, Wi ri ng Di agrams. Before removi ng any uni t
from starti ng system for repai r or di agnosi s, perform
the fol l owi ng i nspecti ons:
BAGS, REFER TO 8, PASSIVE RESTRAINT SYS-
TEMS, BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
Battery - Vi sual l y i nspect battery for i ndi ca-
ti ons of physi cal damage and l oose or corroded cabl e
connecti ons. Determi ne state-of-charge and cranki ng
capaci ty of battery. Charge or repl ace battery i f
requi red. Refer to Battery i n 8, Battery. Note: If
equipped with diesel engine, a dual battery sys-
tem may be used, and both batteries must be
inspected.
Ignition Switch - Vi sual l y i nspect i gni ti on
swi tch for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons. Refer to Igni-
tion Switch and Key Lock Cylinder.
Clutch Pedal Position Switch - I f equi pped
wi th manual transmi ssi on, vi sual l y i nspect cl utch
pedal posi ti on swi tch for i ndi cati ons of physi cal dam-
age and l oose or corroded wi re harness connecti ons.
Refer to Clutch Pedal Position Switch i n 6,
Cl utch.
Park/Neutral Position Switch - I f equi pped
wi th automati c transmi ssi on, vi sual l y i nspect park/
neutral posi ti on swi tch for i ndi cati ons of physi cal
damage and l oose or corroded wi re harness connec-
ti ons. Refer to Park/Neutral Position Switch i n
21, Transmi ssi on.
Starter Relay - Vi sual l y i nspect starter rel ay
for i ndi cati ons of physi cal damage and l oose or cor-
roded wi re harness connecti ons.
Starter Motor - Vi sual l y i nspect starter motor
roded wi re harness connecti ons.
Starter Solenoid - Vi sual l y i nspect starter sol e-
noi d for i ndi cati ons of physi cal damage and l oose or
corroded wi re harness connecti ons.
Wiring - Vi sual l y i nspect wi re harnesses for
damage. Repai r or repl ace any faul ty wi ri ng, as
requi red. Refer to 8, Wi ri ng Di agrams.
TESTING
COLD CRANKING TEST
For compl ete starter wi ri ng ci rcui t di agrams, refer
to 8, Wi ri ng Di agrams. The battery must be ful l y-
charged and l oad-tested before proceedi ng. Refer to
Battery i n 8, Battery.
(1) Connect vol t-ampere tester to battery termi nal s
(Fi g. 1). See i nstructi ons provi ded by manufacturer of
vol t-ampere tester bei ng used. Note: Certain diesel
equipped models use dual batteries. If equipped
with dual battery system, tester should be con-
nected to battery on left side of vehicle only.
Also, tester current reading must be taken from
positive battery cable lead that connects to
starter motor.
(2) Ful l y engage parki ng brake.
(3) I f equi pped wi th manual transmi ssi on, pl ace
gearshi ft sel ector l ever i n Neutral posi ti on and bl ock
cl utch pedal i n ful l y depressed posi ti on. I f equi pped
wi th automati c transmi ssi on, pl ace gearshi ft sel ector
l ever i n Park posi ti on.
(4) Veri fy that al l l amps and accessori es are
turned off.
(5) To prevent a gasol i ne engi ne from starti ng,
remove Automati c ShutDown (ASD) rel ay. To prevent
a di esel engi ne from starti ng, remove Fuel Pump
Rel ay. These rel ays are l ocated i n Power Di stri buti on
Center (PDC). Refer to l abel on PDC cover for rel ay
l ocati on.
WARNING: IF EQUIPPED WITH DIESEL ENGINE,
ATTEMPT TO START ENGINE A FEW TIMES
BEFORE PROCEEDING WITH FOLLOWING STEP.
(6) Rotate and hol d i gni ti on swi tch i n Start posi -
ti on. Note cranki ng vol tage and current (amperage)
draw readi ngs shown on vol t-ampere tester.
(a) I f vol tage reads bel ow 9.6 vol ts, refer to
Starter Motor i n Di agnosi s and Testi ng. I f starter
motor i s OK, refer to Engine Diagnosis i n 9,
Engi ne for further testi ng of engi ne. I f starter
motor i s not OK, repl ace faul ty starter motor.
(b) I f vol tage reads above 9.6 vol ts and current
(amperage) draw reads bel ow speci fi cati ons, refer
to Feed Circuit Test i n thi s secti on.
(c) I f vol tage reads 12.5 vol ts or greater and
starter motor does not turn, refer to Control Cir-
cuit Testing i n thi s secti on.
(d) I f vol tage reads 12.5 vol ts or greater and
starter motor turns very sl owl y, refer to Feed Cir-
cuit Test i n thi s secti on.
NOTE: A cold engine will increase starter current
(amperage) draw reading, and reduce battery volt-
age reading.
FEED CIRCUIT TEST
The starter feed ci rcui t test (vol tage drop method)
wi l l determi ne i f there i s excessi ve resi stance i n
hi gh-amperage feed ci rcui t. For compl ete starter wi r-
i ng ci rcui t di agrams, refer 8, Wi ri ng Di agrams.
When performi ng these tests, i t i s i mportant to
remember that vol tage drop i s gi vi ng an i ndi cati on of
resi stance between two poi nts at whi ch vol tmeter
probes are attached.
Example: When testi ng resi stance of posi ti ve bat-
tery cabl e, touch vol tmeter l eads to posi ti ve battery
cabl e cl amp and cabl e connector at starter sol enoi d.
I f you probe posi ti ve battery termi nal post and cabl e
connector at starter sol enoi d, you are readi ng com-
bi ned vol tage drop i n posi ti ve battery cabl e cl amp-to-
termi nal post connecti on and posi ti ve battery cabl e.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng tests,
be certai n that fol l owi ng procedures are accom-
pl i shed:
Battery i s ful l y-charged and l oad-tested. Refer to
Battery i n 8, Battery.
Ful l y engage parki ng brake.
I f equi pped wi th manual transmi ssi on, pl ace
gearshi ft sel ector l ever i n Neutral posi ti on and bl ock
cl utch pedal i n ful l y depressed posi ti on. I f equi pped
wi th automati c transmi ssi on, pl ace gearshi ft sel ector
l ever i n Park posi ti on.
Veri fy that al l l amps and accessori es are turned
off.
To prevent a gasol i ne engi ne from starti ng,
remove Automati c ShutDown (ASD) rel ay. To prevent
a di esel engi ne from starti ng, remove Fuel Pump
Rel ay. These rel ays are l ocated i n Power Di stri buti on
Fig. 1 Volts-Amps Tester Connections - Typical
1 - POSITIVE CLAMP
2 - NEGATIVE CLAMP
3 - INDUCTION AMMETER CLAMP
l ocati on.
(1) Connect posi ti ve l ead of vol tmeter to negati ve
battery cabl e termi nal post. Connect negati ve l ead of
vol tmeter to negati ve battery cabl e cl amp (Fi g. 2).
Rotate and hol d i gni ti on swi tch i n Start posi ti on.
Observe vol tmeter. I f vol tage i s detected, correct poor
contact between cabl e cl amp and termi nal post.
Note: Certain diesel equipped models use dual
batteries. If equipped with dual battery system,
procedure must be performed twice, once for
each battery.
(2) Connect posi ti ve l ead of vol tmeter to posi ti ve
battery termi nal post. Connect negati ve l ead of vol t-
meter to battery posi ti ve cabl e cl amp (Fi g. 3). Rotate
and hol d i gni ti on swi tch i n Start posi ti on. Observe
vol tmeter. I f vol tage i s detected, correct poor contact
between cabl e cl amp and termi nal post. Note: Cer-
tain diesel equipped models use dual batteries.
If equipped with dual battery system, this pro-
cedure must be performed twice, once for each
battery.
(3) Connect vol tmeter to measure between battery
posi ti ve termi nal post and starter sol enoi d battery
termi nal stud (Fi g. 4). Rotate and hol d i gni ti on
swi tch i n Start posi ti on. Observe vol tmeter. I f read-
i ng i s above 0.2 vol t, cl ean and ti ghten battery cabl e
connecti on at sol enoi d. Repeat test. I f readi ng i s sti l l
above 0.2 vol t, repl ace faul ty posi ti ve battery cabl e.
Note: Certain diesel equipped models use dual
batteries. If equipped with dual battery system,
this procedure must be performed on driver
side battery only.
(4) Connect vol tmeter to measure between nega-
ti ve battery termi nal post and a good cl ean ground
on engi ne bl ock (Fi g. 5). Rotate and hol d i gni ti on
swi tch i n Start posi ti on. Observe vol tmeter. I f read-
i ng i s above 0.2 vol t, cl ean and ti ghten negati ve bat-
tery cabl e attachment on engi ne bl ock. Repeat test. I f
readi ng i s sti l l above 0.2 vol t, repl ace faul ty negati ve
battery cabl e. Note: Certain diesel equipped mod-
els use dual batteries. If equipped with dual
battery system, this procedure must be per-
formed twice, once for each battery.
(5) Connect posi ti ve l ead of vol tmeter to starter
housi ng. Connect negati ve l ead of vol tmeter to nega-
ti ve battery termi nal post (Fi g. 6). Rotate and hol d
i gni ti on swi tch i n Start posi ti on. Observe vol tmeter.
I f readi ng i s above 0.2 vol t, correct poor starter to
engi ne bl ock ground contact. Note: Certain diesel
Fig. 2 Test Negative Battery Cable Connection
Resistance - Typical
1 - VOLTMETER
2 - BATTERY
Fig. 3 Test Positive Battery Cable Connection
Resistance - Typical
1 - VOLTMETER
2 - BATTERY
Fig. 4 Test Positive Battery Cable
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
equipped models use dual batteries. If equipped
with dual battery system, this procedure must
be performed on driver side battery only.
(6) I f equi pped wi th dual battery system (certai n
di esel equi pped model s), connect posi ti ve l ead of vol t-
meter to posi ti ve battery cabl e cl amp on battery
l ocated on l eft si de of vehi cl e. Connect negati ve l ead
of vol tmeter to posi ti ve battery termi nal post on bat-
tery l ocated on ri ght si de of vehi cl e. Rotate and hol d
i gni ti on swi tch i n Start posi ti on. Observe vol tmeter.
I f readi ng i s above 0.2 vol t, cl ean and ti ghten battery
cabl es at both batteri es. Repeat test. I f readi ng i s
sti l l above 0.2 vol t, repl ace faul ty posi ti ve battery
cabl e.
I f resi stance tests detect no feed ci rcui t probl ems,
refer to Starter Motor i n the Di agnosi s and Testi ng.
CONTROL CIRCUIT TESTING
The starter control ci rcui t components shoul d be
tested i n the order i n whi ch they are l i sted, as fol -
l ows:
Starter Relay - Refer to Starter Relay Di ag-
nosi s and Testi ng.
Starter Solenoid - Refer to Starter Motor
Di agnosi s and Testi ng.
Ignition Switch - Refer to Ignition Switch
and Key Lock Cylinder
Clutch Pedal Position Switch - I f equi pped
wi th manual transmi ssi on, refer to Clutch Pedal
Position Switch i n 6, Cl utch.
Park/Neutral Position Switch - I f equi pped
wi th automati c transmi ssi on, refer to Park/Neutral
Position Switch i n 21, Transmi ssi on.
Wire harnesses and connections - Refer to 8,
Wi ri ng Di agrams.
INSPECTION - STARTING SYSTEM
The fol l owi ng starti ng system components shoul d
be careful l y i nspected whenever any starti ng system
probl em i s encountered.
BAGS, DISABLE AIRBAG SYSTEM BEFORE
COLUMN, OR INSTRUMENT PANEL COMPONENT
LATE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR AIRBAG SYSTEM
CAPACITOR TO DISCHARGE BEFORE PERFORM-
ING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE AIRBAG SYS-
TEM. FAILURE TO TAKE PROPER PRECAUTIONS
Battery
Vi sual l y i nspect battery for i ndi cati ons of physi -
cal damage and l oose or corroded cabl e connecti ons.
Determi ne state-of-charge and cranki ng capaci ty of
battery. Charge or repl ace battery, i f requi red. Refer
to Battery for battery cl eani ng and i nspecti on proce-
dures.
Ignition Switch
Vi sual l y i nspect i gni ti on swi tch for i ndi cati ons of
physi cal damage and l oose or corroded wi re harness
connecti ons. Cl ean corroded connecti ons as requi red.
Refer to Wiring Diagrams. Refer to Ignition
Switch and Key Lock Cylinder for i gni ti on swi tch
servi ce procedures.
Fig. 5 Test Ground Circuit Resistance - Typical
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
Fig. 6 Test Starter Ground - Typical
1 - STARTER MOTOR
2 - BATTERY
3 - VOLTMETER
Clutch Pedal Position Switch
I f vehi cl e i s equi pped wi th a manual transmi s-
si on, vi sual l y i nspect cl utch pedal posi ti on swi tch for
i ndi cati ons of physi cal damage and l oose or corroded
wi re harness connecti ons. Cl ean corroded connecti ons
as requi red. Refer to Clutch Hydraulic Linkage for
cl utch pedal posi ti on swi tch servi ce procedures.
Park/Neutral Position Switch
I f vehi cl e i s equi pped wi th an automati c trans-
mi ssi on, vi sual l y i nspect park/neutral posi ti on swi tch
roded wi re harness connecti ons. Cl ean corroded con-
necti ons as requi red. Refer to Park/Neutral
Position Switch for park/neutral posi ti on swi tch
Starter Relay
Vi sual l y i nspect starter rel ay for i ndi cati ons of
Refer to Starter Relay for starter rel ay servi ce pro-
cedures.
Starter Motor
Vi sual l y i nspect starter motor for i ndi cati ons of
I f probl em bei ng di agnosed i nvol ves i mproper starter
engagement, di sengagement or noi se compl ai nts,
starter motor shoul d be removed. Wi th starter motor
removed, i nspect starter pi ni on and ri ng gears for
damaged or mi ssi ng teeth. Repl ace faul ty compo-
nents as requi red. Refer to Starter Motor for
removal /i nstal l ati on procedures.
Starter Solenoid
Vi sual l y i nspect starter sol enoi d for i ndi cati ons
of physi cal damage and l oose or corroded wi re har-
ness connecti ons. Cl ean corroded connecti ons as
requi red. Refer to Starter Motor for starter sol enoi d
Wiring
Vi sual l y i nspect starti ng system wi re harnesses
for i ndi cati ons of physi cal damage. Repai r or repl ace
any faul ty wi ri ng, as requi red. Refer to Wiring Dia-
grams for repai r or connector and termi nal servi ce
procedures.
SPECIFICATIONS
TORQUE - GAS POWERED
Starter Solenoid Battery
Cable Nut
11 - 100
Starter Mounting Bolts -
2.4L
54 40 -
Starter Mounting Bolts
-3.7L
54 40 -
Starter Heat Shield
Mounting Bolts
6 - 55
STARTER MOTOR - GAS POWERED
Starter Motor and Solenoid
Manufacturer Mitsubishi
Engine Application 2.4L / 3.7L
Power Rating 1.4 Kilowatt (1.9 Horsepower)
Voltage 12 Volts
** Number of Permanent Magnets 6
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test Voltage 11.2 Volts
Free Running Test Maximum Amperage Draw 90 Amperes
Free Running Test Minimum Speed 2400 rpm
Solenoid Closing Maximum Voltage Required 7.8 Volts
* Cranking Amperage Draw Test 160 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
**The starter is equipped with permanent magnets. Never strike the starter case to attempt to loosen a sticking/
stuck armature as permanent magnets may crack or break.
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operati on can be confi rmed
by performi ng the fol l owi ng free runni ng bench test.
Thi s test can onl y be performed wi th starter motor
removed from vehi cl e. Refer to Speci fi cati ons for
starter motor speci fi cati ons.
(1) Remove starter motor from vehi cl e. Refer to
Starter Motor Removal and I nstal l ati on.
(2) Mount starter motor securel y i n a soft-jawed
bench vi se. The vi se jaws shoul d be cl amped on the
mounti ng fl ange of starter motor. Never cl amp on
starter motor by fi el d frame.
(3) Connect a sui tabl e vol t-ampere tester and a
12-vol t battery to starter motor i n seri es, and set
ammeter to 100 ampere scal e. See i nstructi ons pro-
vi ded by manufacturer of vol t-ampere tester bei ng
used.
(4) I nstal l jumper wi re from sol enoi d termi nal to
sol enoi d battery termi nal . The starter motor shoul d
operate. I f starter motor fai l s to operate, repl ace
faul ty starter motor assembl y.
(5) Adjust carbon pi l e l oad of tester to obtai n free
runni ng test vol tage. Refer to Speci fi cati ons for
starter motor free runni ng test vol tage speci fi cati ons.
(6) Note readi ng on ammeter and compare readi ng
to free runni ng test maxi mum amperage draw. Refer
to Speci fi cati ons for starter motor free runni ng test
maxi mum amperage draw speci fi cati ons.
(7) I f ammeter readi ng exceeds maxi mum amper-
age draw speci fi cati on, repl ace faul ty starter motor
assembl y.
STARTER SOLENOID
Thi s test can onl y be performed wi th starter motor
removed from vehi cl e.
(1) Remove starter motor from vehi cl e. Refer to
Starter Motor Removal and I nstal l ati on.
(2) Di sconnect wi re from sol enoi d fi el d coi l termi -
nal .
(3) Check for conti nui ty between sol enoi d termi nal
and sol enoi d fi el d coi l termi nal wi th a conti nui ty
tester (Fi g. 7). There shoul d be conti nui ty. I f OK, go
to Step 4. I f not OK, repl ace faul ty starter motor
assembl y.
(4) Check for conti nui ty between sol enoi d termi nal
and sol enoi d case (Fi g. 8). There shoul d be conti nui ty.
I f not OK, repl ace faul ty starter motor assembl y.
REMOVAL
2. 4L 4Cylinder
(1) Di sconnect and i sol ate negati ve battery cabl e.
(3) Remove sol enoi d wi re from sol enoi d termi nal
(Fi g. 11).
(4) Remove battery cabl e from stud on starter sol e-
noi d (Fi g. 11).
(5) Remove 2 starter mounti ng bol ts (Fi g. 9) and
remove starter from vehi cl e.
3. 7L V-6
(1) Di sconnect and i sol ate negati ve battery cabl e.
(3) Remove 2 fl ange bol ts securi ng l eft exhaust
downpi pe to crossover pi pe. Lower pi pe sl i ghtl y to
al l ow front propel l er shaft removal .
(4) Remove front propel l er shaft.
(5) Remove 2 starter heat shi el d bol ts at si de of
starter (Fi g. 10).
(6) Remove starter heat shi el d nut at front of
starter (Fi g. 10).
(7) Remove starter heat shi el d.
(8) Remove sol enoi d wi re from sol enoi d termi nal
(Fi g. 11).
(9) Remove battery cabl e from stud on starter sol e-
noi d (Fi g. 11).
(10) Remove 2 starter mounti ng bol ts (Fi g. 12).
(11) Posi ti on front of starter to face rear of vehi cl e.
Rotate starter unti l sol enoi d posi ti on i s l ocated bel ow
starter.
(12) Remove starter from vehi cl e by passi ng i t
between exhaust pi pe and transmi ssi on bel l housi ng.
Fig. 7 CONTINUITY BETWEEN SOLENOID AND
FIELD COIL TERMINALS - TYPICAL
1 - OHMMETER
2 - SOLENOID TERMINAL
3 - FIELD COIL TERMINAL
Fig. 8 CONTINUITY BETWEEN SOLENOID
TERMINAL AND CASE - TYPICAL
1 - SOLENOID TERMINAL
2 - OHMMETER
3 - SOLENOID
Fig. 9 STARTER - 2.4L
1 - STARTER
Fig. 10 STARTER HEAT SHIELD - 3.7L
1 - STARTER HEAT SHIELD
2 - HEAT SHIELD BOLTS
3 - HEAT SHIELD BOLTS
4 - STARTER
STARTER MOTOR (Continued)
INSTALLATION
2. 4L 4Cylinder
(1) Posi ti on starter i nto bel l housi ng and i nstal l 2
bol ts. Refer to torque speci fi cati ons.
(2) I nstal l battery cabl e and nut to stud on starter
sol enoi d. Refer to torque speci fi cati ons.
(3) I nstal l sol enoi d wi re connector to sol enoi d ter-
mi nal .
3. 7L V-6
(1) Posi ti on front of starter towards rear of vehi cl e
wi th sol enoi d posi ti on rotated unti l i t i s l ocated bel ow
starter. I nstal l starter by passi ng i t between exhaust
pi pe and transmi ssi on bel l housi ng.
(2) Posi ti on starter i nto bel l housi ng and i nstal l 2
bol ts. Refer to torque speci fi cati ons.
(3) I nstal l battery cabl e and nut to stud on starter
sol enoi d. Refer to torque speci fi cati ons.
(4) I nstal l sol enoi d wi re connector to sol enoi d ter-
mi nal .
(5) Posi ti on starter heat shi el d and i nstal l nut at
front of starter.
(6) I nstal l 2 starter heat shi el d bol ts at si de of
starter.
(7) I nstal l front propel l er shaft.
(8) I nstal l 2 fl ange bol ts securi ng l eft exhaust
downpi pe to crossover pi pe.
STARTER MOTOR RELAY
DESCRIPTION
The starter rel ay i s an el ectromechani cal devi ce
that swi tches battery current to the pul l -i n coi l of the
starter sol enoi d when i gni ti on swi tch i s turned to
Start posi ti on. The starter rel ay i s l ocated i n the
Power Di stri buti on Center (PDC) i n the engi ne com-
partment. See PDC cover for rel ay i denti fi cati on and
l ocati on.
The starter rel ay i s a I nternati onal Standards
Organi zati on (I SO) rel ay. Rel ays conformi ng to I SO
speci fi cati ons have common physi cal di mensi ons, cur-
rent capaci ti es, termi nal patterns, and termi nal func-
ti ons.
The starter rel ay cannot be repai red or adjusted
and, i f faul ty or damaged, i t must be repl aced.
Fig. 11 STARTER ELECTRICAL CONNECTORS -
2.4L/3.7L
1 - BATERY CABLE NUT
2 - BATTERY CABLE
3 - SOLENOID CONNECTOR
4 - HEAT SHIELD
Fig. 12 STARTER - 3.7L
1 - STARTER
STARTER MOTOR (Continued)
OPERATION
The I SO rel ay consi sts of an el ectromagneti c coi l , a
resi stor or di ode, and three (two fi xed and one mov-
abl e) el ectri cal contacts. The movabl e (common feed)
rel ay contact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When el ectro-
magneti c coi l i s energi zed, i t draws the movabl e con-
tact away from normal l y cl osed fi xed contact, and
hol ds i t agai nst the other (normal l y open) fi xed con-
tact.
When el ectromagneti c coi l i s de-energi zed, spri ng
pressure returns movabl e contact to normal l y cl osed
posi ti on. The resi stor or di ode i s connected i n paral l el
wi th el ectromagneti c coi l wi thi n rel ay, and hel ps to
di ssi pate vol tage spi kes produced when coi l i s de-en-
ergi zed.
DIAGNOSIS AND TESTING - STARTER RELAY
The starter rel ay i s l ocated i n the Power Di stri bu-
ti on Center (PDC) i n engi ne compartment. Refer to
RELAY TEST
(1) Remove starter rel ay (Fi g. 13) from PDC.
(2) A rel ay i n de-energi zed posi ti on shoul d have
conti nui ty between termi nal s 87A and 30, and no
conti nui ty between termi nal s 87 and 30. I f OK, go to
Step 3. I f not OK, repl ace faul ty rel ay.
(3) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
4. I f not OK, repl ace faul ty rel ay.
(4) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, perform fol l owi ng Rel ay Ci rcui t Test.
I f not OK, repl ace faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r open ci r-
cui t to fused B(+) fuse i n PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to common feed termi nal (30) i n energi zed
posi ti on. Thi s termi nal suppl i es battery vol tage to
starter sol enoi d fi el d coi l . There shoul d be conti nui ty
between cavi ty for rel ay termi nal 87 and starter sol e-
noi d termi nal at al l ti mes. I f OK, go to Step 4. I f not
OK, repai r open engi ne starter motor rel ay output
ci rcui t to starter sol enoi d as requi red.
(4) The coi l battery termi nal (86) i s connected to
el ectromagnet i n rel ay. I t i s energi zed when i gni ti on
swi tch i s hel d i n Start posi ti on. On vehi cl es wi th a
manual transmi ssi on, the cl utch pedal must be
bl ocked i n ful l y depressed posi ti on for thi s test.
Check for battery vol tage at cavi ty for rel ay termi nal
86 wi th i gni ti on swi tch i n Start posi ti on, and no vol t-
age when i gni ti on swi tch i s rel eased to On posi ti on.
I f OK, go to Step 5. I f not OK wi th a manual trans-
mi ssi on, di sconnect cl utch pedal posi ti on swi tch wi re
harness connector and i nstal l a jumper wi re between
two cavi ti es i n body hal f of connector and check for
battery vol tage agai n at cavi ty for rel ay termi nal 86.
I f now OK, repl ace faul ty cl utch pedal posi ti on
swi tch. I f sti l l not OK wi th a manual transmi ssi on or
i f not OK wi th an automati c transmi ssi on, check for
open or shorted fused i gni ti on swi tch output (start)
ci rcui t to i gni ti on swi tch and repai r as requi red. I f
fused i gni ti on swi tch output (start) ci rcui t i s OK,
refer to Ignition Switch and Key Lock Cylinder.
(5) The coi l ground termi nal (85) i s connected to
el ectromagnet i n rel ay. On vehi cl es wi th manual
transmi ssi on, i t i s grounded at al l ti mes. On vehi cl es
wi th automati c transmi ssi on, i t i s grounded through
park/neutral posi ti on swi tch onl y when gearshi ft
sel ector l ever i s i n Park or Neutral posi ti ons. Check
for conti nui ty to ground at cavi ty for rel ay termi nal
85. I f not OK wi th a manual transmi ssi on, repai r
open park/neutral posi ti on swi tch sense ci rcui t to
ground as requi red. I f not OK wi th an automati c
transmi ssi on, check for open or shorted park/neutral
posi ti on swi tch sense ci rcui t to park/neutral posi ti on
swi tch and repai r, as requi red. I f park/neutral posi -
ti on swi tch sense ci rcui t checks OK, refer to Park/
Neutral Position Switch.
Fig. 13 STARTER RELAY (ISO MICRO RELAY)
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
STARTER MOTOR RELAY (Continued)
REMOVAL
The starter rel ay i s l ocated i n the Power Di stri bu-
ti on Center (PDC) (Fi g. 14). Refer to l abel on PDC
cover for rel ay l ocati on.
INSTALLATION
(1) Refer to Power Di stri buti on Center (PDC) cover
for starter rel ay l ocati on.
1 - BATTERY
2 - PDC
3 - PDC COVER
STARTER MOTOR RELAY (Continued)
HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 1
WINDOW DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . 3
HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . 10
HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - HEATED
MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HEATED MIRRORS
DESCRIPTION
Vehi cl es equi pped wi th the opti onal heated mi rror
package have an el ectri c heati ng gri d l ocated behi nd
the mi rror gl ass of each outsi de rear vi ew mi rror.
The heated mi rrors are control l ed by the rear wi n-
dow defogger swi tch. El ectri cal current i s di rected to
the heati ng gri d i nsi de the mi rror onl y when the rear
wi ndow defogger swi tch i s i n the On posi ti on.
I f the outsi de mi rror heati ng gri ds and the rear
wi ndow heati ng gri d are al l i noperati ve, (Refer to 8 -
ELECTRI CAL/HEATED GLASS - DI AGNOSI S AND
TESTI NG). I f the outsi de mi rror heati ng gri ds are
i noperati ve, but the rear wi ndow heati ng gri d i s
operati ng as desi gned, (Refer to 8 - ELECTRI CAL/
HEATED MI RRORS - DI AGNOSI S AND TESTI NG).
The heati ng gri d behi nd each outsi de mi rror gl ass
cannot be repai red and, i f faul ty or damaged, the
enti re power mi rror uni t must be repl aced(Refer to 8
- ELECTRI CAL/POWER MI RRORS/SI DEVI EW MI R-
ROR - REMOVAL) and (Refer to 8 - ELECTRI CAL/
POWER MI RRORS/SI DEVI EW MI RROR -
I NSTALLATI ON).
OPERATION
The heated mi rror i s control l ed by the rear wi ndow
defogger swi tch. The onl y ti me that the heated mi r-
ror i s on i s when the rear wi ndow defogger i s on. The
mi rror shoul d become warm to the touch.
DIAGNOSIS AND TESTING - HEATED MIRRORS
For ci rcui t descri pti ons and di agrams (Refer to
Appropri ate Wi ri ng I nformati on).
(1) Check the fuse i n the juncti on bl ock. I f OK, go
to Step 2. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fuse i n the juncti on
bl ock. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to the i gni ti on swi tch as requi red.
cabl e. Remove the front door tri m panel on the si de
of the vehi cl e wi th the i noperati ve mi rror heati ng
gri d. Unpl ug the wi re harness connector at the mi r-
ror. Check for conti nui ty between the ground ci rcui t
cavi ty i n the body hal f of the power mi rror wi re har-
ness connector and a good ground. I f OK, go to Step
4. I f not OK, repai r the open ci rcui t to ground as
requi red.
(4) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Turn on the rear
wi ndow defogger system. Check for battery vol tage at
the rear wi ndow defogger rel ay output ci rcui t cavi ty
i n the body hal f of the power mi rror wi re harness
connector. I f OK, go to Step 5. I f not OK, repai r the
open ci rcui t to the rear wi ndow defogger rel ay as
requi red.
KJ HEATED SYSTEMS 8G - 1
(5) Check for conti nui ty between the ground ci r-
cui t and the rear wi ndow defogger rel ay output ci r-
cui t cavi ti es i n the mi rror hal f of the power mi rror
wi re harness connector. There shoul d be conti nui ty. I f
not OK, repl ace the faul ty power mi rror(Refer to 8 -
ELECTRI CAL/POWER MI RRORS/SI DEVI EW MI R-
ROR - REMOVAL) and (Refer to 8 - ELECTRI CAL/
I NSTALLATI ON). I f OK, check the resi stance
through the el ectri c heati ng gri d ci rcui t. Correct
resi stance through the el ectri c heati ng gri d shoul d be
from 10 to 16 ohms when measured at an ambi ent
temperature of 21 C (70 F). I f not OK, repl ace the
faul ty power mi rror(Refer to 8 - ELECTRI CAL/
REMOVAL) and (Refer to 8 - ELECTRI CAL/POWER
MI RRORS/SI DEVI EW MI RROR - I NSTALLATI ON).
8G - 2 HEATED MIRRORS KJ
HEATED MIRRORS (Continued)
WINDOW DEFOGGER
TABLE OF CONTENTS
page page
WINDOW DEFOGGER
DESCRIPTION - REAR WINDOW DEFOGGER . . 3
OPERATION - REAR WINDOW DEFOGGER . . . . 3
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . 4
STANDARD PROCEDURE - REAR GLASS
HEATING GRID REPAIR . . . . . . . . . . . . . . . . . 4
REAR WINDOW DEFOGGER GRID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DEFOGGER GRID . . . . . . . . . . . . . . . . . . . . . . 5
REAR WINDOW DEFOGGER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR WINDOW DEFOGGER SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - REAR
WINDOW DEFOGGER SWITCH . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - REAR HVAC
CONTROL ASSEMBLY WINDOW
DEFOGGER FUNCTION . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WINDOW DEFOGGER
DESCRIPTION - REAR WINDOW DEFOGGER
The rear wi ndow defogger system wi l l onl y operate
when the i gni ti on swi tch i s i n the run posi ti on. When
the defogger swi tch i s i n the run posi ti on, an el ectri c
heater gri d on the rear wi ndow gl ass i s energi zed.
Vehi cl es wi th the heated mi rror opti ons al so have
heater gri ds l ocated behi nd the outsi de rear vi ew
mi rror gl ass. Each of these gri ds produce heat to hel p
cl ear the rear wi ndow gl ass and outsi de rear vi ew
mi rrors of i ce, snow, or fog.
OPERATION - REAR WINDOW DEFOGGER
The rear wi ndow defogger system i s control l ed by a
swi tch i nstal l ed wi th the HVAC control assembl y. An
amber i ndi cator l amp i n the swi tch button wi l l l i ght
to i ndi cate when the rear wi ndow defogger system i s
turned on. The HVAC control head ci rcui try, whi ch
contai ns the defogger system ti mer l ogi c, moni tors
the state of the defogger swi tch through a hard-wi red
i nput. The i nstrument cl uster ci rcui try control s the
rear wi ndow defogger system through a hard-wi red
control output to the rear wi ndow defogger rel ay. The
rear wi ndow defogger ti mer and l ogi c ci rcui try cannot
be adjusted or repai red and, i f faul ty or damaged, the
HVAC control head assembl y must be repl aced.
The rear wi ndow defogger system wi l l be automat-
i cal l y turned off after a programmed ti me i nterval of
about ten mi nutes. After the i ni ti al ti me i nterval has
expi red, i f the rear wi ndow defogger swi tch i s turned
on agai n duri ng the same i gni ti on cycl e, the defogger
system wi l l automati cal l y turn off after about fi ve
mi nutes.
The rear wi ndow defogger system wi l l automati -
cal l y shut off i f the i gni ti on swi tch i s turned to the
Off posi ti on, or i t can be turned off manual l y by
depressi ng the i nstrument panel swi tch. Fol l owi ng
are general descri pti ons of the major components i n
the rear wi ndow defogger system. Refer to the own-
mati on on the features, use and operati on of the
defogger system.
KJ WINDOW DEFOGGER 8G - 3
DEFOGGER SYSTEM
For ci rcui t descri pti ons and di agrams, (Refer to
Appropri ate Wi ri ng I nformati on). The operati on of
the el ectri cal l y heated rear wi ndow defogger system
can be confi rmed i n one of the fol l owi ng manners:
Turn the i gni ti on swi tch to the run posi ti on.
Set the defogger swi tch i n the run posi ti on. The
rear wi ndow defogger operati on can be checked by
feel i ng the rear wi ndow or outsi de rear vi ew mi rror
gl ass. A di sti nct di fference i n temperature between
the gri d l i nes and the adjacent cl ear gl ass or the mi r-
ror gl ass can be detected wi thi n three to four mi n-
utes of operati on.
Usi ng a 12-vol t DC vol tmeter, contact the rear
gl ass heati ng gri d termi nal B (ri ght si de) wi th the
negati ve l ead, and termi nal A (l eft si de) wi th the pos-
i ti ve l ead (Fi g. 1). The vol tmeter shoul d read battery
vol tage.
The above checks wi l l confi rm system operati on.
I l l umi nati on of the defogger swi tch i ndi cator l amp
means that there i s el ectri cal current avai l abl e at the
output of the defogger rel ay, but does not confi rm
that the el ectri cal current i s reachi ng the rear gl ass
heati ng gri d l i nes.
I f the defogger system does not operate, the prob-
l em shoul d be i sol ated i n the fol l owi ng manner:
(1) Confi rm that the i gni ti on swi tch i s i n the run
posi ti on.
(2) Ensure that the rear gl ass heati ng gri d feed
and ground wi res are connected to the gl ass. Confi rm
that the ground wi re has conti nui ty to ground.
(3) Check the fuses i n the Power Di stri buti on Cen-
ter (PDC) and i n the juncti on bl ock. The fuses must
be ti ght i n thei r receptacl es and al l el ectri cal connec-
ti ons must be secure.
When the above steps have been compl eted and the
rear gl ass or outsi de rear vi ew mi rror heati ng gri d i s
sti l l i noperati ve, one or more of the fol l owi ng i s
faul ty:
Defogger swi tch
Defogger rel ay
HVAC control head ci rcui try
Rear wi ndow gri d l i nes (al l gri d l i nes woul d
have to be broken or one of the feed wi res di scon-
nected for the enti re system to be i noperati ve)
Outsi de rear vi ew mi rror heati ng gri d.
I f setti ng the defogger swi tch to the On posi ti on
produces a severe vol tmeter defl ecti on, check for a
short ci rcui t between the defogger rel ay output and
the rear gl ass or outsi de rear vi ew mi rror heati ng
gri ds.
STANDARD PROCEDURE - REAR GLASS
HEATING GRID REPAIR
Repai r of the rear gl ass heati ng gri d l i nes, bus
bars, termi nal s or pi gtai l wi res can be accompl i shed
usi ng a Mopar Rear Wi ndow Defogger Repai r Ki t
(Part Number 4267922) or equi val ent.
WARNING: MATERIALS CONTAINED IN THE REPAIR
KIT MAY CAUSE SKIN OR EYE IRRITATION. THE
KIT CONTAINS EPOXY RESIN AND AMINE TYPE
HARDENER, WHICH ARE HARMFUL IF SWAL-
LOWED. AVOID CONTACT WITH THE SKIN AND
EYES. FOR SKIN CONTACT, WASH THE AFFECTED
AREAS WITH SOAP AND WATER. FOR CONTACT
WITH THE EYES, FLUSH WITH PLENTY OF WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
IMMEDIATELY. USE WITH ADEQUATE VENTILA-
TION. DO NOT USE NEAR FIRE OR FLAME. CON-
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
REACH OF CHILDREN.
(1) Mask the repai r area so that the conducti ve
epoxy can be appl i ed neatl y. Extend the epoxy appl i -
cati on onto the gri d l i ne or the bus bar on each si de
of the break (Fi g. 2).
Fig. 1 REAR WINDOW DEFOGGER
1 - DEFOGGER BACKGLASS
2 - HEATED GLASS CONNECTOR A
3 - HINDGE MOUNTING SCREWS (2)
4 - HINDGE (LEFT SIDE)
6 - HINDGE (RIGHT SIDE)
7 - HEATED GLASS CONNECTOR B
8 - BACKGLASS DEFOGGER GRID
8G - 4 WINDOW DEFOGGER KJ
WINDOW DEFOGGER (Continued)
(2) Fol l ow the i nstructi ons i n the repai r ki t for
prepari ng the damaged area.
(3) Remove the package separator cl amp and mi x
the two conducti ve epoxy components thoroughl y
wi thi n the packagi ng. Fol d the package i n hal f and
cut the center corner to di spense the epoxy.
(4) For gri d l i ne repai rs, mask the area to be
repai red wi th maski ng tape or a templ ate.
(5) Appl y the epoxy through the sl i t i n the mask-
i ng tape or templ ate. Overl ap both ends of the break
by at l east 19 mi l l i meters (0.75 i nch).
(6) For a termi nal or pi gtai l wi re repl acement,
mask the adjacent areas so the epoxy can be
extended onto the adjacent gri d l i ne as wel l as the
bus bar. Appl y a thi n l ayer of epoxy to the area
where the termi nal or pi gtai l wi re was fastened and
onto the adjacent gri d l i ne.
(7) Appl y a thi n l ayer of conducti ve epoxy to the
termi nal or bare wi re end of the pi gtai l and pl ace i t
i n the proper l ocati on on the bus bar. To prevent the
termi nal or pi gtai l wi re from movi ng whi l e the epoxy
i s curi ng, i t must be wedged or cl amped.
(8) Careful l y remove the maski ng tape or templ ate.
CAUTION: Do not allow the glass surface to exceed
204 C (400 F) or the glass may fracture.
(9) Al l ow the epoxy to cure 24 hours at room tem-
perature, or use a heat gun that wi l l not over heat
the gl ass. Hol d the heat gun approxi matel y 25.4 cen-
ti meters (10 i nches) from the repai r.
(10) After the conducti ve epoxy i s properl y cured,
remove the wedge or cl amp from the termi nal or pi g-
tai l wi re. Do not attach the wi re harness connectors
unti l the curi ng process i s compl ete.
(11) Check the operati on of the rear wi ndow defog-
ger gl ass heati ng gri d.
REAR WINDOW DEFOGGER
GRID
DESCRIPTION
The heated rear wi ndow gl ass has two el ectri cal l y
conducti ve verti cal bus bars and a seri es of 11 hori -
zontal gri d l i nes made of a si l ver-cerami c materi al ,
whi ch i s baked on and bonded to the i nsi de surface of
the gl ass. The gri d l i nes and bus bars compri se a
paral l el el ectri cal ci rcui t.
OPERATION
When the rear wi ndow defogger swi tch i s pl aced i n
the On posi ti on, el ectri cal current i s di rected to the
rear wi ndow gri d l i nes through the bus bars. The
gri d l i nes heat the rear wi ndow to cl ear the surface
of fog or snow. Protecti on for the heated gri d ci rcui t
i s provi ded by a fuse i n the Power Di stri buti on Cen-
ter (PDC).
The gri d l i nes and bus bars are hi ghl y resi stant to
abrasi on. However, i t i s possi bl e for an open ci rcui t
to occur i n an i ndi vi dual gri d l i ne, resul ti ng i n no
current fl ow through the l i ne.
The gri d l i nes can be damaged or scraped off wi th
sharp i nstruments. Care shoul d be taken when cl ean-
i ng the gl ass or removi ng forei gn materi al s, decal s,
or sti ckers from the gl ass. Normal gl ass cl eani ng sol -
vents or hot water used wi th rags or towel i ng i s rec-
ommended.
A repai r ki t i s avai l abl e to repai r the gri d l i nes and
bus bars, or to rei nstal l the heated gl ass pi gtai l
wi res.
DEFOGGER GRID
Appropri ate Wi ri ng I nformati on). To detect breaks i n
the gri d l i nes, the fol l owi ng procedure i s requi red:
(1) Turn the i gni ti on swi tch to the run posi ti on.
Set the defogger swi tch i n the On posi ti on. The i ndi -
cator l amp shoul d l i ght. I f OK, go to Step 2. I f not
OK, (Refer to 8 - ELECTRI CAL/HEATED GLASS/
REAR WI NDOW DEFOGGER RELAY - DI AGNOSI S
AND TESTI NG)
(2) Usi ng a 12-vol t DC vol tmeter, contact the ver-
ti cal bus bar on the ri ght si de of the vehi cl e wi th the
negati ve l ead. Wi th the posi ti ve l ead, contact the ver-
ti cal bus bar on the l eft si de of the vehi cl e. The vol t-
meter shoul d read battery vol tage. I f OK, go to Step
3. I f not OK, repai r the open ci rcui t to the defogger
rel ay as requi red.
(3) Wi th the negati ve l ead of the vol tmeter, contact
a good body ground poi nt. The vol tage readi ng shoul d
not change. I f OK, go to Step 4. I f not OK, repai r the
ci rcui t to ground as requi red.
Fig. 2 GRID LINE REPAIR
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
WINDOW DEFOGGER (Continued)
(4) Connect the negati ve l ead of the vol tmeter to
the ri ght si de bus bar and touch each gri d l i ne at i ts
mi dpoi nt wi th the posi ti ve l ead (Fi g. 3). A readi ng of
approxi matel y si x vol ts i ndi cates a l i ne i s good. A
readi ng of zero vol ts i ndi cates a break i n the gri d
l i ne between the mi dpoi nt of the gri d l i ne and the
l eft si de bus bar. A readi ng of ten to fourteen vol ts
i ndi cates a break between the mi dpoi nt of the gri d
l i ne and the ri ght si de bus bar. Move the posi ti ve
l ead on the gri d l i ne towards the break and the vol t-
age readi ng wi l l change as soon as the break i s
crossed.
RELAY
DESCRIPTION
The rear wi ndow defogger rel ay i s a I nternati onal
Standards Organi zati on (I SO)-type rel ay. The rear
wi ndow defogger rel ay i s a el ectromechani cal devi ce
that swi tches fused battery current to the rear gl ass
and outsi de mi rror heati ng gri ds, and the i ndi cator
l amp of the defogger swi tch, when the HVAC control
head rear wi ndow defogger ti mer and l ogi c ci rcui try
grounds the rel ay coi l . (Refer to 8 - ELECTRI CAL/
HEATED GLASS/REAR WI NDOW DEFOGGER
RELAY - DI AGNOSI S AND TESTI NG)
The rear wi ndow defogger rel ay i s l ocated i n the
juncti on bl ock, on the l eft si de of the i nstrument
panel i nboard to the center of the vehi cl e (just to the
l eft and above the brake pedal or behi nd the knee
bl ocker). The rear wi ndow defogger rel ay cannot be
repai red and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
resi stor or di ode, and three (two fi xed and one mov-
abl e) el ectri cal contacts. The movabl e (common feed)
rel ay contact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When the el ec-
tromagneti c coi l i s energi zed, i t draws the movabl e
contact away from the normal l y cl osed fi xed contact,
and hol ds i t agai nst the other (normal l y open) fi xed
contact.
When the el ectromagneti c coi l i s de-energi zed,
spri ng pressure returns the movabl e contact to the
normal l y cl osed posi ti on. The resi stor i s connected i n
paral l el wi th the el ectromagneti c coi l i n the rel ay,
and hel ps to di ssi pate vol tage spi kes that are pro-
duced when the coi l i s de-energi zed.
DEFOGGER RELAY
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
RELAY TEST
The defogger rel ay (Fi g. 4) i s l ocated i n the junc-
ti on bl ock, on the l eft si de of the i nstrument panel
i nboard to the center of the vehi cl e (just to the ri ght
and above the brake pedal or behi nd the knee
bl ocker). Remove the defogger rel ay from the juncti on
bl ock to perform the fol l owi ng tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
Fig. 3 REAR WINDOW DEFOGGER
1 - DEFOGGER BACKGLASS
2 - HEATED GLASS CONNECTOR A
4 - HINDGE (LEFT SIDE)
6 - HINDGE (RIGHT SIDE)
7 - HEATED GLASS CONNECTOR B
8 - BACKGLASS DEFOGGER GRID
REAR WINDOW DEFOGGER GRID (Continued)
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
tromagnet) shoul d be 60.7 to 80.3 ohms. I f OK, go to
Step 3. I f not OK, repl ace the faul ty rel ay.
and 30. I f OK, see the Rel ay Ci rcui t Test i n thi s
group. I f not OK, repl ace the faul ty rel ay.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
RELAY CIRCUIT TEST
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the PDC fuse as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the rear gl ass and outsi de rear vi ew mi rror heat-
i ng gri ds and the defogger swi tch i ndi cator l amp.
There shoul d be conti nui ty between the cavi ty for
rel ay termi nal 87 and the rear wi ndow defogger rel ay
output ci rcui t cavi ti es of the rear gl ass heati ng gri d
connector, both outsi de rear vi ew mi rror heati ng gri d
connectors, and the defogger swi tch connector at al l
ci rcui t(s) as requi red.
(4) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. Thi s termi nal i s pro-
vi ded wi th ground by the i nstrument cl uster rear
wi ndow defogger ti mer and l ogi c ci rcui try to energi ze
the defogger rel ay. There shoul d be conti nui ty to
ground at the cavi ty for rel ay termi nal 85 when the
defogger swi tch i s turned On. However, wi th the
defogger rel ay removed, the defogger swi tch i ndi cator
l amp wi l l not l i ght to show that the defogger system
i s turned On. Be certai n that you depress the defog-
ger swi tch at l east twi ce to confi rm that the system
i s turned on duri ng thi s test. I f OK, go to Step 5. I f
not OK, repai r the open ci rcui t to the HVAC control
head as requi red.
(5) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. I t i s connected to
fused i gni ti on swi tch output vol tage and shoul d be
hot when the i gni ti on swi tch i s i n the run posi ti on.
Check for battery vol tage at the cavi ty for rel ay ter-
mi nal 86 wi th the i gni ti on swi tch i n the run posi ti on.
I f OK, see the di agnosi s for I nstrument Cl uster i n
thi s group. I f not OK, repai r the open ci rcui t to the
fuse i n the juncti on bl ock as requi red.
REMOVAL
INJURY.
cabl e.
(2) Unpl ug the rear wi ndow defogger rel ay from
the juncti on bl ock.
INSTALLATION
(1) I nstal l the rear wi ndow defogger rel ay by al i gn-
i ng the rel ay termi nal s wi th the cavi ti es i n the junc-
ti on bl ock and pushi ng the rel ay fi rml y i nto pl ace.
(3) Test the rel ay operati on.
Fig. 4 DEFOGGER RELAY- TERMINAL LEGEND
REAR WINDOW DEFOGGER RELAY (Continued)
SWITCH
DESCRIPTION
The rear wi ndow defogger swi tch i s i nstal l ed i n the
i nstrument panel HVAC contol head assembl y. The
momentary-type swi tch provi des a hard-wi red ground
si gnal to the HVAC control head each ti me i t i s
depressed. The i nstrument cl uster rear wi ndow
defogger ti mer and l ogi c ci rcui try responds by ener-
gi zi ng or de-energi zi ng the rear wi ndow defogger
rel ay.
OPERATION
Energi zi ng the rear wi ndow defogger rel ay pro-
vi des el ectri cal current to the rear wi ndow defogger
gri d and, i f the vehi cl e i s so equi pped, the outsi de
rear vi ew mi rror heati ng gri ds. An amber i ndi cator
l amp i n the defogger swi tch, whi ch l i ghts to i ndi cate
when the defogger system i s turned On, i s al so pow-
ered by the defogger rel ay output.
The defogger swi tch i l l umi nati on l amp and i ndi ca-
tor l amp bul bs are servi ceabl e. The defogger swi tch
cannot be repai red and, i f faul ty or damaged the
enti re HVAC control head assembl y must be
repl aced.
DEFOGGER SWITCH
INJURY.
cabl e. Remove the HVAC control head assembl y from
the i nstrument panel and unpl ug the defogger swi tch
wi re harness connector-B.
cui t cavi ty of the defogger swi tch wi re harness con-
nector and a good ground. There shoul d be
conti nui ty. I f OK, go to Step 3. I f not OK, repai r the
open ci rcui t as requi red.
cui t termi nal and the rear wi ndow defogger swi tch
sense ci rcui t termi nal on the back of the defogger
swi tch housi ng (Fi g. 5). There shoul d be momentary
conti nui ty as the defogger swi tch button i s depressed,
and then no conti nui ty. I f OK, (Refer to 8 - ELEC-
TRI CAL/HEATED GLASS/REAR WI NDOW DEFOG-
GER SWI TCH - DI AGNOSI S AND TESTI NG -
I NSTRUMENT CLUSTER REAR WI NDOW DEFOG-
GER FUNCTI ON) I f not OK, repl ace the faul ty
swi tch (Fi g. 5).
(4) Check swi tch posi ti on conti nui ty between:
CONTACT PINS
1 - OFF LAMPS A-1 - A-7
2 - ON MOMENTARY B-6 - B-8
3 - ILLUMINATION LAMP A-7 - A-1
4 - INDICATOR LAMP B-12 - B-7
Fig. 5 A/C HEATER CONTROL HEAD (Rear View)
1 - A/C HEATER CONTROL HEAD
2 - A/C HEATER CONTROL HEAD LIGHT
3 - REAR WINDOW DEFOGGER SWITCH AND TEMPERATURE
BLEND DOOR- CONNECTOR B (12 PIN)
5 - MODE SELECT CONTROL
6 - BLOWER SPEED CONTROL- CONNECTOR A (7 PIN)
7 - MOUNTING SCREWS (4)
DIAGNOSIS AND TESTING - REAR HVAC
CONTROL ASSEMBLY WINDOW DEFOGGER
FUNCTION
Before performi ng thi s test, compl ete the Defogger
Swi tch and Defogger Rel ay tests as descri bed i n thi s
group. For ci rcui t descri pti ons and di agrams, (Refer
to Appropri ate Wi ri ng I nformati on).
INJURY.
cabl e. Remove the defogger rel ay from the juncti on
bl ock and unpl ug the defogger swi tch wi re harness
connector.
(2) Remove the HVAC control head from the
i nstrument panel . Thi s i s accompl i shed by removi ng
the ashtray and the screw behi nd the ashtray and
uncl i pi ng the center bezel .
(3) Check for conti nui ty between the rear wi ndow
defogger swi tch sense ci rcui t cavi ty of the cl uster
wi re harness connector (connector B) and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 4. I f not OK, repai r the short ci rcui t as
requi red.
defogger swi tch sense ci rcui t cavi ty of the ri ght
i nstrument cl uster wi re harness connector (connector
B) and the defogger swi tch wi re harness connector.
There shoul d be conti nui ty. I f OK, go to Step 5. I f not
OK, repai r the open ci rcui t as requi red.
defogger rel ay control ci rcui t cavi ty of the ri ght
B) and a good ground. There shoul d be no conti nui ty.
I f OK, go to Step 6. I f not OK, repai r the short ci rcui t
as requi red.
defogger rel ay control ci rcui t cavi ti es of the ri ght
B) and the defogger rel ay receptacl e (the cavi ty for
I SO rel ay termi nal 85) i n the juncti on bl ock. There
shoul d be conti nui ty. I f OK, repl ace the faul ty HVAC
control head. I f not OK, repai r the open ci rcui t as
requi red.
REMOVAL
INJURY.
cabl e.
(2) The Rear Wi ndow Defogger swi tch i s part of
the HVAC assembl y and i f damaged or i noperati ve
the enti re HVAC control assembl y must be repl ace-
d(Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
CONTROLS/A/C HEATER CONTROL - REMOVAL).
INSTALLATION
(1) The Rear Wi ndow Defogger swi tch i s part of
the HVAC control assembl y and i f damaged or i nop-
erati ve you must repl ace the enti re HVEAC control
head assembl y(Refer to 24 - HEATI NG & AI R CON-
DI TI ONI NG/CONTROLS/A/C HEATER CONTROL -
I NSTALLATI ON).
REAR WINDOW DEFOGGER SWITCH (Continued)
HEATED SEAT SYSTEM
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DRIVER SEAT HEATER SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
HEATED SEAT ELEMENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HEATED SEAT SENSOR
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PASSENGER SEAT HEATER SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
HEATED SEAT SYSTEM
DESCRIPTION
I ndi vi dual l y control l ed el ectri cal l y heated front
seats are avai l abl e on model s that are al so equi pped
wi th the opti onal l eather tri m package. Vehi cl es wi th
thi s opti on can be vi sual l y i denti fi ed by the two sep-
arate heated seat swi tches mounted on the outboard
seat cushi on si de shi el ds. The heated seat system
al l ows the front seat dri ver and passenger to sel ect
from two di fferent l evel s of suppl emental el ectri cal
seat heati ng, or no seat heati ng to sui t thei r i ndi vi d-
ual comfort requi rements. The heated seat system for
thi s vehi cl e i ncl udes the fol l owi ng major components:
Heated Seat Switches - Two heated seat
swi tches are used per vehi cl e, i ncl udi ng two Li ght-
Emi tti ng Di ode (LED) i ndi cator l amps and an i ncan-
descent back l i ghti ng bul b for each swi tch. One
swi tch for the dri ver and one for the passenger front
seats. The swi tches are mounted on the outboard
seat cushi on si de shi el ds.
Heated Seat Module - al so referred to as the
Seat Heat I nterface Modul e (SHI M), thi s modul e con-
tai ns the sol i d state el ectroni c control and di agnosti c
l ogi c ci rcui try for the heated seat system. One heated
seat modul e i s used per vehi cl e and i s mounted
under the l eft front seat cushi on. Refer to the El ec-
troni c Control Modul es secti on of the servi ce manual
for heated seat modul e i nformati on.
Heated Seat Elements - Four heated seat el e-
ments are used per vehi cl e, one for each front seat
back and one for each front seat cushi on. The el e-
ments are i ntegral to the i ndi vi dual front seat and
seat back cushi ons and cannot be removed from the
cushi ons, once i nstal l ed at the factory.
Heated Seat Sensors - Two heated seat sen-
sors are used per vehi cl e, one for each front seat. The
sensors are i ntegral to the i ndi vi dual front seat heat-
i ng el ements.
Fol l owi ng are general descri pti ons of the major
components i n the heated seat system. See the own-
mati on on the features, use and operati on of the
heated seat system. Refer to Wiring Diagrams for
the l ocati on of compl ete heated seat system wi ri ng
di agrams.
OPERATION
The heated seat modul e recei ves fused battery cur-
rent through fuse #29 i n the Juncti on Bl ock (JB)
when the i gni ti on swi tch i s i n the ON posi ti on. The
heated seat swi tches recei ve battery current through
fuse #25 i n the Juncti on Bl ock al so, when the i gni -
ti on swi tch i s i n the ON posi ti on. The heated seat
modul e shares a common ground ci rcui t wi th each of
the heated seat el ements. The heated seat el ements
wi l l onl y operate when the surface temperature of
the seat cushi on i s bel ow the desi gned temperature
set poi nts of the system.
The heated seat system wi l l al so be turned off
automati cal l y whenever the i gni ti on swi tch i s turned
to any posi ti on except On. I f the i gni ti on swi tch i s
turned to the Off posi ti on whi l e a heated seat i s
turned ON, the heated seat wi l l remai n Off after the
i gni ti on swi tch i s turned back ON unti l a heated
seat swi tch i s depressed agai n.
8G - 10 HEATED SEAT SYSTEM KJ
The heated seat modul e moni tors i nputs from the
heated seat sensors and the heated seat swi tches. I n
response to these i nputs the heated seat modul e uses
i ts i nternal programmi ng to control outputs to the
heated seat el ements i n both front seats and to con-
trol the heated seat LED i ndi cator l amps l ocated i n
both of the heated seat swi tches. The heated seat
modul e i s al so programmed to provi de sel f-di agnosti c
capabi l i ty. When the modul e detects certai n fai l ures
wi thi n the heated seat system, i t wi l l provi de a
vi sual i ndi cati on of the fai l ure by fl ashi ng the i ndi ca-
tor l amps i n the affected heated seat swi tch. The
heated seat modul e wi l l automati cal l y turn off the
heated seat el ements i f i t detects a short or open i n
the heated seat el ement ci rcui t or a heated seat sen-
sor val ue that i s out of range.
SYSTEM
HEATED SEAT SYSTEM SELF-DIAGNOSIS
The heated seat system i s capabl e of performi ng
some sel f-di agnosti cs. The fol l owi ng tabl e depi cts the
vari ous moni tored fai l ures whi ch wi l l be reported to
the vehi cl e operator or techni ci an by fl ashi ng the
i ndi vi dual heated seat swi tch Li ght Emi tti ng Di ode
(LED) i ndi cator l amps. Refer to the Heated Seat Sys-
tem Sel f-Di agnosi s tabl e for fai l ure i denti fi cati on.
The dri ver si de heated seat swi tch i ndi cator l amps
wi l l fl ash i f a fai l ure occurs i n the dri ver si de heated
seat, and the passenger si de heated seat swi tch i ndi -
cator l amps wi l l fl ash for a passenger si de heated
seat fai l ure. I f a moni tored heated seat system fai l -
ure occurs, the swi tch i ndi cator l amps wi l l fl ash at a
pul se rate of about one-hal f second on, fol l owed by
about one-hal f second off for a durati on of about one
mi nute after the swi tch for the faul ty heated seat i s
depressed i n ei ther the Low or Hi gh di recti on. Thi s
process wi l l repeat every ti me the faul ty heated seat
swi tch i s actuated unti l the probl em has been cor-
rected.
Heated Seat System Self-Diagnosis
Monitored Failure
Switch High
Indicator Lamp
Switch Low
Indicator Lamp
Heated Seat
Element Shorted
Flashing Flashing
Heated Seat
Element Open
Flashing Off
Heated Seat
Sensor Value Out
of Range
Off Flashing
I f the heated seat system fai l ure i s i denti fi ed by
fl ashi ng heated seat swi tch i ndi cator l amps, go to the
appropri ate di agnosi s and testi ng procedure i n thi s
secti on and confi rm the condi ti on, usi ng the step by
step procedure. I f the moni tored fai l ure i s confi rmed,
repl ace the component. I f the moni tored fai l ure i s not
confi rmed, repl ace the heated seat modul e wi th a
known good uni t and retest the system.
HEATED SEAT SYSTEM TESTING
Refer to Wiring Diagrams for the l ocati on of com-
pl ete heated seat system wi ri ng di agrams. Before
testi ng the i ndi vi dual components i n the heated seat
system, perform the fol l owi ng prel i mi nary checks:
I f a si ngl e i ndi cator l amp for one heated seat
swi tch does not operate and the heated seat el ements
do heat, refer to Diagnosis and Testing the
Heated Seat Switch i n thi s secti on for the l ocati on
of heated seat swi tch di agnosi s and testi ng proce-
dures.
I f both i ndi cator l amps for a heated seat swi tch
operate, but the heated seat el ements do not heat,
refer to Diagnosis and Testing the Heated Seat
Module i n El ectroni c Control Modul es for the l oca-
ti on of heated seat modul e di agnosi s and testi ng pro-
cedures.
I f an i ndi cator l amp on ei ther heated seat swi tch
remai ns i l l umi nated after the heated seat has been
turned Off, refer to Diagnosis and Testing the
Heated Seat Module i n El ectroni c Control Modul es
for the l ocati on of heated seat modul e di agnosi s and
testi ng procedures. Al so refer to the Body Di agnosti c
Manual for addi ti onal di agnosi s and testi ng proce-
dures.
DRIVER SEAT HEATER
SWITCH
DESCRIPTION
The heated seat swi tches are l ocated on the out-
board cushi on si de shi el d of the dri ver and passenger
front seats (Fi g. 1). The two, three-posi ti on rocker
type swi tches provi de a resi stor mul ti pl exed si gnal to
the Heated Seat Modul e through separate hard wi red
ci rcui ts. Each swi tch has an Off, Low and Hi gh set-
ti ng. Each swi tch contai ns two l i ght emi tti ng di odes
(LED), one for each Hi gh and Low setti ng to l et the
occupant know that the seat heater system i s on.
The heated seat swi tches and thei r LEDs cannot
be repai red. I f ei ther swi tch i s faul ty or damaged the
enti re swi tch must be repl aced.
KJ HEATED SEAT SYSTEM 8G - 11
HEATED SEAT SYSTEM (Continued)
OPERATION
There are three posi ti ons that can be sel ected wi th
each of the heated seat swi tches: Off, Low, and Hi gh.
When the front of the swi tch rocker i s ful l y
depressed, the Hi gh posi ti on i s sel ected and the hi gh
posi ti on LED i ndi cator i l l umi nates. When the rear of
the swi tch rocker i s ful l y depressed, the Low posi ti on
i s sel ected and the l ow posi ti on LED i ndi cator i l l umi -
nates. When the swi tch rocker i s depressed a second
ti me i n ei ther di recti on, Off i s sel ected and both LED
i ndi cators are exti ngui shed.
Both swi tches provi de separate resi stor mul ti -
pl exed hard wi re i nputs to the Heated Seat Modul e
to i ndi cate the sel ected swi tch posi ti on. The heated
seat modul e moni tors the swi tch i nputs and responds
to the heated seat swi tch status messages by control -
l i ng the output to the seat heater el ements of the
sel ected seat. The Low heat posi ti on set poi nt i s
about 36 C (97 F), and the Hi gh heat posi ti on set
poi nt i s about 41 C (105 F).
SWITCH
thi s secti on for fl ashi ng LED fai l ure i denti fi cati on.
Refer to Wiring Diagrams for compl ete heated seat
system wi ri ng di agrams.
(1) I f the probl em bei ng di agnosed i nvol ves a
heated seat swi tch i ndi cator l amp that remai ns i l l u-
mi nated after the heated seat has been turned Off,
Module i n the El ectroni c Control Modul es secti on for
heated seat modul e di agnosi s and testi ng procedures.
I f not, go to Step 2
(2) Remove the heated seat swi tch (Refer to 8 -
ELECTRI CAL/HEATED SEATS/DRI VER HEATED
SEAT SWI TCH - REMOVAL). Check for conti nui ty
between the ground ci rcui t cavi ty #5 of the heated
seat swi tch connector and a good ground. There
shoul d be conti nui ty. I f OK, go to Step 3. I f not OK,
repai r the open ground ci rcui t as requi red.
(3) Turn the i gni ti on swi tch to the ON posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output ci rcui t cavi ty #1 of the heated seat swi tch con-
nector. I f OK, go to Step 4. I f not OK, repai r the open
fused i gni ti on swi tch output ci rcui t as requi red.
(4) Check the conti nui ty between pi n #1 and pi n
#3 of the heated seat swi tch (Fi g. 2). I f the readi ngs
do not correspond to those i n the Heated Seat Swi tch
Conti nui ty tabl e bel ow, repl ace the heated seat
swi tch. I f OK, and the heated seat system i s sti l l not
operati ng properl y refer to Diagnosis and Testing
the Heated Seat Module.
OF MEASURING DEVICE IS USED, THE VALUES
Fig. 1 KJ POWER / HEATED SEAT
Fig. 2 Heated Seat Switches
DRIVER SEAT HEATER SWITCH (Continued)
HEATED SEAT SWITCH CONTINUITY
CONTINUITY
BETWEEN
SWITCH
POSITION
OHMS
READING +/
10%
PIN 1 AND 3 OFF 2.2 K (2200)
OHMS
PIN 1 AND 3 LO .415 K (415)
OHMS
PIN 1 AND 3 HI 33 OHMS
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Remove the appropri ate seat cushi on si de
shi el d (Refer to 23 - BODY/SEATS/SEAT CUSHI ON
SI DE COVERS - REMOVAL).
(3) Di sconnect the heated seat swi tch el ectri cal
connector. Depress the l ocki ng tab and pul l strai ght
apart.
(4) Worki ng from the undersi de of the swi tch, gen-
tl y rock the swi tch back and forth out of i ts mounti ng
l ocati on.
INSTALLATION
(1) Gentl y rock the swi tch back and forth i n to i ts
mounti ng l ocati on.
(2) Connect the heated seat swi tch el ectri cal con-
nector.
(3) I nstal l the appropri ate seat cushi on si de shi el d.
Refer to the Body secti on of the servi ce manual for
the procedure.
(4) Connect the negati ve battery cabl e.
HEATED SEAT ELEMENT
DESCRIPTION
The heated seat system i ncl udes four seat heati ng
el ements. Two are l ocated i n each front seat, one for
the seat cushi on and the other for the seat back. Al l
model s use two resi stor wi re heati ng el ements for
each seat that are connected i n seri es wi th the
Heated Seat Modul e (HSM). The temperature sensor
i s a Negati ve Temperature Coeffi ci ent (NTC) ther-
mi stor. One temperature sensor i s used for each seat,
and i t i s l ocated on the seat cushi on heati ng el ement
for al l model s.
The seat heati ng el ements are permanentl y
attached to the seat cushi ons. The heated seat el e-
ments and the temperature sensor cannot be
adjusted or repai red and, i f faul ty or damaged, the
seat cushi ons must be repl aced. Refer to the Body
secti on for the seat cushi on servi ce procedures.
OPERATION
The heated seat el ements resi st the fl ow of el ectri cal
current. When battery current i s passed through the
el ements, the energy l ost by the resi stance of the el e-
ments to the current fl ow i s rel eased i n the form of
heat. When the temperature of the seat cushi on cover
ri ses, the resi stance of the sensor decreases. The Heated
Seat Modul e suppl i es a fi ve-vol t current to one si de of
each sensor, and moni tors the vol tage drop through the
sensor on a return ci rcui t. The Heated Seat Modul e
uses thi s temperature sensor i nput to moni tor the tem-
perature of the seat, and regul ates the current fl ow to
the seat heati ng el ements accordi ngl y.
ELEMENT
SEAT CUSHION ELEMENT
cabl e. Di sconnect the green heated seat cushi on el e-
ment wi re harness connector from the power seat
wi re harness. The power seat wi re harness connec-
tors for the seat cushi on heati ng el ements are
secured to a bracket l ocated under the seat cushi on
frame. Refer to Wiring for connector pi n i nformati on.
(2) Check for conti nui ty between the two heated
seat el ement ci rcui t cavi ti es. There shoul d be conti -
nui ty. I f OK, the el ements wi thi n the seat assembl y
test OK, go to Step 3. I f not OK, repl ace the faul ty
seat heati ng el ement and cushi on assembl y.
(3) Test the seat wi re harness between the heated
seat modul e connector and the heated seat wi re har-
ness el ement connector for a shorted or open ci rcui t.
I f OK, el ement i s OK, proceed wi th testi ng the
heated seat sensor and modul e. I f not OK, repai r the
shorted or open seat wi re harness as requi red.
SEAT BACK ELEMENT
cabl e. Di sconnect the green heated seat back el ement
wi re harness connector from the power seat wi re har-
ness. The power seat wi re harness connectors for the
seat cushi on heati ng el ements are secured to a
bracket l ocated under the seat cushi on frame. Refer
to Wiring for connector pi n i nformati on.
(2) Check for conti nui ty between the two heated
seat el ement ci rcui t cavi ti es. There shoul d be conti -
nui ty. I f OK, the el ements wi thi n the seat assembl y
test OK, go to Step 3. I f not OK, repl ace the faul ty
seat heati ng el ement and cushi on assembl y.
ness el ement connector for a shorted or open ci rcui t.
I f OK, el ement i s OK, proceed wi th testi ng the
heated seat sensor and modul e. I f not OK, repai r the
shorted or open seat wi re harness as requi red.
DRIVER SEAT HEATER SWITCH (Continued)
HEATED SEAT SENSOR
SENSOR
For compl ete ci rcui t di agrams, refer to WIRING.
OF MEASURING DEVICE IS USED THE VALUES
(1) Di sconnect the heated seat wi re harness con-
nector from under the seat. Usi ng an ohmmeter,
check the resi stance between the heated seat sensor
i nput ci rcui t cavi ty and the heated seat sensor feed
ci rcui t cavi ty i n the heated seat wi re harness connec-
tor. The heated seat sensor resi stance shoul d be
between 1 ki l ohm and 100 ki l ohms. I f OK, go to Step
2. I f not OK, repl ace the faul ty seat heati ng el ement
assembl y.
ness connector for a shorted or open ci rcui t. I f OK,
Module i n El ectroni c Control Modul es, for the
proper heated seat modul e di agnosi s and testi ng pro-
cedures. I f not OK, repai r the shorted or open heated
seat wi re harness as requi red.
PASSENGER SEAT HEATER
SWITCH
DESCRIPTION
The heated seat swi tches are l ocated on the out-
board cushi on si de shi el d of the dri ver and passenger
front seats (Fi g. 3). The two, three-posi ti on rocker
type swi tches provi de a resi stor mul ti pl exed si gnal to
the Heated Seat Modul e through separate hard wi red
ci rcui ts. Each swi tch has an Off, Low and Hi gh set-
ti ng. Each swi tch contai ns two l i ght emi tti ng di odes
(LED), one for each Hi gh and Low setti ng to l et the
occupant know that the seat heater system i s on.
The heated seat swi tches and thei r LEDs cannot
be repai red. I f ei ther swi tch i s faul ty or damaged the
enti re swi tch must be repl aced.
OPERATION
There are three posi ti ons that can be sel ected wi th
each of the heated seat swi tches: Off, Low, and Hi gh.
When the front of the swi tch rocker i s ful l y
depressed, the Hi gh posi ti on i s sel ected and the hi gh
posi ti on LED i ndi cator i l l umi nates. When the rear of
the swi tch rocker i s ful l y depressed, the Low posi ti on
i s sel ected and the l ow posi ti on LED i ndi cator i l l umi -
nates. When the swi tch rocker i s depressed a second
ti me i n ei ther di recti on, Off i s sel ected and both LED
i ndi cators are exti ngui shed.
Both swi tches provi de separate resi stor mul ti -
pl exed hard wi re i nputs to the Heated Seat Modul e
to i ndi cate the sel ected swi tch posi ti on. The heated
seat modul e moni tors the swi tch i nputs and responds
to the heated seat swi tch status messages by control -
l i ng the output to the seat heater el ements of the
sel ected seat. The Low heat posi ti on set poi nt i s
about 36 C (97 F), and the Hi gh heat posi ti on set
poi nt i s about 41 C (105 F).
SWITCH
thi s secti on for fl ashi ng LED fai l ure i denti fi cati on.
Refer to Wiring Diagrams for compl ete heated seat
system wi ri ng di agrams.
(1) I f the probl em bei ng di agnosed i nvol ves a
heated seat swi tch i ndi cator l amp that remai ns i l l u-
mi nated after the heated seat has been turned Off,
Module i n the El ectroni c Control Modul es secti on for
heated seat modul e di agnosi s and testi ng procedures.
I f not, go to Step 2
Fig. 3 KJ POWER / HEATED SEAT
(2) Remove the heated seat swi tch (Refer to 8 -
ELECTRI CAL/HEATED SEATS/DRI VER HEATED
SEAT SWI TCH - REMOVAL). Check for conti nui ty
between the ground ci rcui t cavi ty #5 of the heated
seat swi tch connector and a good ground. There
repai r the open ground ci rcui t as requi red.
(3) Turn the i gni ti on swi tch to the ON posi ti on.
output ci rcui t cavi ty #1 of the heated seat swi tch con-
nector. I f OK, go to Step 4. I f not OK, repai r the open
fused i gni ti on swi tch output ci rcui t as requi red.
(4) Check the conti nui ty between pi n #1 and pi n
#3 of the heated seat swi tch (Fi g. 4). I f the readi ngs
do not correspond to those i n the Heated Seat Swi tch
Conti nui ty tabl e bel ow, repl ace the heated seat
swi tch. I f OK, and the heated seat system i s sti l l not
operati ng properl y refer to Diagnosis and Testing
the Heated Seat Module.
OF MEASURING DEVICE IS USED, THE VALUES
HEATED SEAT SWITCH CONTINUITY
CONTINUITY
BETWEEN
SWITCH
POSITION
OHMS
READING +/
10%
PIN 1 AND 3 OFF 2.2 K (2200)
OHMS
PIN 1 AND 3 LO .415 K (415)
OHMS
PIN 1 AND 3 HI 33 OHMS
REMOVAL
cabl e.
(2) Remove the appropri ate seat cushi on si de
shi el d (Refer to 23 - BODY/SEATS/SEAT CUSHI ON
(3) Di sconnect the heated seat swi tch el ectri cal
connector. Depress the l ocki ng tab and pul l strai ght
apart.
(4) Worki ng from the undersi de of the swi tch, gen-
tl y rock the swi tch back and forth out of i ts mounti ng
l ocati on.
INSTALLATION
(1) Gentl y rock the swi tch back and forth i n to i ts
mounti ng l ocati on.
(2) Connect the heated seat swi tch el ectri cal con-
nector.
(3) I nstal l the appropri ate seat cushi on si de shi el d.
Refer to the Body secti on of the servi ce manual for
the procedure.
Fig. 4 Heated Seat Switches
PASSENGER SEAT HEATER SWITCH (Continued)
HORN
TABLE OF CONTENTS
page page
HORN SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - HORN SYSTEM . . . 1
HORN
DIAGNOSIS AND TESTING - HORN . . . . . . . . . . 2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN RELAY
DIAGNOSIS AND TESTING - HORN RELAY . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - HORN SWITCH . . . 4
HORN SYSTEM
DESCRIPTION
A dual -note el ectri c horn system i s standard facto-
ry-i nstal l ed equi pment on thi s model (Fi g. 1).
The dual -note horn system features dual el ectro-
magneti c horn uni ts. The horn system i ncl udes the
fol l owi ng major components:
Horn - The two horns are l ocated bel ow the
Power Di stri buti on Center (PDC).
Horn Relay - The horn rel ay i s l ocated i n the
Juncti on Bl ock (JB).
Horn Switch - The horn swi tch i s mol ded i nto
the dri ver ai rbag assembl y.
OPERATION
The horn system operates on battery current
recei ved through fuse 3 i n the Juncti on Bl ock (JB).
The horn system ci rcui t i s desi gned so that the sys-
tem wi l l remai n operati onal , regardl ess of the i gni -
ti on swi tch posi ti on.
DIAGNOSIS AND TESTING - HORN SYSTEM
I n most cases, any probl em i nvol vi ng conti nual l y
soundi ng horns can be qui ckl y al l evi ated by removi ng
the horn rel ay from the Juncti on Bl ock (JB). Refer to
horn rel ay for the removal procedure. Refer to the
nector repai r procedures, further detai l s on wi re
harness routi ng and retenti on, as wel l as pi n-out and
INJURY.
Fig. 1 HORN LOCATION
1 - HIGH NOTE HORN
2 - LOW NOTE HORN
KJ HORN 8H - 1
HORN SYSTEM DIAGNOSIS TABLE
BOTH HORNS
INOPERATIVE
1. Faulty fuse. 1. Check the fuse in the Junction Block (JB).
Replace the fuse and repair the shorted circuit or
component, if required.
2. Faulty horn relay. 2. Refer to horn relay for the proper diagnosis
and testing procedures. Replace the horn relay or
repair the open horn relay circuit, if required.
3. Faulty horn switch. 3. Refer to horn switch for the proper diagnosis
and testing procedure. Replace the horn switch or
repair the open horn switch circuit, if required.
4. Faulty horns. 4. Refer to horn for the proper diagnosis and
testing procedure. Replace the horns or repair the
open horn circuit, if required.
ONE HORN INOPERATIVE 1. Faulty horn. 1. Refer to horn for the proper diagnosis and
testing procedures. Replace the horn or repair the
open horn circuit, if required.
HORN SOUNDS
CONTINUOUSLY
1. Faulty horn relay. 1. Refer to horn relay for the proper diagnosis
and testing procedure. Replace the horn relay or
repair the shorted horn relay control circuit, if
required.
2. Faulty horn switch. 2. Refer to horn switch for the proper diagnosis
and testing procedure. Replace the horn switch or
repair the shorted horn switch circuit, if required.
HORN
DIAGNOSIS AND TESTING - HORN
INJURY.
(1) Di sconnect the wi re harness connector from the
horn. Measure the resi stance between the horn
ground ci rcui t cavi ty of the wi re harness connector
and a good ground. There shoul d be no measurabl e
resi stance. I f OK, go to Step 2. I f not OK, repl ace
wi ri ng as necessary.
(2) Check for battery vol tage at the horn rel ay out-
put ci rcui t cavi ty of the wi re harness connector for
the horn. There shoul d be zero vol ts. I f OK, go to
Step 3. I f not OK, refer to horn rel ay and horn rel ay
ci rcui t for the proper di agnosi s and testi ng proce-
dures.
(3) Depress the horn swi tch. There shoul d now be
battery vol tage at the horn rel ay output ci rcui t cavi ty
of the wi re harness connector for the horn. I f OK, but
the horn does not sound, repl ace the faul ty horn. I f
not OK, refer to horn rel ay and horn rel ay ci rcui t for
the proper di agnosi s and testi ng procedures.
8H - 2 HORN KJ
HORN SYSTEM (Continued)
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve cabl e.
(2) Di sconnect the el ectri cal harness connector
from the horns.
(3) Remove the mounti ng bol t (Fi g. 2).
(4) Remove the horns.
INSTALLATION
(1) I nstal l the horns.
(2) I nstal l the mounti ng bol t. Ti ghten bol t to 25
Nm (19 l b. ft.).
(3) Connect the el ectri cal harness connector to the
horns
HORN RELAY
DIAGNOSIS AND TESTING - HORN RELAY
(1) Remove horn rel ay (Refer to 8 - ELECTRI CAL/
HORN/HORN RELAY - REMOVAL).
(2) Usi ng ohmmeter, test between rel ay connector
termi nal s 85 to 86 for 75 8 ohms resi stance. I f
resi stance not OK, repl ace rel ay (Fi g. 3).
(3) Test for conti nui ty between ground and termi -
nal 85 of horn rel ay.
(a) When the horn swi tch i s not depressed, no
conti nui ty shoul d be present.
(b) Conti nui ty to ground when horn swi tch i s
depressed.
(c) I f conti nui ty i s not correct repl ace horn
swi tch or wi ri ng as necessary, refer to the appro-
i ncl udes wi ri ng di agrams, proper wi re and connec-
tor repai r procedures, detai l s of wi re harness rout-
i ng and retenti on, connector pi n-out i nformati on
and l ocati on vi ews for the vari ous wi re harness
connectors, spl i ces and grounds.
(4) Usi ng vol tmeter, test vol tage at:
(a) Termi nal s 30 and 86 of the horn rel ay to
body ground.
(b) I f NO vol tage check fuse 3 of the Juncti on
Bl ock (JB).
(c) I f i ncorrect vol tage, repai r as necessary. Refer
to the appropri ate wi ri ng i nformati on. The wi ri ng
i nformati on i ncl udes wi ri ng di agrams, proper wi re
and connector repai r procedures, detai l s of wi re
(5) I nsert a jumper wi re between termi nal 30 and
87 of the Juncti on Bl ock (JB).
(a) I f horn sounds repl ace rel ay.
(b) I f the horn does not sound, i nstal l horn rel ay
and test horn (Refer to 8 - ELECTRI CAL/HORN/
HORN - DI AGNOSI S AND TESTI NG).
REMOVAL
cabl e.
(2) Remove the i nstrument panel end cap.
(3) Locate and pul l the horn rel ay from the Junc-
ti on Bl ock (JB).
INSTALLATION
(1) Locate proper connector, and press rel ay i nto
posi ti on.
(2) I nstal l i nstrument panel end cap.
Fig. 2 HORN MOUNTING
1 - POWER DISTRIBUTION CENTER
2 - LOW NOTE HORN
3 - HIGH NOTE HORN
Fig. 3 Horn Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
KJ HORN 8H - 3
HORN (Continued)
HORN SWITCH
DESCRIPTION
The horn swi tch i s mol ded i nto the dri ver ai rbag
assembl y. The horn swi tch can not be servi ced sepa-
ratel y. For servi ce procedures, (Refer to 8 - ELEC-
TRI CAL/RESTRAI NTS/DRI VER AI RBAG -
REMOVAL).
DIAGNOSIS AND TESTING - HORN SWITCH
For compl ete ci rcui t di agrams, refer to the appro-
INJURY.
cabl e.
(2) Remove the steeri ng col umn openi ng cover.
(3) Check for conti nui ty between the metal steer-
i ng col umn jacket and a good ground. There shoul d
be conti nui ty. I f OK, go to Step 4. I f not OK,(Refer to
19 - STEERI NG/COLUMN - I NSTALLATI ON) for
proper i nstal l ati on of the steeri ng col umn.
(4) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/DRI VER AI RBAG - REMOVAL). Di scon-
nect the horn swi tch wi re harness connectors from
the dri ver si de ai rbag modul e (Fi g. 4).
(5) Remove the horn rel ay from the Juncti on Bl ock
(JB). Check for conti nui ty between the steeri ng col -
umn hal f of the horn swi tch feed wi re harness con-
nector and a good ground. There shoul d be no
shorted horn rel ay control ci rcui t to the horn rel ay i n
the Juncti on Bl ock as requi red.
(6) Check for conti nui ty between the steeri ng col -
umn hal f of the horn swi tch feed wi re harness con-
nector and the horn rel ay control ci rcui t cavi ty for
the horn rel ay i n the Juncti on Bl ock. There shoul d be
open horn rel ay control ci rcui t to the horn rel ay i n
the Juncti on Bl ock as requi red.
(7) Check for conti nui ty between the horn swi tch
feed wi re and the horn swi tch ground wi re on the
dri ver si de ai rbag modul e. There shoul d be no conti -
nui ty. I f OK, go to Step 8. I f not OK, repl ace the
faul ty horn swi tch.
(8) Depress the center of the dri ver si de ai rbag
modul e tri m cover and check for conti nui ty between
the horn swi tch feed wi re and the horn swi tch
ground wi re on the dri ver si de ai rbag modul e. There
shoul d now be conti nui ty. I f not OK, repl ace the
faul ty horn swi tch (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/DRI VER AI RBAG - REMOVAL).
Fig. 4 Driver Airbag Housing
1 - HOUSING
2 - HORN SWITCH GROUND WIRE
3 - HORN SWITCH FEED WIRE
4 - INFLATOR
5 - TRIM COVER
8H - 4 HORN KJ
IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
SPECIFICATIONS - IGNITION TIMING . . . . . . . 2
ENGINE FIRING ORDER - 2.4L 4-CYLINDER . 2
ENGINE FIRING ORDER - 3.7L V-6 . . . . . . . . . 2
IGNITION COIL RESISTANCE - 2.4L . . . . . . . . 2
IGNITION COIL RESISTANCE - 3.7L V-6 . . . . . 3
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 3
SPARK PLUG CABLE RESISTANCE - 2.4L . . . 3
TORQUE - IGNITION SYSTEM . . . . . . . . . . . . 3
AUTO SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT . . . . . . . . . . . . . 4
OPERATION
OPERATION - ASD SENSE - PCM INPUT . . . . 4
OPERATION - PCM OUTPUT . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - ASD AND FUEL
PUMP RELAYS . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CAMSHAFT POSITION SENSOR
DESCRIPTION
DESCRIPTION - 2.4L . . . . . . . . . . . . . . . . . . . . 5
DESCRIPTION-3.7L . . . . . . . . . . . . . . . . . . . . . 6
OPERATION
OPERATION - 2.4L . . . . . . . . . . . . . . . . . . . . . 6
OPERATION - 3.7L . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
IGNITION COIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
KNOCK SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPARK PLUG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CLEANING SPARK PLUGS . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
IGNITION COIL CAPACITOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
IGNITION CONTROL
DESCRIPTION
The i gni ti on system consi sts of:
Spark Pl ugs
I gni ti on Coi l (s)
Powertrai n Control Modul e (PCM)
2 Knock Sensors (3.7L onl y)
Camshaft Posi ti on Sensor
The MAP, TPS, I AC and ECT al so have an effect
on the control of the i gni ti on system.
OPERATION
2. 4L
A common i gni ti on coi l di vi ded i nto 2 hal ves i s
used. Secondary, hi gh-tensi on spark pl ug cabl es are
al so used. One hal f of the coi l fi res two spark pl ugs
si mul taneousl y (one pl ug i s the cyl i nder under com-
pressi on, and the other pl ug i s the cyl i nder on the
exhaust stroke). Coi l hal f number one fi res cyl i nders
1 and 4. Coi l hal f number two fi res cyl i nders 2 and 3.
The PCM determi nes whi ch of the coi l s to charge and
fi re at the correct ti me.
The Auto Shutdown (ASD) rel ay provi des battery
vol tage to the i gni ti on coi l . The PCM provi des a
ground contact (ci rcui t) for energi zi ng the coi l . When
the PCM breaks the contact, the energy i n the coi l
pri mary transfers to the secondary causi ng a spark.
The PCM wi l l de-energi ze the ASD rel ay i f i t does
not recei ve i nputs from ei ther the crankshaft or cam-
shaft posi ti on sensors.
A di stri butor i s not used wi th the 2.4L engi ne.
3. 7L
The 3.7L V6 engi ne uses a separate i gni ti on coi l for
each cyl i nder. The one-pi ece coi l bol ts di rectl y to the
cyl i nder head. Rubber boots seal the secondary ter-
mi nal ends of the coi l s to the top of al l 6 spark pl ugs.
A separate el ectri cal connector i s used for each coi l .
KJ IGNITION CONTROL 8I - 1
Because of coi l desi gn, spark pl ug cabl es (second-
ary cabl es) are not used. A di stri butor i s not used
wi th the 3.7L engi ne.
Two knock sensors (one for each cyl i nder bank) are
used to hel p control spark knock.
vol tage to each i gni ti on coi l . The Powertrai n Control
Modul e (PCM) provi des a ground contact (ci rcui t) for
energi zi ng each coi l . When the PCM breaks the con-
tact, the energy i n the coi l pri mary transfers to the
secondary causi ng a spark. The PCM wi l l de-energi ze
the ASD rel ay i f i t does not recei ve i nputs from
ei ther the crankshaft or camshaft posi ti on sensors.
SPECIFICATIONS
SPECIFICATIONS - IGNITION TIMING
Ignition timing is not adjustable on any
engine.
ENGINE FIRING ORDER - 2. 4L 4-CYLINDER 1 - 3 - 4 - 2
ENGINE FIRING ORDER - 3. 7L V-6 1 - 6 - 5 - 4 - 3 - 2
IGNITION COIL RESISTANCE - 2. 4L
Engine Coil Manufacture
Primary Resistance at
21C-27C (70F-80F)
Secondary Resistance at
21C-27C (70F-80F)
2.4L Toyodenso or Diamond 0.51 to 0.61 Ohms 11,500 to 13,500 Ohms
Fig. 1 IGNITION COIL - 2.4L
8I - 2 IGNITION CONTROL KJ
IGNITION CONTROL (Continued)
IGNITION COIL RESISTANCE - 3. 7L V-6
PRIMARY RESISTANCE
21-27C (70-80F)
SECONDARY
RESISTANCE 21-27C
(70-80F)
0.6 - 0.9 Ohms 6,000 - 9,000 Ohms
SPARK PLUGS
ENGINE PLUG TYPE ELECTRODE GAP
2.4L RE14MCC5 (Champion #) 1.24 to 1.37 mm (0.048 to 0.053 in.)
3.7L V-6 2FR6F - 11G (NGK #) 1.1 mm (0.042 in.)
SPARK PLUG CABLE RESISTANCE - 2. 4L
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
TORQUE - IGNITION SYSTEM
Camshaft Position Sensor-2.4L 23 21 205
Camshaft Position Sensor3.7L 12 - 106
Crankshaft Position Sensor Bolt-2.4L 12 - 106
Crankshaft Position Sensor Nut/Bolt-3.7L 23 21 205
* Knock Sensor Bolt - 3.7L * 20 * 15
Ignition Coil Mounting Bolts - 2.4L 11 - 105
Ignition Coil Mounting Nuts - 3.7L 8 - 70
Ignition Coil Capacitor Nuts- 3.7L 8 - 70
** Spark Plugs - 2.4L ** 15 ** 11 -
Spark Plugs - 3.7L 27 20 -
* Do not apply any sealant, thread-locker or adhesive to
bolts. Poor sensor performance may result.
** Torque critical tapered design. Do not exceed 15 ft. lbs.
IGNITION CONTROL (Continued)
AUTO SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT
The 5pi n, 12vol t, Automati c Shutdown (ASD)
rel ay i s l ocated i n the Power Di stri buti on Center
(PDC). Refer to l abel on PDC cover for rel ay l ocati on.
OPERATION
OPERATION - ASD SENSE - PCM INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the ASD has been acti vated. The rel ay i s used to
connect the oxygen sensor heater el ements, oxygen
sensor heater rel ay, i gni ti on coi l and fuel i njectors to
12 vol t + power suppl y.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the Powertrai n Control Modul e
(PCM) does not see 12 vol ts at thi s i nput when the
ASD shoul d be acti vated, i t wi l l set a Di agnosti c
Troubl e Code (DTC).
OPERATION - PCM OUTPUT
The ASD rel ay suppl i es battery vol tage (12+ vol ts)
to the fuel i njectors and i gni ti on coi l (s). Wi th certai n
emi ssi ons packages i t al so suppl i es 12vol ts to the
oxygen sensor heati ng el ements and the oxygen sen-
sor heater rel ay.
The ground ci rcui t for the coi l wi thi n the ASD
rel ay i s control l ed by the Powertrai n Control Modul e
(PCM). The PCM operates the ASD rel ay by swi tch-
i ng i ts ground ci rcui t on and off.
The ASD rel ay wi l l be shutdown, meani ng the
12vol t power suppl y to the ASD rel ay wi l l be de-ac-
ti vated by the PCM i f the i gni ti on key i s l eft i n the
ON posi ti on. Thi s i s i f the engi ne has not been run-
ni ng for approxi matel y 1.8 seconds.
DIAGNOSIS AND TESTING - ASD AND FUEL
PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The termi nal s on the
bottom of each rel ay are numbered. Two di fferent
types of rel ays may be used, (Fi g. 2) or (Fi g. 3).
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and fuel pump rel ays, termi -
nal 30 i s connected to battery vol tage at al l ti mes.
The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the ASD and fuel
pump rel ays, termi nal number 87A connects to termi -
nal 30. Thi s i s the Off posi ti on. I n the off posi ti on,
vol tage i s not suppl i ed to the rest of the ci rcui t. Ter-
mi nal 87A i s the center termi nal on the rel ay.
When the PCM energi zes the ASD and fuel
pump rel ays, termi nal 87 connects to termi nal 30.
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
The fol l owi ng procedure appl i es to the ASD and
fuel pump rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be 75 ohms +/-
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
Fig. 2 TYPE 1 RELAY (ISO MICRO RELAY)
Fig. 3 ASD AND FUEL PUMP RELAY TERMINALS
TYPE 2
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
(4) Connect the ohmmeter between termi nal s 87
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
DAMAGE TO OHMMETER MAY RESULT.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and fuel pump rel ay ci rcui ts. Refer to 8, Wi ri ng Di a-
grams.
REMOVAL
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 4). Refer to l abel on PDC cover
for rel ay l ocati on.
INSTALLATION
The ASD rel ay i s l ocated i n the Power Di stri buti on
l ocati on.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
DESCRIPTION - 2. 4L
The Camshaft Posi ti on Sensor (CMP) on the 2.4L
4cyl i nder engi ne i s bol ted to the ri ght-front si de of
the cyl i nder head (Fi g. 5).
1 - BATTERY
2 - PDC
3 - PDC COVER
Fig. 5 CMP LOCATION - 2.4L
1 - CMP SENSOR
3 -
4 - SLOTTED HOLES
AUTO SHUT DOWN RELAY (Continued)
DESCRIPTION-3. 7L
the ri ght cyl i nder head (Fi g. 6).
OPERATION
OPERATION - 2. 4L
The Camshaft Posi ti on Sensor (CMP) sensor con-
tai ns a hal l effect devi ce referred to as a sync si gnal
generator. A rotati ng target wheel (tonewheel ) for the
CMP i s l ocated behi nd the exhaust val ve-camshaft
dri ve gear (Fi g. 7). The target wheel i s equi pped wi th
a cutout (notch) around 180 degrees of the wheel .
The CMP detects thi s cutout every 180 degrees of
camshaft gear rotati on. I ts si gnal i s used i n conjunc-
ti on wi th the Crankshaft Posi ti on Sensor (CKP) to
di fferenti ate between fuel i njecti on and spark events.
I t i s al so used to synchroni ze the fuel i njectors wi th
thei r respecti ve cyl i nders.
When the l eadi ng edge of the target wheel cutout
enters the ti p of the CMP, the i nterrupti on of mag-
neti c fi el d causes the vol tage to swi tch hi gh, resul t-
i ng i n a sync si gnal of approxi matel y 5 vol ts.
When the trai l i ng edge of the target wheel cutout
l eaves the ti p of the CMP, the change of the magneti c
fi el d causes the sync si gnal vol tage to swi tch l ow to 0
vol ts.
OPERATION - 3. 7L
The Camshaft Posi ti on Sensor (CMP) sensor con-
tai ns a hal l effect devi ce referred to as a sync si gnal
generator. A rotati ng target wheel (tonewheel ) for the
CMP i s l ocated at the front of the camshaft for the
ri ght cyl i nder head (Fi g. 8). Thi s sync si gnal genera-
tor detects notches l ocated on a tonewheel . As the
tonewheel rotates, the notches pass through the sync
si gnal generator. The si gnal from the CMP sensor i s
used i n conjuncti on wi th the Crankshaft Posi ti on
Sensor (CKP) to di fferenti ate between fuel i njecti on
and spark events. I t i s al so used to synchroni ze the
fuel i njectors wi th thei r respecti ve cyl i nders.
When the l eadi ng edge of the tonewheel notch
enters the ti p of the CMP, the i nterrupti on of mag-
neti c fi el d causes the vol tage to swi tch hi gh, resul t-
i ng i n a sync si gnal of approxi matel y 5 vol ts.
When the trai l i ng edge of the tonewheel notch
l eaves then ti p of the CMP, the change of the mag-
neti c fi el d causes the sync si gnal vol tage to swi tch
l ow to 0 vol ts.
Fig. 6 CAMSHAFT POSITION SENSOR - 3.7L
1 - RIGHT/FRONT OF RIGHT CYLINDER HEAD
2 - CMP MOUNTING BOLT
3 - CMP LOCATION
Fig. 7 CMP FACE AT TARGET WHEEL-2.4L
1 - CAMSHAFT DRIVE GEAR
2 - TARGETWHEEL (TONEWHEEL)
3 - FACE OF CMP SENSOR
4 - CUTOUT (NOTCH)
CAMSHAFT POSITION SENSOR (Continued)
REMOVAL
2. 4L
the cyl i nder head (Fi g. 9). Sensor posi ti on (depth) i s
adjustabl e.
(1) Di sconnect el ectri cal connector at CMP sensor.
(2) Remove 2 sensor mounti ng bol ts.
(3) Remove sensor from cyl i nder head by sl i di ng
towards rear of engi ne.
3. 7L
V-6 engi ne i s bol ted to the front/top of the ri ght cyl -
i nder head (Fi g. 10).
(1) Di sconnect el ectri cal connector at CMP sensor.
(2) Remove sensor mounti ng bol t (Fi g. 10).
(3) Careful l y remove sensor from cyl i nder head i n
a rocki ng and twi sti ng acti on. Twi sti ng sensor eases
removal .
(4) Check condi ti on of sensor o-ri ng.
Fig. 8 CAMSHAFT POSITION SENSOR LOCATION -
3.7L
1 - NOTCHES
2 - RIGHT CYLINDER HEAD
3 - CMP
4 - TONEWHEEL (TARGET WHEEL)
Fig. 9 CMP LOCATION - 2.4L
1 - CMP SENSOR
3 -
4 - SLOTTED HOLES
Fig. 10 CAMSHAFT POSITION SENSOR (CMP) - 3.7L
1 - RIGHT/FRONT OF RIGHT CYLINDER HEAD
2 - CMP MOUNTING BOLT
3 - CMP LOCATION
INSTALLATION
2. 4L
the cyl i nder head. Sensor position (depth) is
adjustable.
(1) Remove pl asti c, upper ti mi ng bel t cover (ti mi ng
gear cover) (Fi g. 11) by removi ng 3 bol ts. Before
attempti ng to remove cover, remove el ectri cal connec-
tor from Engi ne Cool ant Temperature (ECT) sensor
(Fi g. 11). Thi s wi l l prevent damage to sensor.
(2) Rotate (bump over) engi ne unti l camshaft ti m-
i ng gear and target wheel (tonewheel ) are posi ti oned
and al i gned to face of sensor as shown i n (Fi g. 12). If
not positioned as shown in (Fig. 12), damage to
both sensor and target wheel will occur when
attempting to start engine. Face of sensor
MUST be behind target wheel while adjusting.
(3) Posi ti on sensor to cyl i nder head and i nstal l 2
sensor mounti ng bol ts fi nger ti ght.
(4) SENSOR AIR GAP: .030Set ai r gap between
rear of target wheel and face of sensor to .030. Thi s
can best be accompl i shed usi ng an L-shaped, wi re-
type spark pl ug gappi ng gauge (Fi g. 13). A pi ece of
.030 brass shi m stock may al so be used.
(5) Gentl y push sensor forward unti l i t contacts
gappi ng gauge. Do not push hard on sensor.
Ti ghten 2 sensor mounti ng bol ts. Refer to torque
speci fi cati ons.
CAUTION: After tightening sensor mounting bolts,
recheck air gap and adjust as necessary. Retorque
bolts.
(6) I nstal l upper ti mi ng bel t cover and 3 bol ts.
(7) Connect el ectri cal connector to ECT sensor.
(8) Connect el ectri cal connector to CMP sensor.
Fig. 11 UPPER TIMING BELT COVER/BOLTS-2.4L
1 - UPPER TIMING BELT COVER
2 - ELECTRICAL CONNECTOR (ECT)
Fig. 12 CMP FACE AT TARGET WHEEL-2.4L
2 - TARGETWHEEL (TONEWHEEL)
3 - FACE OF CMP SENSOR
4 - CUTOUT (NOTCH)
Fig. 13 CMP ADJUSTMENT - 2.4L
1 - FACE OF SENSOR
2 - WIRE GAPPING TOOL
3. 7L
V-6 engi ne i s bol ted to the front/top of the ri ght cyl -
i nder head.
(1) Cl ean out machi ned hol e i n cyl i nder head.
(2) Appl y a smal l amount of engi ne oi l to sensor
o-ri ng.
(3) I nstal l sensor i nto cyl i nder head wi th a sl i ght
rocki ng and twi sti ng acti on.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder head.
If sensor is not flush, damage to sensor mounting
tang may result.
(4) I nstal l mounti ng bol t and ti ghten. Refer to
(5) Connect el ectri cal connector to sensor.
IGNITION COIL
DESCRIPTION
2. 4L
The coi l assembl y consi sts of 2 di fferent coi l s
mol ded together. The assembl y i s mounted to the top
of the engi ne (Fi g. 14).
3. 7L
The 3.7L V-6 engi ne uses 6 dedi cated, and i ndi vi d-
ual l y fi red coi l for each spark pl ug (Fi g. 15). Each
coi l i s mounted di rectl y i nto the cyl i nder head and
onto the top of each spark pl ug (Fi g. 16).
OPERATION
2. 4L
The coi l fi res two spark pl ugs si mul taneousl y. One
pl ug i s under compressi on, the other pl ug fi res on the
exhaust stroke (l ost spark). Coi l number one fi res
1 - IGNITION COIL
1 - O-RING
2 - IGNITION COIL
Fig. 16 IGNITION COIL LOCATION - 3.7L
1 - IGNITION COIL
2 - COIL MOUNTING NUT
cyl i nders 1 and 4, and coi l number two fi res cyl i nders
2 and 3.
vol tage to the i gni ti on coi l . The PCM provi des a
ground contact (ci rcui t) for energi zi ng the coi l (s). The
PCM wi l l de-energi ze the ASD rel ay i f i t does not
recei ve the crankshaft posi ti on sensor and camshaft
posi ti on sensor i nputs.
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
ati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
Spark pl ug cabl es (secondary wi res or cabl es) are
used wi th the 2.4L engi ne.
3. 7L
Battery vol tage i s suppl i ed to the 6 i gni ti on coi l s
from the ASD rel ay. The Powertrai n Control Modul e
(PCM) opens and cl oses each i gni ti on coi l ground ci r-
cui t at a determi ned ti me for i gni ti on coi l operati on.
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
ati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
Because of coi l desi gn, spark pl ug cabl es (second-
ary cabl es) are not used wi th the 3.7L engi ne.
REMOVAL
2. 4L
(1) Di sconnect el ectri cal connector at rear of coi l .
(2) Remove al l secondary cabl es from coi l .
(3) Remove 4 coi l mounti ng bol ts (Fi g. 17).
(4) Remove coi l from vehi cl e.
3. 7L
An i ndi vi dual i gni ti on coi l i s used for each spark
pl ug (Fi g. 19). The coi l fi ts i nto machi ned hol es i n the
cyl i nder head. A mounti ng stud/nut secures each coi l
to the top of the i ntake mani fol d (Fi g. 18). The bot-
tom of the coi l i s equi pped wi th a rubber boot to seal
the spark pl ug to the coi l . I nsi de each rubber boot i s
a spri ng. The spri ng i s used for a mechani cal contact
between the coi l and the top of the spark pl ug. These
rubber boots and spri ngs are a permanent part of the
coi l and are not servi ced separatel y. An o-ri ng (Fi g.
19) i s used to seal the coi l at the openi ng i nto the cyl -
i nder head.
(1) Dependi ng on whi ch coi l i s bei ng removed, the
throttl e body ai r i ntake tube or i ntake box may need
to be removed to gai n access to coi l .
(2) Di sconnect el ectri cal connector from coi l by
pushi ng downward on rel ease l ock on top of connec-
tor and pul l connector from coi l .
(3) Cl ean area at base of coi l wi th compressed ai r
before removal .
(4) Remove coi l mounti ng nut from mounti ng stud
(Fi g. 18).
(5) Careful l y pul l up coi l from cyl i nder head open-
i ng wi th a sl i ght twi sti ng acti on.
(6) Remove coi l from vehi cl e.
INSTALLATION
2. 4L
(1) Posi ti on coi l to engi ne.
(2) I nstal l 4 mounti ng bol ts. Refer to torque speci -
fi cati ons.
(3) I nstal l secondary cabl es.
(4) I nstal l el ectri cal connector at rear of coi l .
(5) I nstal l ai r cl eaner tube and housi ng.
3. 7L
(1) Usi ng compressed ai r, bl ow out any di rt or con-
tami nants from around top of spark pl ug.
(2) Check condi ti on of coi l o-ri ng and repl ace as
necessary. To ai d i n coi l i nstal l ati on, appl y si l i cone to
coi l o-ri ng.
1 - IGNITION COIL
IGNITION COIL (Continued)
(3) Posi ti on i gni ti on coi l i nto cyl i nder head openi ng
and push onto spark pl ug. Do thi s whi l e gui di ng coi l
base over mounti ng stud.
(4) I nstal l coi l mounti ng stud nut. Refer to torque
speci fi cati ons.
(5) Connect el ectri cal connector to coi l by snappi ng
i nto posi ti on.
(6) I f necessary, i nstal l throttl e body ai r tube or
box.
KNOCK SENSOR
DESCRIPTION
The 2 knock sensors are bol ted i nto the cyl i nder
bl ock under the i ntake mani fol d. The sensors are
used onl y wi th the 3.7L engi ne.
OPERATION
Two knock sensors are used on the 3.7L V-6
engi ne; one for each cyl i nder bank. When the knock
sensor detects a knock i n one of the cyl i nders on the
correspondi ng bank, i t sends an i nput si gnal to the
Powertrai n Control Modul e (PCM). I n response, the
PCM retards i gni ti on ti mi ng for al l cyl i nders by a
schedul ed amount.
Knock sensors contai n a pi ezoel ectri c materi al
whi ch constantl y vi brates and sends an i nput vol tage
(si gnal ) to the PCM whi l e the engi ne operates. As the
i ntensi ty of the crystal s vi brati on i ncreases, the
knock sensor output vol tage al so i ncreases.
The vol tage si gnal produced by the knock sensor
i ncreases wi th the ampl i tude of vi brati on. The PCM
recei ves the knock sensor vol tage si gnal as an i nput.
I f the si gnal ri ses above a predetermi ned l evel , the
PCM wi l l store that val ue i n memory and retard
i gni ti on ti mi ng to reduce engi ne knock. I f the knock
sensor vol tage exceeds a preset val ue, the PCM
retards i gni ti on ti mi ng for al l cyl i nders. I t i s not a
sel ecti ve cyl i nder retard.
The PCM i gnores knock sensor i nput duri ng engi ne
i dl e condi ti ons. Once the engi ne speed exceeds a
speci fi ed val ue, knock retard i s al l owed.
Knock retard uses i ts own short term and l ong
term memory program.
Long term memory stores previ ous detonati on
i nformati on i n i ts battery-backed RAM. The maxi -
mum authori ty that l ong term memory has over ti m-
i ng retard can be cal i brated.
Short term memory i s al l owed to retard ti mi ng up
to a preset amount under al l operati ng condi ti ons (as
l ong as rpm i s above the mi ni mum rpm) except at
Wi de Open Throttl e (WOT). The PCM, usi ng short
term memory, can respond qui ckl y to retard ti mi ng
when engi ne knock i s detected. Short term memory
i s l ost any ti me the i gni ti on key i s turned off.
Fig. 18 IGNITION COIL LOCATION - 3.7L
1 - IGNITION COIL
2 - COIL MOUNTING NUT
1 - O-RING
2 - IGNITION COIL
IGNITION COIL (Continued)
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors.
REMOVAL
The 2 knock sensors are bol ted i nto the cyl i nder
bl ock under the i ntake mani fol d (Fi g. 20).
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
(1) Di sconnect knock sensor dual pi gtai l harness
from engi ne wi ri ng harness. thi s connecti on i s made
near rear of l eft val ve cover (Fi g. 20).
(2) Remove i ntake mani fol d. Refer to Engi ne sec-
ti on.
(3) Remove sensor mounti ng bol ts (Fi g. 20). Note
foam stri p on bol t threads. Thi s foam i s used onl y to
retai n the bol ts to sensors for pl ant assembl y. I t i s
not used as a seal ant. Do not appl y any adhesi ve,
seal ant or thread l ocki ng compound to these bol ts.
(4) Remove sensors from engi ne.
INSTALLATION
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
(1) Thoroughl y cl ean knock sensor mounti ng hol es.
(2) I nstal l sensors i nto cyl i nder bl ock.
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
(3) I nstal l and ti ghten mounti ng bol ts. Refer to
(4) I nstal l i ntake mani fol d. Refer to Engi ne sec-
ti on.
(5) Connect knock sensor wi ri ng harness to engi ne
harness at rear of i ntake mani fol d.
SPARK PLUG
DESCRIPTION
Resi stor type spark pl ugs are used.
Spark pl ug resi stance val ues range from 6,000 to
20,000 ohms (when checked wi th at l east a 1000 vol t
spark pl ug tester). Do not use an ohmmeter to
check the resistance values of the spark plugs.
Inaccurate readings will result.
OPERATION
To prevent possi bl e pre-i gni ti on and/or mechani cal
engi ne damage, the correct type/heat range/number
spark pl ug must be used.
Al ways use the recommended torque when ti ghten-
i ng spark pl ugs. Thi s i s especi al l y true when pl ugs
are equi pped wi th tapered seats. I ncorrect torque can
di stort the spark pl ug and change pl ug gap. I t can
al so pul l the pl ug threads and do possi bl e damage to
both the spark pl ug and the cyl i nder head.
Remove the spark pl ugs and exami ne them for
burned el ectrodes and foul ed, cracked or broken por-
cel ai n i nsul ators. Keep pl ugs arranged i n the order
i n whi ch they were removed from the engi ne. A si n-
Fig. 20 KNOCK SENSOR LOCATION
1 - KNOCK SENSORS (2)
2 - MOUNTING BOLTS
KNOCK SENSOR (Continued)
gl e pl ug di spl ayi ng an abnormal condi ti on i ndi cates
that a probl em exi sts i n the correspondi ng cyl i nder.
Repl ace spark pl ugs at the i nterval s recommended i n
the Lubri cati on and Mai ntenance secti on.
Spark pl ugs that have l ow mi l eage may be cl eaned
and reused i f not otherwi se defecti ve, carbon or oi l
foul ed. Al so refer to Spark Pl ug Condi ti ons.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
NORMAL OPERATING
The few deposi ts present on the spark pl ug wi l l
probabl y be l i ght tan or sl i ghtl y gray i n col or. Thi s i s
evi dent wi th most grades of commerci al gasol i ne
(Fi g. 21). There wi l l not be evi dence of el ectrode
burni ng. Gap growth wi l l not average more than
approxi matel y 0.025 mm (.001 i n) per 3200 km (2000
mi l es) of operati on. Spark pl ugs that have normal
wear can usual l y be cl eaned, have the el ectrodes
fi l ed, have the gap set and then be i nstal l ed.
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
causes the enti re ti p of the spark pl ug to be coated
wi th a rust col ored deposi t. Thi s rust col or can be
mi sdi agnosed as bei ng caused by cool ant i n the com-
busti on chamber. Spark pl ug performance may be
affected by MMT deposi ts.
COLD FOULING/CARBON FOULING
Col d foul i ng i s someti mes referred to as carbon
foul i ng. The deposi ts that cause col d foul i ng are basi -
cal l y carbon (Fi g. 21). A dry, bl ack deposi t on one or
two pl ugs i n a set may be caused by sti cki ng val ves
or defecti ve spark pl ug cabl es. Col d (carbon) foul i ng
of the enti re set of spark pl ugs may be caused by a
cl ogged ai r cl eaner el ement or repeated short operat-
i ng ti mes (short tri ps).
WET FOULING OR GAS FOULING
A spark pl ug coated wi th excessi ve wet fuel or oi l
i s wet foul ed. I n ol der engi nes, worn pi ston ri ngs,
l eaki ng val ve gui de seal s or excessi ve cyl i nder wear
can cause wet foul i ng. I n new or recentl y overhaul ed
engi nes, wet foul i ng may occur before break-i n (nor-
mal oi l control ) i s achi eved. Thi s condi ti on can usu-
al l y be resol ved by cl eani ng and rei nstal l i ng the
foul ed pl ugs.
OIL OR ASH ENCRUSTED
I f one or more spark pl ugs are oi l or oi l ash
encrusted (Fi g. 22), eval uate engi ne condi ti on for the
cause of oi l entry i nto that parti cul ar combusti on
chamber.
ELECTRODE GAP BRIDGING
El ectrode gap bri dgi ng may be traced to l oose
deposi ts i n the combusti on chamber. These deposi ts
accumul ate on the spark pl ugs duri ng conti nuous
stop-and-go dri vi ng. When the engi ne i s suddenl y
Fig. 21 Normal Operation and Cold (Carbon) Fouling
1 - NORMAL
2 - DRY BLACK DEPOSITS
3 - COLD (CARBON) FOULING
Fig. 22 Oil or Ash Encrusted
SPARK PLUG (Continued)
subjected to a hi gh torque l oad, deposi ts parti al l y l i q-
uefy and bri dge the gap between el ectrodes (Fi g. 23).
Thi s short ci rcui ts the el ectrodes. Spark pl ugs wi th
el ectrode gap bri dgi ng can be cl eaned usi ng standard
procedures.
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or yel -
l ow (Fi g. 24). They may appear to be harmful , but
thi s i s a normal condi ti on caused by chemi cal addi -
ti ves i n certai n fuel s. These addi ti ves are desi gned to
change the chemi cal nature of deposi ts and decrease
spark pl ug mi sfi re tendenci es. Noti ce that accumul a-
ti on on the ground el ectrode and shel l area may be
heavy, but the deposi ts are easi l y removed. Spark
pl ugs wi th scavenger deposi ts can be consi dered nor-
mal i n condi ti on and can be cl eaned usi ng standard
procedures.
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the
spark pl ug el ectrode gap. Under certai n condi ti ons,
severe detonati on can al so separate the i nsul ator
from the center el ectrode (Fi g. 25). Spark pl ugs wi th
thi s condi ti on must be repl aced.
PREIGNITION DAMAGE
Prei gni ti on damage i s usual l y caused by excessi ve
combusti on chamber temperature. The center el ec-
trode di ssol ves fi rst and the ground el ectrode di s-
sol ves somewhat l atter (Fi g. 26). I nsul ators appear
rel ati vel y deposi t free. Determi ne i f the spark pl ug
has the correct heat range rati ng for the engi ne.
Determi ne i f i gni ti on ti mi ng i s over advanced or i f
other operati ng condi ti ons are causi ng engi ne over-
heati ng. (The heat range rati ng refers to the operat-
i ng temperature of a parti cul ar type spark pl ug.
Spark pl ugs are desi gned to operate wi thi n speci fi c
temperature ranges. Thi s depends upon the thi ck-
ness and l ength of the center el ectrodes porcel ai n
i nsul ator.)
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
27). The i ncrease i n el ectrode gap wi l l be consi der-
abl y i n excess of 0.001 i nch per 2000 mi l es of opera-
ti on. Thi s suggests that a pl ug wi th a cool er heat
range rati ng shoul d be used. Over advanced i gni ti on
ti mi ng, detonati on and cool i ng system mal functi ons
can al so cause spark pl ug overheati ng.
Fig. 23 Electrode Gap Bridging
1 - GROUND ELECTRODE
2 - DEPOSITS
3 - CENTER ELECTRODE
Fig. 24 Scavenger Deposits
1 - GROUND ELECTRODE COVERED WITH WHITE OR
YELLOW DEPOSITS
Fig. 25 Chipped Electrode Insulator
1 - GROUND ELECTRODE
3 - CHIPPED INSULATOR
REMOVAL
2. 4L
I f spark pl ug for #2 or #3 cyl i nder i s bei ng
removed, throttl e body must be removed. Refer to
Throttl e Body Removal .
(1) Remove ai r cl eaner tube and housi ng.
(2) Twi st secondary cabl e at cyl i nder head to break
l oose at spark pl ug. Remove cabl e from pl ug.
(3) Pri or to removi ng spark pl ug, spray com-
pressed ai r i nto cyl i nder head openi ng. Thi s wi l l hel p
prevent forei gn materi al from enteri ng combusti on
chamber.
(4) Remove spark pl ug from cyl i nder head usi ng a
qual i ty socket wi th a rubber or foam i nsert.
(5) I nspect spark pl ug condi ti on. Refer to Spark
Pl ug Condi ti ons.
3. 7L
Each i ndi vi dual spark pl ug i s l ocated under each
i gni ti on coi l . Each i ndi vi dual i gni ti on coi l must be
removed to gai n access to each spark pl ug. Refer to
I gni ti on Coi l Removal /I nstal l ati on.
(1) Pri or to removi ng i gni ti on coi l , spray com-
pressed ai r around coi l base at cyl i nder head.
(2) Pri or to removi ng spark pl ug, spray com-
pressed ai r i nto cyl i nder head openi ng. Thi s wi l l hel p
prevent forei gn materi al from enteri ng combusti on
chamber.
(3) Remove spark pl ug from cyl i nder head usi ng a
qual i ty socket wi th a rubber or foam i nsert. Al so
check condi ti on of i gni ti on coi l o-ri ng and repl ace as
necessary.
(4) I nspect spark pl ug condi ti on. Refer to Spark
Pl ug Condi ti ons.
CLEANING SPARK PLUGS
The pl ugs may be cl eaned usi ng commerci al l y
avai l abl e spark pl ug cl eani ng equi pment. After cl ean-
i ng, fi l e the center el ectrode fl at wi th a smal l poi nt
fi l e or jewel ers fi l e before adjusti ng gap.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
INSTALLATION
2. 4L
CAUTION: Spark plug tightening on the 2.4L is
torque critical. The plugs are equipped with tapered
seats. Do not exceed 15 ft. lbs. torque.
Speci al care shoul d be taken when i nstal l i ng spark
pl ugs i nto the cyl i nder head spark pl ug wel l s. Be
sure the pl ugs do not drop i nto the pl ug wel l s as el ec-
trodes can be damaged.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap or a cracked porcel ai n
i nsul ator.
(1) Start the spark pl ug i nto the cyl i nder head by
(2) Ti ghten spark pl ugs. Refer to torque speci fi ca-
ti ons.
(3) I nstal l throttl e body. Refer to Throttl e Body
I nstal l ati on.
(4) I nstal l ai r cl eaner tube and housi ng.
3. 7L
Speci al care shoul d be taken when i nstal l i ng spark
pl ugs i nto the cyl i nder head spark pl ug wel l s. Be
Fig. 26 Preignition Damage
1 - GROUND ELECTRODE STARTING TO DISSOLVE
2 - CENTER ELECTRODE DISSOLVED
Fig. 27 Spark Plug Overheating
1 - BLISTERED WHITE OR GRAY COLORED INSULATOR
sure the pl ugs do not drop i nto the pl ug wel l s as el ec-
trodes can be damaged.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap or a cracked porcel ai n
i nsul ator.
(1) Start the spark pl ug i nto the cyl i nder head by
(2) Ti ghten spark pl ugs. Refer to torque speci fi ca-
ti ons.
(3) Before i nstal l i ng coi l (s), check condi ti on of coi l
o-ri ng and repl ace as necessary. To ai d i n coi l i nstal -
l ati on, appl y si l i cone to coi l o-ri ng.
(4) I nstal l i gni ti on coi l (s). Refer to I gni ti on Coi l
Removal /I nstal l ati on.
IGNITION COIL CAPACITOR
DESCRIPTION
One coi l capaci tor i s used. I t i s l ocated i n the
engi ne compartment and attached (cl i pped) to a wi r-
i ng trough near the brake power booster.
OPERATION
The coi l capaci tor(s) hel p dampen the amount of
conducted el ectri cal noi se to the camshaft posi ti on
sensor, crankshaft posi ti on sensor, and throttl e posi -
ti on sensor. Thi s noi se i s generated on the 12V sup-
pl y wi re to the i gni ti on coi l s and fuel i njectors.
REMOVAL
The coi l capaci tor i s l ocated i n the engi ne compart-
ment and i s attached (cl i pped) to a wi ri ng harness
trough near the brake power booster (graphi c not
avai l abl e).
(1) Uncl i p capaci tor from wi ri ng harness trough.
(2) Di sconnect el ectri cal connector at capaci tor.
INSTALLATION
(1) Connect el ectri cal connector to coi l capaci tor.
(2) Posi ti on capaci tor i nto v-cl i p on wi ri ng harness
trough.
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
ABS INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AIRBAG INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BRAKE/PARK BRAKE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - BRAKE
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHARGING INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
COOLANT LOW INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CRUISE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DOOR AJAR INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE TEMPERATURE GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FRONT FOG LAMP INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
GATE AJAR INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
GLASS AJAR INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HIGH BEAM INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LOW FUEL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LOW OIL PRESSURE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MALFUNCTION INDICATOR LAMP (MIL)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ODOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OVERDRIVE OFF INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REAR FOG LAMP INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SEATBELT INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECURITY INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SHIFT INDICATOR (TRANSFER CASE)
DESCRIPTION
DESCRIPTION - PART TIME INDICATOR . . . . 29
DESCRIPTION - FULL TIME INDICATOR . . . . 29
DESCRIPTION - FOUR LOW MODE
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION
OPERATION - PART TIME INDICATOR . . . . . 29
OPERATION - FULL TIME INDICATOR . . . . . 30
OPERATION - FOUR LOW MODE
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SKIS INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SPEEDOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TACHOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TRANS TEMP INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
KJ INSTRUMENT CLUSTER 8J - 1
TURN SIGNAL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
WAIT-TO-START INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
WASHER FLUID INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING - WASHER FLUID
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 36
WATER-IN-FUEL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTRUMENT CLUSTER
DESCRIPTION
The i nstrument cl uster for thi s model i s an El ec-
troMechani cal I nstrument Cl uster (EMI C) modul e
that i s l ocated i n the i nstrument panel above the
steeri ng col umn openi ng, di rectl y i n front of the
dri ver (Fi g. 1). The remai nder of the EMI C, i ncl udi ng
the mounts and the el ectri cal connecti ons, are con-
ceal ed behi nd the cl uster bezel . The EMI C gauges
and i ndi cators are protected by an i ntegral cl ear
pl asti c cl uster l ens, and are vi si bl e through a dedi -
cated openi ng i n the cl uster bezel on the i nstrument
panel . Just behi nd the cl uster l ens i s the cl uster hood
and an i ntegral cl uster mask, whi ch are constructed
of mol ded bl ack pl asti c. Two cl uster masks are used;
a base bl ack versi on i s used on base model s, whi l e a
premi um bl ack versi on features a chrome tri m ri ng
around the peri meter of each gauge openi ng i s used
on premi um model s. The cl uster hood serves as a
vi sor and shi el ds the face of the cl uster from ambi ent
l i ght and refl ecti ons to reduce gl are, whi l e the cl uster
mask serves to separate and defi ne the i ndi vi dual
gauges and i ndi cators of the EMI C. On the l ower
edge of the cl uster l ens just ri ght of the speedometer,
the bl ack pl asti c odometer/tri p odometer swi tch but-
ton protrudes through dedi cated hol es i n the cl uster
mask and the cl uster l ens. The mol ded pl asti c EMI C
l ens, hood and mask uni t has three i ntegral mount-
i ng tabs, one each on the l ower outboard corners of
the uni t and one on the upper surface of the hood
near the center. These mounti ng tabs are used to
secure the EMI C to the mol ded pl asti c i nstrument
panel cl uster carri er wi th two screws at the top, and
one screw at each outboard tab. A si ngl e mol ded con-
nector receptacl e l ocated on the EMI C el ectroni c ci r-
cui t board i s accessed from the back of the cl uster
housi ng and i s connected to the vehi cl e el ectri cal sys-
tem through a si ngl e dedi cated take out and connec-
tor of the i nstrument panel wi re harness.
Behi nd the cl uster l ens, hood, and mask uni t i s the
cl uster overl ay and gauges. The overl ay i s a l ami -
nated pl asti c uni t. The dark, vi si bl e, outer surface of
the overl ay i s marked wi th al l of the gauge di al faces
and graduati ons, but thi s l ayer i s al so transl ucent.
The darkness of thi s outer l ayer prevents the cl uster
from appeari ng cl uttered or busy by conceal i ng the
cl uster i ndi cators that are not i l l umi nated, whi l e the
transl ucence of thi s l ayer al l ows those i ndi cators and
i cons that are i l l umi nated to be readi l y vi si bl e. The
underl yi ng l ayer of the overl ay i s opaque and al l ows
l i ght from the vari ous i ndi cators and i l l umi nati on
l amps behi nd i t to be vi si bl e through the outer l ayer
of the overl ay onl y through predetermi ned cutouts.
The orange gauge poi nters are each i l l umi nated
i nternal l y. The EMI C el ectroni c ci rcui try i s protected
by a mol ded pl asti c rear cover that features several
round access hol es for servi ce of the cl uster i l l umi na-
ti on l i ghti ng and a si ngl e rectangul ar access hol e for
the EMI C connector receptacl e. The EMI C housi ng,
ci rcui t board, gauges, and overl ay uni t are sand-
wi ched between the l ens, hood, and mask uni t and
the rear cover wi th screws.
Twel ve versi ons of the EMI C modul e are offered on
thi s model , si x base and si x premi um. These versi ons
accommodate al l of the vari ati ons of opti onal equi p-
ment and regul atory requi rements for the vari ous
markets i n whi ch the vehi cl e wi l l be offered. Thi s
modul e uti l i zes i ntegrated ci rcui try and i nformati on
carri ed on the Programmabl e Communi cati ons I nter-
face (PCI ) data bus network for control of al l gauges
and many of the i ndi cators. (Refer to 8 - ELECTRI -
CAL/ELECTRONI C CONTROL MODULES/COM-
MUNI CATI ON - DESCRI PTI ON - PCI BUS). The
EMI C al so uses several hard wi red i nputs i n order to
Fig. 1 Instrument Cluster
2 - INSTRUMENT CLUSTER
8J - 2 INSTRUMENT CLUSTER KJ
perform i ts many functi ons. The EMI C modul e i ncor-
porates a bl ue-green di gi tal Vacuum Fl uorescent Di s-
pl ay (VFD) for di spl ayi ng odometer and tri p
odometer i nformati on, as wel l as several warni ng
messages and certai n di agnosti c i nformati on. I n addi -
ti on to i nstrumentati on and i ndi cators, the EMI C has
the hardware and software needed to provi de the fol -
l owi ng features:
Chime Warning Service - A chi me tone gener-
ator on the EMI C el ectroni c ci rcui t board provi des
audi bl e al erts to the vehi cl e operator and el i mi nates
the need for a separate chi me modul e. (Refer to 8 -
ELECTRI CAL/CHI ME WARNI NG SYSTEM -
DESCRI PTI ON).
Panel Lamps Dimming Service - The EMI C
provi des a hard wi red 12-vol t Pul se-Wi dth Modul ated
(PWM) output that synchroni zes the di mmi ng l evel
of the radi o di spl ay, gear sel ector i ndi cator, heater-ai r
condi ti oner control , and al l other di mmabl e l i ghti ng
on the panel l amps di mmer ci rcui t wi th that of the
cl uster i l l umi nati on l amps and VFD.
The EMI C houses four anal og gauges and has pro-
vi si ons for up to twenty-four i ndi cators (Fi g. 2). The
EMI C i ncl udes the fol l owi ng anal og gauges:
Coolant Temperature Gauge
Fuel Gauge
Speedometer
Tachometer
Some of the EMI C i ndi cators are automati cal l y
confi gured when the EMI C i s connected to the vehi -
cl e el ectri cal system for compati bi l i ty wi th certai n
opti onal equi pment or equi pment requi red for regul a-
tory purposes i n certai n markets. Whi l e each EMI C
may have provi si ons for i ndi cators to support every
avai l abl e opti on, the confi gurabl e i ndi cators wi l l not
be functi onal i n a vehi cl e that does not have the
equi pment that an i ndi cator supports. The EMI C
i ncl udes provi si ons for the fol l owi ng i ndi cators (Fi g.
2):
Airbag Indicator (with Airbag System only)
Antilock Brake System (ABS) Indicator
(with ABS only)
Brake Indicator
Charging Indicator
Coolant Low Indicator (with Diesel Engine
only)
Cruise Indicator (with Speed Control Sys-
tem only)
Four-Wheel Drive Full Time Indicator (with
Selec-Trac Transfer Case only)
Four-Wheel Drive Low Mode Indicator
Four-Wheel Drive Part Time Indicator
Front Fog Lamp Indicator (with Front Fog
Lamps only)
High Beam Indicator
Low Fuel Indicator
Low Oil Pressure Indicator
Malfunction Indicator Lamp (MIL)
Overdrive-Off Indicator (with Automatic
Transmission only)
Rear Fog Lamp Indicator (with Rear Fog
Lamps only)
Seatbelt Indicator
Security Indicator (with Vehicle Theft
Security System only)
Sentry Key Immobilizer System (SKIS)
Indicator (with SKIS only)
Transmission Overtemp Indicator (with
Automatic Transmission only)
Turn Signal (Right and Left) Indicators
Wait-To-Start Indicator (with Diesel Engine
only)
Water-In-Fuel Indicator (with Diesel Engine
only)
Each i ndi cator i n the EMI C i s i l l umi nated by a
dedi cated Li ght Emi tti ng Di ode (LED) that i s sol -
dered onto the EMI C el ectroni c ci rcui t board. The
LEDs are not avai l abl e for servi ce repl acement and,
i f damaged or faul ty, the enti re EMI C must be
repl aced. Cl uster i l l umi nati on i s accompl i shed by
di mmabl e i ncandescent back l i ghti ng, whi ch i l l umi -
nates the gauges for vi si bi l i ty when the exteri or
l i ghti ng i s turned on. Each of the i ncandescent bul bs
i s secured by an i ntegral bul b hol der to the el ectroni c
ci rcui t board from the back of the cl uster housi ng.
The i ncandescent bul b/bul b hol der uni ts are avai l abl e
for servi ce repl acement.
Hard wi red ci rcui try connects the EMI C to the
el ectri cal system of the vehi cl e. These hard wi red ci r-
cui ts are i ntegral to several wi re harnesses, whi ch
are routed throughout the vehi cl e and retai ned by
many di fferent methods. These ci rcui ts may be con-
nected to each other, to the vehi cl e el ectri cal system
and to the EMI C through the use of a combi nati on of
sol dered spl i ces, spl i ce bl ock connectors, and many
di fferent types of wi re harness termi nal connectors
and i nsul ators. Refer to the appropri ate wi ri ng i nfor-
mati on. The wi ri ng i nformati on i ncl udes wi ri ng di a-
grams, proper wi re and connector repai r procedures,
further detai l s on wi re harness routi ng and reten-
ti on, as wel l as pi n-out and l ocati on vi ews for the
vari ous wi re harness connectors, spl i ces and grounds.
The EMI C modul es for thi s model are servi ced onl y
as compl ete uni ts. The EMI C modul e cannot be
adjusted or repai red. I f a gauge, an LED i ndi cator,
the VFD, the el ectroni c ci rcui t board, the ci rcui t
board hardware, the cl uster overl ay, or the EMI C
housi ng are damaged or faul ty, the enti re EMI C mod-
ul e must be repl aced. The cl uster l ens, hood and
mask uni t and the i ndi vi dual i ncandescent l amp
bul bs wi th hol ders are avai l abl e for servi ce repl ace-
ment.
INSTRUMENT CLUSTER (Continued)
OPERATION
The El ectroMechani cal I nstrument Cl uster (EMI C)
i s desi gned to al l ow the vehi cl e operator to moni tor
the condi ti ons of many of the vehi cl e components and
operati ng systems. The gauges and i ndi cators i n the
EMI C provi de val uabl e i nformati on about the vari ous
standard and opti onal powertrai ns, fuel and emi s-
si ons systems, cool i ng systems, l i ghti ng systems,
safety systems and many other conveni ence i tems.
The EMI C i s i nstal l ed i n the i nstrument panel so
that al l of these moni tors can be easi l y vi ewed by the
vehi cl e operator when dri vi ng, whi l e sti l l al l owi ng
rel ati ve ease of access for servi ce. The mi croproces-
sor-based EMI C hardware and software uses vari ous
i nputs to control the gauges and i ndi cators vi si bl e on
the face of the cl uster. Some of these i nputs are hard
wi red, but most are i n the form of el ectroni c mes-
sages that are transmi tted by other el ectroni c mod-
ul es over the Programmabl e Communi cati ons
I nterface (PCI ) data bus network. (Refer to 8 -
ELECTRI CAL/ELECTRONI C CONTROL MOD-
ULES/COMMUNI CATI ON - OPERATI ON).
The EMI C mi croprocessor smooths the i nput data
usi ng al gori thms to provi de gauge readi ngs that are
accurate, stabl e and responsi ve to operati ng condi -
ti ons. These al gori thms are desi gned to provi de
Fig. 2 EMIC Gauges & Indicators
1 - SKIS INDICATOR 16 - REAR FOG LAMP INDICATOR
2 - AIRBAG INDICATOR 17 - ABS INDICATOR
3 - LOW FUEL INDICATOR 18 - CHARGING INDICATOR
4 - WAIT-TO-START INDICATOR 19 - WATER-IN-FUEL INDICATOR
5 - OVERDRIVE-OFF INDICATOR 20 - ENGINE TEMPERATURE GAUGE
6 - COOLANT LOW INDICATOR 21 - ODOMETER/TRIP ODOMETER SWITCH BUTTON
7 - SEATBELT INDICATOR 22 - ODOMETER/TRIP ODOMETER DISPLAY
8 - TACHOMETER 23 - CRUISE INDICATOR
9 - LEFT TURN INDICATOR 24 - LOW OIL PRESSURE INDICATOR
10 - HIGH BEAM INDICATOR 25 - TRANSMISSION OVERTEMP INDICATOR
11 - RIGHT TURN INDICATOR 26 - PART TIME 4WD INDICATOR
12 - SPEEDOMETER 27 - BRAKE INDICATOR
13 - FRONT FOG LAMP INDICATOR 28 - FULL TIME 4WD INDICATOR
14 - 4WD LOW MODE INDICATOR 29 - SECURITY INDICATOR
15 - MALFUNCTION INDICATOR LAMP (MIL) 30 - FUEL GAUGE
gauge readi ngs duri ng normal operati on that are con-
si stent wi th customer expectati ons. However, when
abnormal condi ti ons exi st such as hi gh cool ant tem-
perature, the al gori thm can dri ve the gauge poi nter
to an extreme posi ti on and the mi croprocessor can
sound a chi me through the on-board chi me tone gen-
erator to provi de di sti nct vi sual and audi bl e i ndi ca-
ti ons of a probl em to the vehi cl e operator. The
i nstrument cl uster ci rcui try may al so perform chi me
servi ce for other el ectroni c modul es i n the vehi cl e
based upon el ectroni c chi me tone request messages
recei ved over the PCI data bus to provi de the vehi cl e
operator wi th an audi bl e al ert to suppl ement a vi sual
i ndi cati on. One such al ert i s a door ajar warni ng
chi me, whi ch the EMI C provi des by moni tori ng PCI
bus messages from the Body Control Modul e (BCM).
The EMI C ci rcui try operates on battery current
recei ved through a fused B(+) fuse i n the Juncti on
Bl ock (JB) on a non-swi tched fused B(+) ci rcui t, and
on battery current recei ved through a fused i gni ti on
swi tch output (run-start) fuse i n the JB on a fused
i gni ti on swi tch output (run-start) ci rcui t. Thi s
arrangement al l ows the EMI C to provi de some fea-
tures regardl ess of the i gni ti on swi tch posi ti on, whi l e
other features wi l l operate onl y wi th the i gni ti on
swi tch i n the On or Start posi ti ons. The EMI C
recei ves a ground i nput from the BCM as a wake-up
si gnal i n order to provi de the i gni ti on-off features.
The EMI C ci rcui try i s grounded through a ground
ci rcui t and take out of the i nstrument panel wi re
harness wi th an eyel et termi nal connector that i s
secured by a nut to a ground stud l ocated on the l eft
i nstrument panel end bracket.
The EMI C al so has a sel f-di agnosti c actuator test
capabi l i ty, whi ch wi l l test each of the PCI bus mes-
sage-control l ed functi ons of the cl uster by l i ghti ng
the appropri ate i ndi cators (except the ai rbag i ndi ca-
tor), sweepi ng the gauge needl es to several cal i bra-
ti on poi nts across the gauge faces, and steppi ng the
odometer di spl ay sequenti al l y from al l ones through
al l ni nes. (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). See the
owners manual i n the vehi cl e gl ove box for more
i nformati on on the features, use and operati on of the
EMI C.
GAUGES Al l gauges recei ve battery current
through the EMI C ci rcui try when the i gni ti on swi tch
i s i n the On or Start posi ti ons. Wi th the i gni ti on
swi tch i n the Off posi ti on battery current i s not sup-
pl i ed to any gauges, and the EMI C ci rcui try i s pro-
grammed to move al l of the gauge needl es back to
the l ow end of thei r respecti ve scal es. Therefore, the
gauges do not accuratel y i ndi cate any vehi cl e condi -
ti on unl ess the i gni ti on swi tch i s i n the On or Start
posi ti ons. Al l of the EMI C gauges, except the odome-
ter, are ai r core magneti c uni ts. Two fi xed el ectro-
magneti c coi l s are l ocated wi thi n each gauge. These
coi l s are wrapped at ri ght angl es to each other
around a movabl e permanent magnet. The movabl e
magnet i s suspended wi thi n the coi l s on one end of a
pi vot shaft, whi l e the gauge needl e i s attached to the
other end of the shaft. One of the coi l s has a fi xed
current fl owi ng through i t to mai ntai n a constant
magneti c fi el d strength. Current fl ow through the
second coi l changes, whi ch causes changes i n i ts
magneti c fi el d strength. The current fl owi ng through
the second coi l i s changed by the EMI C ci rcui try i n
response to messages recei ved over the PCI data bus.
The gauge needl e moves as the movabl e permanent
magnet al i gns i tsel f to the changi ng magneti c fi el ds
created around i t by the el ectromagnets.
The gauges are di agnosed usi ng the EMI C sel f-di -
agnosti c actuator test. (Refer to 8 - ELECTRI CAL/
I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). Proper testi ng of the PCI data bus and
the el ectroni c data bus message i nputs to the EMI C
that control each gauge requi re the use of a DRBI I I
scan tool . Refer to the appropri ate di agnosti c i nfor-
mati on. Speci fi c operati on detai l s for each gauge may
be found el sewhere i n thi s servi ce i nformati on.
VACUUM-FLUORESCENT DI SPLAY The Vacu-
um-Fl uorescent Di spl ay (VFD) modul e i s sol dered to
the EMI C ci rcui t board. The di spl ay i s acti ve when
the dri ver door i s opened wi th the i gni ti on swi tch i n
the Off or Accessory posi ti ons (Rental Car mode), and
wi th the i gni ti on swi tch i n the On or Start posi ti ons.
The VFD i s i nacti ve when the i gni ti on swi tch i s i n
the Off or Accessory posi ti ons and the dri ver door i s
cl osed. The i l l umi nati on i ntensi ty of the VFD i s con-
trol l ed by the EMI C ci rcui try based upon el ectroni c
di mmi ng l evel messages recei ved from the BCM over
the PCI data bus, and i s synchroni zed wi th the i l l u-
mi nati on i ntensi ty of other VFDs i n the vehi cl e. The
BCM provi des di mmi ng l evel messages based upon
i nternal programmi ng and i nputs i t recei ves from the
control knob and control ri ng on the l eft (l i ghti ng)
control stal k of the mul ti -functi on swi tch on the
steeri ng col umn.
The VFD has several di spl ay capabi l i ti es i ncl udi ng
odometer, tri p odometer, and warni ng messages
whenever the appropri ate condi ti ons exi st. The VFD
warni ng messages i ncl ude:
door - i ndi cati ng a door i s ajar.
gate - i ndi cati ng the tai l gate i s ajar.
glass - i ndi cati ng the tai l gate gl ass i s ajar.
lowash - i ndi cati ng that the washer fl ui d
l evel i s l ow.
no bus - i ndi cati ng there i s no PCI data bus
communi cati on detected.
An odometer/tri p odometer swi tch on the EMI C ci r-
cui t board i s used to control the di spl ay modes. Thi s
swi tch i s actuated manual l y by depressi ng the odom-
eter/tri p odometer swi tch button that extends
through the l ower edge of the cl uster l ens, just ri ght
of the speedometer. Actuati ng thi s swi tch momen-
tari l y wi th the i gni ti on swi tch i n the On posi ti on wi l l
toggl e the VFD between the odometer and tri p odom-
eter modes. Depressi ng the swi tch button for about
two seconds whi l e the VFD i s i n the tri p odometer
mode wi l l reset the tri p odometer val ue to zero. Hol d-
i ng thi s swi tch depressed whi l e turni ng the i gni ti on
swi tch from the Off posi ti on to the On posi ti on wi l l
i ni ti ate the EMI C sel f-di agnosti c actuator test. The
VFD wi l l al so di spl ay the cl uster software versi on
l evel near the compl eti on of the EMI C sel f-di agnosti c
actuator test. Refer to the appropri ate di agnosti c
i nformati on for addi ti onal detai l s on thi s VFD func-
ti on.
The VFD i s di agnosed usi ng the EMI C sel f-di ag-
nosti c actuator test. (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). Proper testi ng of the PCI data bus and
the el ectroni c data bus message i nputs to the EMI C
that control some of the VFD functi ons requi res the
use of a DRBI I I scan tool . Refer to the appropri ate
di agnosti c i nformati on. Speci fi c operati on detai l s for
the odometer, the tri p odometer, and the vari ous
warni ng message functi ons of the VFD may be found
el sewhere i n thi s servi ce i nformati on.
I NDI CATORS I ndi cators are l ocated i n vari ous
posi ti ons wi thi n the EMI C and are al l connected to
the EMI C ci rcui t board. The turn si gnal i ndi cators,
securi ty i ndi cator, washer fl ui d i ndi cator, and cool ant
l ow i ndi cator (di esel engi ne onl y) use hard wi red
i nputs to the EMI C. The brake i ndi cator i s control l ed
by PCI data bus messages from the Control l er
Anti l ock Brake (CAB) as wel l as by hard wi red park
brake swi tch and brake fl ui d l evel swi tch i nputs to
the EMI C. The Mal functi on I ndi cator Lamp (MI L) i s
normal l y control l ed by PCI data bus messages from
the Powertrai n Control Modul e (PCM); however, i f
the EMI C l oses PCI data bus communi cati on, the
EMI C ci rcui try wi l l automati cal l y turn the MI L on
unti l PCI data bus communi cati on i s restored. The
EMI C uses PCI data bus messages from the Body
Control Modul e (BCM), the PCM, the Ai rbag Control
Modul e (ACM), and the CAB to control al l of the
remai ni ng i ndi cators.
The vari ous i ndi cators are control l ed by di fferent
strategi es; some recei ve fused i gni ti on swi tch output
from the EMI C ci rcui try and have a swi tched ground,
others are grounded through the EMI C ci rcui try and
have a swi tched battery feed, whi l e sti l l others are
compl etel y control l ed by the EMI C mi croprocessor
based upon vari ous hard wi red and el ectroni c mes-
sage i nputs. Some i ndi cators are i l l umi nated at a
fi xed i ntensi ty, whi l e the i l l umi nati on i ntensi ty of
others i s synchroni zed wi th that of the EMI C general
i l l umi nati on l amps.
I n addi ti on, certai n i ndi cators i n thi s i nstrument
cl uster are automati cal l y confi gured or sel f-confi g-
ured. Thi s feature al l ows the confi gurabl e i ndi cators
to be enabl ed by the EMI C ci rcui try for compati bi l i ty
wi th certai n opti onal equi pment. The ABS i ndi cator,
ai rbag i ndi cator, SKI S i ndi cator are automati cal l y
confi gured by PCI data bus messages recei ved by the
EMI C from the CAB, ACM, or Sentry Key I mmobi -
l i zer Modul e (SKI M) after the EMI C i s i nstal l ed i n
the vehi cl e. Once these confi gurati on setti ngs are
l earned by the EMI C, the DRBI I I scan tool must be
used to remove these setti ngs from the EMI C non-
vol ati l e memory. The sel f-confi gured i ndi cators
remai n l atent i n each EMI C at al l ti mes and wi l l be
acti vated onl y when the EMI C recei ves the appropri -
ate PCI message i nputs for the opti onal system or
equi pment.
The hard wi red i ndi cators are di agnosed usi ng con-
venti onal di agnosti c methods. The EMI C and PCI
bus message control l ed i ndi cators are di agnosed
usi ng the EMI C sel f-di agnosti c actuator test. (Refer
to 8 - ELECTRI CAL/I NSTRUMENT CLUSTER -
DI AGNOSI S AND TESTI NG). Proper testi ng of the
PCI data bus and the el ectroni c data bus message
i nputs to the EMI C that control each i ndi cator
requi re the use of a DRBI I I scan tool . Refer to the
appropri ate di agnosti c i nformati on. Speci fi c detai l s of
the operati on for each i ndi cator may be found el se-
where i n thi s servi ce i nformati on.
CLUSTER I LLUMI NATI ON The EMI C has several
i l l umi nati on l amps that are i l l umi nated when the
exteri or l i ghti ng i s turned on wi th the headl amp
(mul ti -functi on) swi tch. The i l l umi nati on i ntensi ty of
these l amps i s adjusted by a 12-vol t Pul se Wi dth
Modul ated (PWM) output of the EMI C when the
i nteri or l i ghti ng control ri ng on the l eft control stal k
of the mul ti -functi on swi tch i s rotated (down to di m,
up to bri ghten) to one of si x avai l abl e mi nor detent
posi ti ons. The BCM provi des el ectroni c di mmi ng
l evel messages based upon i nternal programmi ng
and i nputs i t recei ves from the control knob and con-
trol ri ng on the l eft (l i ghti ng) control stal k of the
mul ti -functi on swi tch on the steeri ng col umn, then
provi des a control output to energi ze or de-energi ze
the park l amp rel ay as appropri ate. The energi zed
park l amp rel ay provi des battery current to the
EMI C on the hard wi red fused park l amp rel ay out-
put ci rcui t, and the BCM provi des the el ectroni c di m-
mi ng l evel message to the EMI C over the PCI data
bus. The EMI C el ectroni c ci rcui try provi des the
proper PWM output to the cl uster i l l umi nati on l amps
and the VFD on the EMI C ci rcui t board, then pro-
vi des a synchroni zed PWM output on the hard wi red
fused panel l amps di mmer swi tch si gnal ci rcui t. The
cl uster i l l umi nati on l amps are grounded at al l ti mes.
I n addi ti on, the control ri ng on the l eft (l i ghti ng)
control stal k of the mul ti -functi on swi tch has a
Parade Mode posi ti on to provi de a parade mode. The
BCM moni tors the request for thi s mode from the
mul ti -functi on swi tch, then sends an el ectroni c di m-
mi ng l evel message to the EMI C over the PCI data
bus to i l l umi nate al l VFDs i n the vehi cl e at ful l
i ntensi ty for easi er vi si bi l i ty when dri vi ng i n dayl i ght
wi th the exteri or l i ghti ng turned On.
The hard wi red cl uster i l l umi nati on l amp ci rcui ts
may be di agnosed usi ng conventi onal di agnosti c
methods. However, proper testi ng of the PWM output
of the EMI C and the el ectroni c di mmi ng l evel mes-
sages sent by the BCM over the PCI data bus
CHI ME WARNI NG SERVI CE The EMI C i s pro-
grammed to provi de chi me servi ce when certai n i ndi -
cators are i l l umi nated. When the programmed
condi ti ons are met, the EMI C generates an el ectroni c
chi me tone through i ts i ntegral chi me tone generator.
I n addi ti on, the EMI C i s programmed to provi de
chi me servi ce for other el ectroni c modul es i n the
vehi cl e when i t recei ves the proper el ectroni c chi me
request messages over the PCI data bus. Upon
recei vi ng the proper chi me request message, the
EMI C acti vates the i ntegral chi me tone generator to
provi de the audi bl e chi me tone to the vehi cl e opera-
tor. (Refer to 8 - ELECTRI CAL/CHI ME/BUZZER -
OPERATI ON). Proper testi ng of the EMI C and the
PCI data bus chi me request message functi ons
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER
I f al l of the i nstrument cl uster gauges and/or i ndi -
cators are i noperati ve, refer to PRELI MI NARY
DI AGNOSI S . I f an i ndi vi dual gauge or Programma-
bl e Communi cati ons I nterface (PCI ) data bus mes-
sage-control l ed i ndi cator i s i noperati ve, refer to
ACTUATOR TEST . I f an i ndi vi dual hard wi red i ndi -
cator i s i noperati ve, refer to the di agnosi s and testi ng
i nformati on for that speci fi c i ndi cator. I f the i nstru-
ment cl uster chi me servi ce i s i noperati ve, refer to
CHI ME SERVI CE DI AGNOSI S . I f the i nstrument
cl uster i l l umi nati on l i ghti ng i s i noperati ve, refer to
CLUSTER I LLUMI NATI ON DI AGNOSI S . Refer to
NOTE: Certain indicators in this instrument cluster
are automatically configured. This feature allows
those indicators to be activated for compatibility
with certain optional equipment. If the problem
being diagnosed involves illumination of the ABS
indicator, the airbag indicator, or the SKIS indicator
when the vehicle does not have this equipment, a
DRBIII scan tool must be used to disable the erro-
neous indicator(s). Refer to the appropriate diag-
nostic information.
PRELIMINARY DIAGNOSIS
PERSONAL INJURY.
(1) Check the fused B(+) fuse (Fuse 34 - 15
ampere) i n the Juncti on Bl ock (JB). I f OK, go to Step
2. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse.
(Fuse 34 - 15 ampere) i n the JB. I f OK, go to Step 3.
I f not OK, repai r the open fused B(+) ci rcui t between
the JB and the Power Di stri buti on Center (PDC) as
requi red.
cabl e. Remove the i nstrument cl uster. Reconnect the
battery negati ve cabl e. Check for battery vol tage at
the fused B(+) ci rcui t cavi ty of the i nstrument panel
wi re harness connector for the i nstrument cl uster. I f
OK, go to Step 4. I f not OK, repai r the open fused
B(+) ci rcui t between the i nstrument cl uster and the
JB as requi red.
(4) Check the fused i gni ti on swi tch output (run-
start) fuse (Fuse 13 - 10 ampere) i n the JB. I f OK, go
output (run-start) fuse (Fuse 13 - 10 ampere) i n the
JB. I f OK, go to Step 6. I f not OK, repai r the open
fused i gni ti on swi tch output (run-start) ci rcui t
between the JB and the i gni ti on swi tch as requi red.
(6) Wi th the i gni ti on swi tch sti l l i n the On posi -
ti on, check for battery vol tage at the fused i gni ti on
swi tch output (run-start) ci rcui t cavi ty of the i nstru-
ment panel wi re harness connector for the i nstru-
ment cl uster. I f OK, go to Step 7. I f not OK, repai r
the open fused i gni ti on swi tch output ci rcui t (run-
start) between the i nstrument cl uster and the JB as
requi red.
(7) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the i nstrument panel wi re harness connector
for the i nstrument cl uster and a good ground. There
shoul d be conti nui ty. I f OK, refer to ACTUATOR
TEST . I f not OK, repai r the open ground ci rcui t
between the i nstrument cl uster and ground (G202) as
requi red.
ACTUATOR TEST
PERSONAL INJURY.
The i nstrument cl uster actuator test wi l l put the
i nstrument cl uster i nto i ts sel f-di agnosti c mode. I n
thi s mode the i nstrument cl uster can perform a sel f-
di agnosti c test that wi l l confi rm that the i nstrument
cl uster ci rcui try, the gauges, the PCI data bus mes-
sage control l ed i ndi cator l amps, and the chi me tone
generator are capabl e of operati ng as desi gned. Dur-
i ng the actuator test the i nstrument cl uster ci rcui try
wi l l sound the chi me tone generator, posi ti on each of
the gauge needl es at vari ous speci fi ed cal i brati on
poi nts, i l l umi nate each of the segments i n the Vacu-
um-Fl uorescent Di spl ay (VFD), and turn al l of the
PCI data bus message-control l ed i ndi cators on and
off agai n.
Successful compl eti on of the actuator test wi l l con-
fi rm that the i nstrument cl uster i s operati onal . How-
ever, there may sti l l be a probl em wi th the PCI data
bus, the Powertrai n Control Modul e (PCM), the Ai r-
bag Control Modul e (ACM), the Sentry Key I mmobi -
l i zer Modul e (SKI M), or the i nputs to one of these
el ectroni c control modul es. Use a DRBI I I scan tool
to di agnose these components. Refer to the appropri -
ate di agnosti c i nformati on.
(1) Begi n the test wi th the i gni ti on swi tch i n the
Off posi ti on.
(2) Depress the odometer/tri p odometer swi tch but-
ton.
(3) Whi l e sti l l hol di ng the odometer/tri p odometer
swi tch button depressed, turn the i gni ti on swi tch to
the On posi ti on, but do not start the engi ne.
(4) Rel ease the odometer/tri p odometer swi tch but-
ton.
(5) The i nstrument cl uster wi l l automati cal l y
begi n the actuator test sequence, as fol l ows:
(a) The cl uster wi l l turn on, then off agai n each
of the PCI data bus message control l ed i ndi cators
to confi rm the functi onal i ty of the i ndi cator and
the cl uster control ci rcui try:
(b) The cl uster wi l l sweep the needl es for each of
the gauges to several cal i brati on poi nts i n sequence
to confi rm the functi onal i ty of the gauge and the
cl uster control ci rcui try:
(c) The cl uster wi l l sequenti al l y step the odome-
ter/tri p odometer VFD di spl ay from al l ones
(111111) through al l ni nes (999999) to confi rm the
functi onal i ty of al l VFD segments and thei r control
ci rcui try, then di spl ay the software versi on number.
(d) The cl uster wi l l generate fi ve (5) chi me tones
to confi rm the functi onal i ty of the chi me tone gen-
erator and the chi me control ci rcui try.
(6) The actuator test i s now compl eted. The i nstru-
ment cl uster wi l l automati cal l y exi t the sel f-di agnos-
ti c mode and return to normal operati on at the
compl eti on of the test, i f the i gni ti on swi tch i s turned
to the Off posi ti on duri ng the test, or i f an engi ne
rpm message i ndi cati ng that the engi ne i s runni ng i s
recei ved from the PCM over the PCI data bus duri ng
the test.
(7) Go back to Step 1 to repeat the test, i f
requi red.
CHIME SERVICE DIAGNOSIS
The most rel i abl e, effi ci ent, and accurate means to
di agnose the Chi me Servi ce functi on of the i nstru-
ment cl uster requi res the use of a DRBI I I scan tool .
Refer to the appropri ate di agnosti c i nformati on.
CLUSTER ILLUMINATION DIAGNOSIS
I f the probl em bei ng di agnosed i s a si ngl e i nopera-
ti ve i l l umi nati on l amp, be certai n that the bul b and
bul b hol der uni t are properl y i nstal l ed i n the i nstru-
ment cl uster el ectroni c ci rcui t board. I f no i nstal l a-
ti on probl ems are found repl ace the faul ty bul b and
bul b hol der uni t. I f al l of the cl uster i l l umi nati on
l amps are i noperati ve, the most rel i abl e, effi ci ent,
and accurate means to di agnose the cl uster i l l umi na-
ti on functi on of the i nstrument cl uster requi res the
use of a DRBI I I scan tool . Refer to the appropri ate
di agnosti c i nformati on.
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Remove the cl uster bezel from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Remove the four screws that secure the i nstru-
ment cl uster to the i nstrument panel (Fi g. 3).
(4) Pul l the i nstrument cl uster rearward far
enough to access and di sconnect the i nstrument
panel wi re harness connector for the cl uster from the
cl uster connector receptacl e.
(5) Remove the i nstrument cl uster from the i nstru-
ment panel .
DISASSEMBLY
Some of the components for the i nstrument cl uster
used i n thi s vehi cl e are servi ced i ndi vi dual l y. The
servi ced components i ncl ude the i ncandescent i nstru-
ment cl uster i l l umi nati on l amp bul bs (i ncl udi ng the
i ntegral bul b hol ders), and the cl uster l ens, hood and
mask uni t. Fol l owi ng are the procedures for di sas-
sembl i ng these components from the i nstrument cl us-
ter uni t.
PERSONAL INJURY.
Fig. 3 Instrument Cluster Remove/Install
2 - SCREW (4)
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp and bul b hol der uni ts.
cabl e.
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) Turn the bul b hol der countercl ockwi se about
si xty degrees on the cl uster el ectroni c ci rcui t board
(Fi g. 4).
(4) Pul l the bul b and bul b hol der uni t strai ght
back to remove i t from the bul b mounti ng hol e i n the
cl uster el ectroni c ci rcui t board.
CLUSTER LENS, HOOD, AND MASK
cabl e.
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) From the back of the i nstrument cl uster,
remove the si x screws that secure the rear cover and
the l ens, hood, and mask uni t to the cl uster housi ng
(Fi g. 5).
(4) Remove the l ens, hood, and mask uni t from the
face of the i nstrument cl uster.
ASSEMBLY
PERSONAL INJURY.
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp and bul b hol der uni ts.
CAUTION: Always use the correct bulb size and
type for replacement. An incorrect bulb size or type
may overheat and cause damage to the instrument
cluster, the electronic circuit board and/or the
gauges.
(1) I nsert the bul b and bul b hol der uni t strai ght
i nto the correct bul b mounti ng hol e i n the cl uster
el ectroni c ci rcui t board (Fi g. 4).
Fig. 4 Cluster Bulb Remove/Install
2 - BULB & HOLDER (9)
Fig. 5 Instrument Cluster Components
1 - REAR COVER
2 - CLUSTER HOUSING
3 - LENS, HOOD & MASK
4 - SCREW (6)
(2) Wi th the bul b hol der ful l y seated agai nst the
cl uster el ectroni c ci rcui t board, turn the bul b hol der
cl ockwi se about si xty degrees to l ock i t i nto pl ace.
(3) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
CLUSTER LENS, HOOD, AND MASK
(1) Posi ti on the cl uster l ens, hood, and mask uni t
over the face of the i nstrument cl uster (Fi g. 5). Be
certai n that the odometer/tri p odometer swi tch but-
ton i s i nserted through the proper cl earance hol es i n
the mask and the l ens.
(2) From the back of the i nstrument cl uster, i nstal l
and ti ghten the si x screws that secure the rear cover
and the l ens, hood, and mask uni t to the cl uster
housi ng. Ti ghten the screws to 1 Nm (10 i n. l bs.).
(3) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the i nstrument cl uster to the i nstru-
ment panel .
connector for the cl uster to the cl uster connector
receptacl e.
(3) Posi ti on the i nstrument cl uster i nto the i nstru-
ment panel .
the i nstrument cl uster to the i nstrument panel (Fi g.
3). Ti ghten the screws to 2 Nm (17 i n. l bs.).
(5) Rei nstal l the cl uster bezel onto the i nstrument
CLUSTER BEZEL - I NSTALLATI ON).
NOTE: Some of the indicators in this instrument
cluster are self configured or automatically config-
ured when the cluster is connected to the vehicle
electrical system. This feature allows those indica-
tors to be enabled for compatibility with certain
optional equipment. However, if an instrument clus-
ter was previously connected to another vehicle
with different equipment options than the current
vehicle, some of the automatically configured indi-
cator settings may have to be disabled using a
DRBIII scan tool. Refer to the appropriate diagnos-
tic information.
ABS INDICATOR
DESCRIPTION
An Anti l ock Brake System (ABS) i ndi cator i s stan-
dard equi pment on al l i nstrument cl usters. However,
the i nstrument cl uster i s programmed to automati -
cal l y enabl e thi s i ndi cator onl y on vehi cl es equi pped
wi th the opti onal anti l ock brake system. The ABS
i ndi cator i s l ocated above the engi ne temperature
gauge and to the ri ght of the speedometer i n the
i nstrument cl uster. The ABS i ndi cator consi sts of a
stenci l -l i ke cutout of the I nternati onal Control and
Di spl ay Symbol i con for Fai l ure of Anti -l ock Braki ng
System i n the opaque l ayer of the i nstrument cl us-
ter overl ay. The dark outer l ayer of the overl ay pre-
vents the i ndi cator from bei ng cl earl y vi si bl e when i t
i s not i l l umi nated. An amber Li ght Emi tti ng Di ode
(LED) behi nd the cutout i n the opaque l ayer of the
overl ay causes the i con to appear i n amber through
the transl ucent outer l ayer of the overl ay when i t i s
i l l umi nated from behi nd by the LED, whi ch i s sol -
dered onto the i nstrument cl uster el ectroni c ci rcui t
board. The ABS i ndi cator i s servi ced as a uni t wi th
the i nstrument cl uster.
OPERATION
The ABS i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the ABS system i s faul ty or i nop-
erati ve. Thi s i ndi cator i s control l ed by a transi stor on
the i nstrument cl uster ci rcui t board based upon cl us-
ter programmi ng and el ectroni c messages recei ved by
the cl uster from the Control l er Anti l ock Brake (CAB)
over the Programmabl e Communi cati ons I nterface
(PCI ) data bus. The ABS i ndi cator Li ght Emi tti ng
Di ode (LED) i s compl etel y control l ed by the i nstru-
ment cl uster l ogi c ci rcui t, and that l ogi c wi l l onl y
al l ow thi s i ndi cator to operate when the i nstrument
cl uster recei ves a battery current i nput on the fused
i gni ti on swi tch output (run-start) ci rcui t. Therefore,
the LED wi l l al ways be off when the i gni ti on swi tch
i s i n any posi ti on except On or Start. The LED onl y
i l l umi nates when i t i s provi ded a path to ground by
the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the ABS i ndi cator for the fol l ow-
i ng reasons:
Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on the ABS i ndi cator i s i l l u-
mi nated by the cl uster for about three seconds as a
bul b test.
ABS Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the CAB, the
ABS i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a
l amp-off message from the CAB, or unti l the i gni ti on
swi tch i s turned to the Off posi ti on, whi chever occurs
fi rst.
Communication Error - I f the cl uster recei ves
no l amp-on or l amp-off messages from the CAB for
si x consecuti ve seconds, the ABS i ndi cator i s i l l umi -
nated. The i ndi cator remai ns i l l umi nated unti l the
cl uster recei ves a val i d message from the CAB, or
unti l the i gni ti on swi tch i s turned to the Off posi ti on,
Actuator Test - Each ti me the i nstrument cl us-
ter i s put through the actuator test, the ABS i ndi ca-
tor wi l l be turned on, then off agai n duri ng the bul b
check porti on of the test to confi rm the functi onal i ty
of the LED and the cl uster control ci rcui try.
ABS Diagnostic Test - The ABS i ndi cator i s
bl i nked on and off by l amp-on and l amp-off messages
from the CAB duri ng the performance of the ABS
di agnosti c tests.
The CAB conti nual l y moni tors the ABS ci rcui ts
and sensors to deci de whether the system i s i n good
operati ng condi ti on. The CAB then sends the proper
l amp-on or l amp-off messages to the i nstrument cl us-
ter. I f the CAB sends a l amp-on message after the
bul b test, i t i ndi cates that the CAB has detected a
system mal functi on and/or that the ABS system has
become i noperati ve. The CAB wi l l each store a Di ag-
nosti c Troubl e Code (DTC) for any mal functi on i t
detects. Each ti me the ABS i ndi cator fai l s to l i ght
due to an open or short i n the cl uster ABS i ndi cator
ci rcui t, the cl uster sends a message noti fyi ng the
CAB of the condi ti on, then the i nstrument cl uster
and the CAB wi l l each store a DTC. For proper di ag-
nosi s of the anti l ock brake system, the CAB, the PCI
data bus, or the message i nputs to the i nstrument
cl uster that control the ABS i ndi cator, a DRBI I I
scan tool i s requi red. Refer to the appropri ate di ag-
nosti c i nformati on.
AIRBAG INDICATOR
DESCRIPTION
An ai rbag i ndi cator i s standard equi pment on al l
i nstrument cl usters. However, the i nstrument cl uster
i s programmed to automati cal l y enabl e thi s i ndi cator
onl y on vehi cl es equi pped wi th the ai rbag system,
whi ch i s not avai l abl e i n some markets. The ai rbag
i ndi cator i s l ocated above the fuel gauge and to the
l eft of the tachometer i n the i nstrument cl uster. The
ai rbag i ndi cator consi sts of a stenci l -l i ke cutout of the
words AI R BAG i n the opaque l ayer of the i nstru-
ment cl uster overl ay. The dark outer l ayer of the
overl ay prevents the i ndi cator from bei ng cl earl y vi s-
i bl e when i t i s not i l l umi nated. A red Li ght Emi tti ng
Di ode (LED) behi nd the cutout i n the opaque l ayer of
the overl ay causes the AI R BAG text to appear i n
red through the transl ucent outer l ayer of the over-
l ay when i t i s i l l umi nated from behi nd by the LED,
whi ch i s sol dered onto the i nstrument cl uster el ec-
troni c ci rcui t board. The ai rbag i ndi cator i s servi ced
as a uni t wi th the i nstrument cl uster.
OPERATION
The ai rbag i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the ai rbag system i s faul ty or
i noperati ve. The ai rbag i ndi cator i s control l ed by a
transi stor on the i nstrument cl uster ci rcui t board
based upon cl uster programmi ng and el ectroni c mes-
sages recei ved by the cl uster from the Ai rbag Control
Modul e (ACM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The ai rbag i ndi cator
Li ght Emi tti ng Di ode (LED) i s compl etel y control l ed
by the i nstrument cl uster l ogi c ci rcui t, and that l ogi c
wi l l onl y al l ow thi s i ndi cator to operate when the
i nstrument cl uster recei ves a battery current i nput
on the fused i gni ti on swi tch output (run-start) ci r-
cui t. Therefore, the LED wi l l al ways be off when the
i gni ti on swi tch i s i n any posi ti on except On or Start.
The LED onl y i l l umi nates when i t i s provi ded a path
to ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the ai rbag i ndi cator
for the fol l owi ng reasons:
turned to the On posi ti on the ai rbag i ndi cator i s i l l u-
mi nated for about si x seconds. The enti re si x second
bul b test i s a functi on of the ACM.
ACM Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the ACM, the
ai rbag i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated for about twel ve seconds or unti l
the cl uster recei ves a l amp-off message from the
ACM, whi chever i s l onger.
no ai rbag messages for si x consecuti ve seconds, the
ai rbag i ndi cator i s i l l umi nated. The i ndi cator
ABS INDICATOR (Continued)
remai ns i l l umi nated unti l the cl uster recei ves a si n-
gl e l amp-off message from the ACM.
Actuator Test - Each ti me the cl uster i s put
through the actuator test, the ai rbag i ndi cator wi l l be
turned on, then off agai n duri ng the bul b check por-
ti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try. The actuator
test i l l umi nati on of the ai rbag i ndi cator i s a functi on
of the i nstrument cl uster.
The ACM conti nual l y moni tors the ai rbag system
ci rcui ts and sensors to deci de whether the system i s
i n good operati ng condi ti on. The ACM then sends the
proper l amp-on or l amp-off messages to the i nstru-
ment cl uster. I f the ACM sends a l amp-on message
after the bul b test, i t i ndi cates that the ACM has
detected a system mal functi on and/or that the ai r-
bags and dri ver seat bel t tensi oner may not depl oy
when requi red, or may depl oy when not requi red.
The ACM wi l l store a Di agnosti c Troubl e Code (DTC)
for any mal functi on i t detects. Each ti me the ai rbag
i ndi cator fai l s to i l l umi nate due to an open or short
i n the cl uster ai rbag i ndi cator ci rcui t, the cl uster
sends a message noti fyi ng the ACM of the condi ti on,
then the i nstrument cl uster and the ACM wi l l each
store a DTC. For proper di agnosi s of the ai rbag sys-
tem, the ACM, the PCI data bus, or the message
i nputs to the i nstrument cl uster that control the ai r-
bag i ndi cator, a DRBI I I scan tool i s requi red. Refer
to the appropri ate di agnosti c i nformati on.
BRAKE/PARK BRAKE
INDICATOR
DESCRIPTION
A brake i ndi cator i s standard equi pment on al l
i nstrument cl usters. The brake i ndi cator i s l ocated
near the l ower edge of the tachometer di al face i n the
i nstrument cl uster. The brake i ndi cator consi sts of
stenci l -l i ke cutouts of the word BRAKE and the
I nternati onal Control and Di spl ay Symbol i con for
Brake Fai l ure i n the opaque l ayer of the i nstru-
i bl e when i t i s not i l l umi nated. A red Li ght Emi tti ng
the overl ay causes the BRAKE text and the i con to
appear i n red through the transl ucent outer l ayer of
the overl ay when the i ndi cator i s i l l umi nated from
behi nd by the LED, whi ch i s sol dered onto the
i nstrument cl uster el ectroni c ci rcui t board. The brake
i ndi cator i s servi ced as a uni t wi th the i nstrument
cl uster.
OPERATION
The brake i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the parki ng brake i s appl i ed, when
there are certai n brake hydraul i c system mal func-
ti ons as i ndi cated by a l ow brake hydraul i c fl ui d l evel
condi ti on, or when the brake fl ui d l evel swi tch i s di s-
connected. On model s equi pped wi th an opti onal
Anti l ock Brake System (ABS), the brake i ndi cator
can al so gi ve an i ndi cati on when certai n faul ts are
detected i n the ABS. Thi s i ndi cator i s control l ed by a
transi stor on the i nstrument cl uster el ectroni c ci rcui t
board based upon cl uster programmi ng, el ectroni c
messages recei ved by the cl uster from the Control l er
Anti l ock Brake (CAB) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus (ABS onl y), and
hard wi red i nputs from the park brake swi tch and
the brake fl ui d l evel swi tch. The brake i ndi cator
Li ght Emi tti ng Di ode (LED) i s compl etel y control l ed
by the i nstrument cl uster l ogi c ci rcui t, and that l ogi c
wi l l onl y al l ow thi s i ndi cator to operate when the
i nstrument cl uster recei ves a battery current i nput
on the fused i gni ti on swi tch output (run-start) ci r-
cui t. Therefore, the LED wi l l al ways be off when the
i gni ti on swi tch i s i n any posi ti on except On or Start.
The LED onl y i l l umi nates when i t i s provi ded a path
to ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the brake i ndi cator
for the fol l owi ng reasons:
turned to the On posi ti on the brake i ndi cator i s i l l u-
mi nated by the i nstrument cl uster for about three
seconds as a bul b test.
Brake Lamp-On Message - Each ti me the
cl uster recei ves a l amp-on message from the CAB,
the brake i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a
l amp-off message from the CAB, or unti l the i gni ti on
fi rst.
Park Brake Switch Input - Each ti me the
cl uster detects ground on the park brake swi tch
sense ci rcui t (park brake swi tch cl osed = park brake
appl i ed or not ful l y rel eased) the brake i ndi cator i s
i l l umi nated. The i ndi cator remai ns i l l umi nated unti l
the park brake swi tch sense i nput to the cl uster i s an
open ci rcui t (park brake swi tch open = park brake
ful l y rel eased), or unti l the i gni ti on swi tch i s turned
to the Off posi ti on, whi chever occurs fi rst.
Brake Fluid Level Switch Input - Each ti me
the cl uster detects ground on the red brake warni ng
i ndi cator dri ver ci rcui t (brake fl ui d l evel swi tch
cl osed = brake hydraul i c system fl ui d l evel l ow) the
brake i ndi cator i s i l l umi nated sol i d. The i ndi cator
remai ns i l l umi nated unti l the status of the red brake
warni ng i ndi cator dri ver i nput to the cl uster i s off
(brake fl ui d l evel swi tch off = brake hydraul i c system
AIRBAG INDICATOR (Continued)
fl ui d l evel i s not l ow), or unti l the i gni ti on swi tch i s
turned to the Off posi ti on, whi chever occurs fi rst.
Brake Fluid Level Switch Input Fault - The
brake fl ui d l evel swi tch al so features a 1 ki l ohm
di agnosti c resi stor connected i n paral l el between the
swi tch i nput and output to provi de the cl uster wi th
veri fi cati on that the red brake warni ng i ndi cator
dri ver ci rcui t i s not open. I f the cl uster does not see a
proper i nput on the red brake warni ng i ndi cator
dri ver ci rcui t, i t wi l l turn on the brake i ndi cator. The
i ndi cator remai ns i l l umi nated unti l the red brake
warni ng i ndi cator dri ver ci rcui t faul t i s resol ved, or
Actuator Test - Each ti me the i nstrument cl us-
ter i s put through the actuator test, the brake i ndi -
cator wi l l be turned on, then off agai n duri ng the
bul b check porti on of the test to confi rm the functi on-
al i ty of the LED and the cl uster control ci rcui try.
The park brake swi tch on the park brake pedal
mechani sm provi des a hard wi red ground i nput to
the i nstrument cl uster ci rcui try through the park
brake swi tch sense ci rcui t whenever the park brake
i s appl i ed or not ful l y rel eased. The brake fl ui d l evel
swi tch on the brake master cyl i nder reservoi r pro-
vi des a hard wi red ground i nput to the i nstrument
cl uster ci rcui try through the red brake warni ng i ndi -
cator dri ver ci rcui t whenever the fl ui d l evel i n the
reservoi r becomes l ow. On model s equi pped wi th the
opti onal ABS, the CAB sends the proper l amp-on or
l amp-off messages to the i nstrument cl uster. I f the
CAB sends a l amp-on message after the bul b test, i t
i ndi cates that the CAB has detected a brake hydrau-
l i c system mal functi on and/or that the ABS system
has become i noperati ve. The CAB wi l l store a Di ag-
nosti c Troubl e Code (DTC) for any mal functi on i t
detects.
For further di agnosi s of the brake i ndi cator or the
i nstrument cl uster ci rcui try that control s the LED,
(Refer to 8 - ELECTRI CAL/I NSTRUMENT CLUS-
TER - DI AGNOSI S AND TESTI NG). The park brake
swi tch i nput to the i nstrument cl uster can be di ag-
nosed usi ng conventi onal di agnosti c tool s and meth-
ods. For proper di agnosi s of the brake fl ui d l evel
swi tch i nput to the i nstrument cl uster, the anti l ock
brake system, the CAB, the PCI data bus, or the
el ectroni c message i nputs to the i nstrument cl uster
that control the brake i ndi cator, a DRBI I I scan tool
i s requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
DIAGNOSIS AND TESTING - BRAKE INDICATOR
The di agnosi s found here addresses an i noperati ve
brake i ndi cator condi ti on. I f there are probl ems wi th
several i ndi cators i n the i nstrument cl uster, (Refer to
8 - ELECTRI CAL/I NSTRUMENT CLUSTER - DI AG-
NOSI S AND TESTI NG). I f the brake i ndi cator stays
on wi th the i gni ti on swi tch i n the On posi ti on and
the park brake rel eased, or comes on whi l e dri vi ng,
(Refer to 5 - BRAKES - DI AGNOSI S AND TEST-
I NG). I f no brake system probl em i s found, the fol -
l owi ng procedures wi l l hel p to l ocate a shorted or
open ci rcui t, or a faul ty park brake swi tch i nput.
PERSONAL INJURY.
INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES
NOT WHEN PARK BRAKE APPLIED
cabl e. Di sconnect the front body wi re harness connec-
tor for the park brake swi tch from the swi tch termi -
nal . Appl y the parki ng brake. Check for conti nui ty
between the park brake swi tch termi nal and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
2. I f not OK, repl ace the faul ty park brake swi tch.
connector for the i nstrument cl uster from the cl uster
connector receptacl e. Check for conti nui ty between
the park brake swi tch sense ci rcui t cavi ti es of the
front body wi re harness connector for the park brake
swi tch and the i nstrument panel wi re harness con-
nector for the i nstrument cl uster. There shoul d be
conti nui ty. I f not OK, repai r the open park brake
swi tch sense ci rcui t between the park brake swi tch
and the i nstrument cl uster as requi red.
INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM
CHECKS OK
cabl e. Di sconnect the front body wi re harness connec-
BRAKE/PARK BRAKE INDICATOR (Continued)
tor for the park brake swi tch from the swi tch termi -
nal . Check for conti nui ty between the termi nal of the
park brake swi tch and a good ground. There shoul d
be no conti nui ty wi th the park brake rel eased, and
conti nui ty wi th the park brake appl i ed. I f OK, go to
Step 2. I f not OK, repl ace the faul ty park brake
swi tch.
connector for the i nstrument cl uster from the cl uster
connector receptacl e. Check for conti nui ty between
the park brake swi tch sense ci rcui t cavi ty of the front
body wi re harness connector for the park brake
swi tch and a good ground. There shoul d be no conti -
nui ty. I f not OK, repai r the shorted park brake
swi tch sense ci rcui t between the park brake swi tch
and the i nstrument cl uster as requi red.
CHARGING INDICATOR
DESCRIPTION
A chargi ng i ndi cator i s standard equi pment on al l
i nstrument cl usters. The chargi ng i ndi cator i s l ocated
above the engi ne temperature gauge and to the ri ght
of the speedometer i n the i nstrument cl uster. The
chargi ng i ndi cator consi sts of a stenci l -l i ke cutout of
the I nternati onal Control and Di spl ay Symbol i con
for Battery Chargi ng Condi ti on i n the opaque l ayer
of the i nstrument cl uster overl ay. The dark outer
l ayer of the overl ay prevents the i ndi cator from bei ng
cl earl y vi si bl e when i t i s not i l l umi nated. A red Li ght
Emi tti ng Di ode (LED) behi nd the cutout i n the
opaque l ayer of the overl ay causes the i con to appear
i n red through the transl ucent outer l ayer of the
overl ay when the i ndi cator i s i l l umi nated from
i nstrument cl uster el ectroni c ci rcui t board. The
chargi ng i ndi cator i s servi ced as a uni t wi th the
i nstrument cl uster.
OPERATION
The chargi ng i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the el ectri cal system vol tage i s
too l ow or too hi gh. Thi s i ndi cator i s control l ed by a
board based upon the cl uster programmi ng and el ec-
troni c messages recei ved by the cl uster from the
Powertrai n Control Modul e (PCM) over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus. The
chargi ng i ndi cator Li ght Emi tti ng Di ode (LED) i s
compl etel y control l ed by the i nstrument cl uster l ogi c
ci rcui t, and that l ogi c wi l l onl y al l ow thi s i ndi cator to
operate when the i nstrument cl uster recei ves a bat-
tery current i nput on the fused i gni ti on swi tch out-
put (run-start) ci rcui t. Therefore, the LED wi l l
al ways be off when the i gni ti on swi tch i s i n any posi -
ti on except On or Start. The LED onl y i l l umi nates
when i t i s provi ded a path to ground by the i nstru-
ment cl uster transi stor. The i nstrument cl uster wi l l
turn on the chargi ng i ndi cator for the fol l owi ng rea-
sons:
turned to the On posi ti on the chargi ng i ndi cator i s
i l l umi nated by the i nstrument cl uster for about three
seconds as a bul b test.
Charge Fail Message - Each ti me the cl uster
recei ves a charge fai l message from the PCM (system
vol tage i s ni ne vol ts or l ower, the chargi ng i ndi cator
wi l l be i l l umi nated. The i ndi cator remai ns i l l umi -
nated unti l the cl uster recei ves a message from the
PCM i ndi cati ng there i s no charge fai l condi ti on (sys-
tem vol tage i s twel ve vol ts or hi gher, but l ower than
si xteen vol ts), or unti l the i gni ti on swi tch i s turned to
the Off posi ti on, whi chever occurs fi rst.
Voltage High Message - Each ti me the cl uster
recei ves a message from the PCM i ndi cati ng a vol t-
age hi gh condi ti on (system vol tage i s si xteen vol ts or
hi gher), the l amp wi l l be i l l umi nated. The l amp
remai ns i l l umi nated unti l the cl uster recei ves a mes-
sage from the PCM i ndi cati ng there i s no vol tage
hi gh condi ti on (system vol tage i s l ower than si xteen
vol ts, but hi gher than ni ne vol ts), or unti l the i gni -
ti on swi tch i s turned to the Off posi ti on, whi chever
occurs fi rst.
through the actuator test, the chargi ng i ndi cator wi l l
be turned on, then off agai n duri ng the bul b check
porti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the el ectri cal sys-
tem vol tage to control the generator output. The
PCM then sends the proper system vol tage messages
to the i nstrument cl uster. I f the i nstrument cl uster
turns on the i ndi cator after the bul b test, i t may
i ndi cate that the chargi ng system requi res servi ce.
For further di agnosi s of the chargi ng i ndi cator or the
i nstrument cl uster ci rcui try that control s the i ndi ca-
tor, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). For
proper di agnosi s of the chargi ng system, the PCI
data bus, or the el ectroni c message i nputs to the
i nstrument cl uster that control the chargi ng i ndi ca-
tor, a DRBI I I scan tool i s requi red. Refer to the
COOLANT LOW INDICATOR
DESCRIPTION
A cool ant l ow i ndi cator i s onl y found i n the i nstru-
ment cl usters of vehi cl es equi pped wi th an opti onal
di esel engi ne. The cool ant l ow i ndi cator i s l ocated
BRAKE/PARK BRAKE INDICATOR (Continued)
above the fuel gauge and to the l eft of the tachometer
i n the i nstrument cl uster. The cool ant l ow i ndi cator
consi sts of a stenci l -l i ke cutout of the I nternati onal
Control and Di spl ay Symbol i con for Low Engi ne
Cool ant i n the opaque l ayer of the i nstrument cl us-
the transl ucent outer l ayer of the overl ay when the
i ndi cator i s i l l umi nated from behi nd by the LED,
troni c ci rcui t board. The cool ant l ow i ndi cator i s ser-
vi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The cool ant l ow i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the di esel engi ne cool ant l evel
i s l ow. Thi s i ndi cator i s control l ed by a transi stor on
the i nstrument cl uster ci rcui t board based upon cl us-
ter programmi ng and a hard wi red i nput recei ved by
the cl uster from the engi ne cool ant l evel swi tch. The
cool ant l ow i ndi cator Li ght Emi tti ng Di ode (LED) i s
turn on the cool ant l ow i ndi cator for the fol l owi ng
reasons:
turned to the On posi ti on the cool ant l ow i ndi cator i s
i l l umi nated for about three seconds as a bul b test.
Engine Coolant Level Switch Input - Each
ti me the cl uster detects ground on the l ow cool ant
fl ui d l evel sense ci rcui t (engi ne cool ant l evel swi tch
cl osed = engi ne cool ant l evel l ow) the cl uster appl i es
an al gori thm to confi rm that the i nput i s correct and
not the resul t of cool ant sl oshi ng i n the cool ant bot-
tl e. The cl uster tests the status of the ci rcui t about
seven mi l l i seconds after i gni ti on On, and about once
every second thereafter, then uses an i nternal
counter to count up or down. When the counter accu-
mul ates thi rty ground i nputs on the ci rcui t, the cool -
ant l ow i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the l ow cool ant fl ui d l evel
sense i nput to the cl uster i s an open ci rcui t (engi ne
cool ant l evel swi tch open = engi ne cool ant l evel ful l ),
or unti l the i gni ti on swi tch i s turned to the Off posi -
ti on, whi chever occurs fi rst.
Engine Coolant Level Switch Input Fault -
The engi ne cool ant l evel swi tch al so features a 3.3
ki l ohm di agnosti c resi stor connected i n paral l el
between the swi tch i nput and output to provi de the
cl uster wi th veri fi cati on that the l ow cool ant fl ui d
l evel sense ci rcui t i s not open or shorted. I f the cl us-
ter does not see a proper i nput on the l ow cool ant
fl ui d l evel sense ci rcui t, i t wi l l suspend cool ant l ow
i ndi cator operati on. The i ndi cator operati on remai ns
suspended unti l the l ow cool ant fl ui d l evel sense ci r-
cui t faul t i s resol ved.
through the actuator test, the cool ant l ow i ndi cator
wi l l be turned on, then off agai n duri ng the bul b
The engi ne cool ant l evel swi tch on the cool ant bot-
tl e provi des a hard wi red ground i nput to the i nstru-
ment cl uster ci rcui try through the l ow cool ant fl ui d
l evel sense ci rcui t whenever the l evel of the cool ant
i n the bottl e i s l ow. For further di agnosi s of the cool -
ant l ow i ndi cator or the i nstrument cl uster ci rcui try
that control s the LED, (Refer to 8 - ELECTRI CAL/
I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). For proper di agnosi s of the engi ne cool -
ant l evel swi tch i nput to the i nstrument cl uster that
control the cool ant l ow i ndi cator, a DRBI I I scan tool
i s requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
CRUISE INDICATOR
DESCRIPTION
A crui se i ndi cator i s standard equi pment on al l
i nstrument cl usters, but i s onl y functi onal on vehi -
cl es equi pped wi th the opti onal speed control system.
The crui se i ndi cator i s l ocated near the l ower edge of
the i nstrument cl uster, between the tachometer and
the speedometer. The crui se i ndi cator consi sts of a
stenci l -l i ke cutout of the word CRUI SE i n the
opaque l ayer of the i nstrument cl uster overl ay. The
dark outer l ayer of the overl ay prevents the i ndi cator
from bei ng cl earl y vi si bl e when i t i s not i l l umi nated.
A green Li ght Emi tti ng Di ode (LED) behi nd the cut-
out i n the opaque l ayer of the overl ay causes the
CRUI SE text to appear i n green through the trans-
l ucent outer l ayer of the overl ay when i t i s i l l umi -
nated from behi nd by the LED, whi ch i s sol dered
onto the i nstrument cl uster el ectroni c ci rcui t board.
When the exteri or l i ghti ng i s turned On, the i l l umi -
nati on i ntensi ty of the crui se i ndi cator i s di mmabl e,
whi ch i s adjusted usi ng the panel l amps di mmer con-
trol ri ng on the l eft control stal k of the mul ti -func-
ti on swi tch. The crui se i ndi cator i s servi ced as a uni t
wi th the i nstrument cl uster.
COOLANT LOW INDICATOR (Continued)
OPERATION
The crui se i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the speed control system i s turned
On, regardl ess of whether the speed control i s
engaged. Thi s i ndi cator i s control l ed by a transi stor
on the i nstrument cl uster el ectroni c ci rcui t board
based upon the cl uster programmi ng and el ectroni c
messages recei ved by the cl uster from the Powertrai n
Control Modul e (PCM) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus. The crui se
i ndi cator Li ght Emi tti ng Di ode (LED) i s compl etel y
control l ed by the i nstrument cl uster l ogi c ci rcui t, and
that l ogi c wi l l onl y al l ow thi s i ndi cator to operate
when the i nstrument cl uster recei ves a battery cur-
rent i nput on the fused i gni ti on swi tch output (run-
start) ci rcui t. Therefore, the LED wi l l al ways be off
when the i gni ti on swi tch i s i n any posi ti on except On
or Start. The LED onl y i l l umi nates when i t i s pro-
vi ded a path to ground by the i nstrument cl uster
transi stor. The i nstrument cl uster wi l l turn on the
crui se i ndi cator for the fol l owi ng reasons:
Cruise Lamp-On Message - Each ti me the
cl uster recei ves a crui se l amp-on message from the
PCM i ndi cati ng the speed control system has been
turned On, the crui se i ndi cator i s i l l umi nated. The
i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves a crui se l amp-off message from the PCM or
through the actuator test, the crui se i ndi cator wi l l be
ti on of the test i n order to confi rm the functi onal i ty
The PCM conti nual l y moni tors the speed control
swi tches to determi ne the proper outputs to the
speed control servo. The PCM then sends the proper
crui se i ndi cator l amp-on and l amp-off messages to
the i nstrument cl uster. For further di agnosi s of the
crui se i ndi cator or the i nstrument cl uster ci rcui try
that control s the i ndi cator, (Refer to 8 - ELECTRI -
CAL/I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). For proper di agnosi s of the speed control
system, the PCM, the PCI data bus, or the el ectroni c
message i nputs to the i nstrument cl uster that control
the crui se i ndi cator, a DRBI I I scan tool i s requi red.
DOOR AJ AR INDICATOR
DESCRIPTION
A door ajar i ndi cator i s standard equi pment on al l
i nstrument cl usters. The door ajar i ndi cator consi sts
of the word door, whi ch appears i n pl ace of the
odometer/tri p odometer i nformati on i n the Vacuum-
Fl uorescent Di spl ay (VFD) of the i nstrument cl uster.
The VFD i s part of the cl uster el ectroni c ci rcui t
board, and i s vi si bl e through a cutout l ocated near
the l ower edge of the speedometer di al face i n the
i nstrument cl uster. The dark outer l ayer of the over-
l ay prevents the VFD from bei ng cl earl y vi si bl e when
i t i s not i l l umi nated. The word door appears i n the
same bl ue-green col or and at the same l i ghti ng l evel
as the odometer/tri p odometer i nformati on through
i l l umi nated by the i nstrument cl uster el ectroni c ci r-
cui t board. The door ajar i ndi cator i s servi ced as a
uni t wi th the i nstrument cl uster.
OPERATION
The door ajar i ndi cator gi ves an i ndi cati on to the
vehi cl e operator that one or more of the passenger
compartment doors may be open or not compl etel y
l atched. Thi s i ndi cator i s control l ed by the i nstru-
ment cl uster el ectroni c ci rcui t board based upon cl us-
ter programmi ng and el ectroni c messages recei ved by
the cl uster from the Body Control Modul e (BCM)
(PCI ) data bus. The door ajar i ndi cator functi on of
the Vacuum Fl uorescent Di spl ay (VFD) i s compl etel y
start) ci rcui t. Therefore, the VFD door ajar i ndi cati on
wi l l al ways be off when the i gni ti on swi tch i s i n any
posi ti on except On or Start. The i nstrument cl uster
wi l l turn on the door ajar i ndi cator for the fol l owi ng
reasons:
Door Ajar Lamp-On Message - Each ti me the
cl uster recei ves a door ajar l amp-on message from
the BCM i ndi cati ng that a door i s open or not com-
pl etel y l atched, the door ajar i ndi cator wi l l be i l l umi -
nated. I f the vehi cl e i s not movi ng when the door
ajar l amp-on message i s recei ved, the VFD wi l l
repeatedl y and sequenti al l y cycl e i ts i ndi cati on i n
two second i nterval s wi th the odometer/tri p odometer
i nformati on, the door ajar warni ng, and any other
acti ve warni ngs i ncl udi ng: gate ajar, gl ass ajar, and
l ow washer fl ui d. I f the vehi cl e i s movi ng, or once the
cl uster of a non-movi ng vehi cl e recei ves an el ectroni c
vehi cl e speed message from the Powertrai n Control
Modul e (PCM) i ndi cati ng a speed greater than zero,
the warni ng sequence wi l l consi st of three compl ete
di spl ay cycl es, then revert to onl y the odometer/tri p
odometer di spl ay unti l the door ajar swi tch i s cycl ed.
The door ajar i ndi cator wi l l al so be exti ngui shed
when the cl uster recei ves a door ajar l amp-off mes-
sage from the BCM, or i f the i gni ti on swi tch i s
CRUISE INDICATOR (Continued)
The BCM conti nual l y moni tors the door ajar
swi tches that are i ntegral to each door l atch to deter-
mi ne the status of the doors. The BCM then sends
the proper door ajar l amp-on and l amp-off messages
to the i nstrument cl uster. For further di agnosi s of
the door ajar i ndi cator or the i nstrument cl uster ci r-
cui try that control s the i ndi cator, (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER - DI AGNOSI S
AND TESTI NG). For proper di agnosi s of the door
ajar swi tches and ci rcui ts, the BCM, the PCI data
bus, or the el ectroni c message i nputs to the i nstru-
ment cl uster that control the door ajar i ndi cator, a
DRBI I I scan tool i s requi red. Refer to the appropri -
ENGINE TEMPERATURE
GAUGE
DESCRIPTION
An engi ne cool ant temperature gauge i s standard
equi pment on al l i nstrument cl usters. The engi ne
cool ant temperature gauge i s l ocated i n the ri ght
l ower corner of the i nstrument cl uster, to the ri ght of
the speedometer. The engi ne cool ant temperature
gauge consi sts of a movabl e gauge needl e or poi nter
control l ed by the i nstrument cl uster ci rcui try and a
fi xed 90 degree scal e on the cl uster overl ay that
reads l eft-to-ri ght from C (or Col d) to H (or Hot)
for al l engi nes. An I nternati onal Control and Di spl ay
Symbol i con for Engi ne Cool ant Temperature i s
l ocated on the cl uster overl ay, i n the center of the
gauge di rectl y above the hub of the gauge needl e.
The engi ne cool ant temperature gauge graphi cs are
dark bl ue and bl ack agai nst a bei ge fi el d, except for a
si ngl e l i ght bl ue graduati on at the far l eft (Col d) end
of the gauge scal e and a si ngl e red graduati on at the
far ri ght (Hot) end of the gauge scal e, maki ng them
cl earl y vi si bl e wi thi n the i nstrument cl uster i n day-
l i ght. When i l l umi nated from behi nd by the panel
l amps di mmer control l ed cl uster i l l umi nati on l i ghti ng
wi th the exteri or l amps turned On, the bl ue graphi cs
appear bl ue and the red graphi cs appear red. The
orange gauge needl e i s i nternal l y i l l umi nated. Gauge
i l l umi nati on i s provi ded by repl aceabl e i ncandescent
bul b and bul b hol der uni ts l ocated on the i nstrument
cl uster el ectroni c ci rcui t board. The engi ne cool ant
temperature gauge i s servi ced as a uni t wi th the
OPERATION
The engi ne cool ant temperature gauge gi ves an
i ndi cati on to the vehi cl e operator of the engi ne cool -
ant temperature. Thi s gauge i s control l ed by the
i nstrument cl uster ci rcui t board based upon cl uster
programmi ng and el ectroni c messages recei ved by
the cl uster from the Powertrai n Control Modul e
(PCM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The engi ne cool ant temper-
ature gauge i s an ai r core magneti c uni t that recei ves
battery current on the i nstrument cl uster el ectroni c
ci rcui t board through the fused i gni ti on swi tch out-
put (run-start) ci rcui t whenever the i gni ti on swi tch i s
i n the On or Start posi ti ons. The cl uster i s pro-
grammed to move the gauge needl e back to the l ow
end of the scal e after the i gni ti on swi tch i s turned to
the Off posi ti on. The i nstrument cl uster ci rcui try
control s the gauge needl e posi ti on and provi des the
fol l owi ng features:
Engine Temperature Normal Message - Each
ti me the cl uster recei ves a message from the PCM
i ndi cati ng the engi ne cool ant temperature i s wi thi n
the normal operati ng range [up to about 124 C (255
F) for gasol i ne engi nes, or about 110 C (230 F) for
di esel engi nes], the gauge needl e i s moved to the rel -
ati ve temperature posi ti on of the gauge scal e.
Engine Temperature High Message - Each
ti me the cl uster recei ves a message from the PCM
i ndi cati ng the engi ne cool ant temperature i s hi gh
[above about 127 C (260 F) for gasol i ne engi nes, or
112 C (233 F) for di esel engi nes], the gauge needl e
i s moved i nto the center of the red warni ng zone on
the gauge scal e.
Engine Temperature Critical Message -
Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the engi ne cool ant temperature i s
cri ti cal [above about 132 C (269 F) for gasol i ne
engi nes, or 115 C (239 F) for di esel engi nes], the
gauge needl e i s moved to the hi gh end of the red
warni ng zone on the gauge scal e.
through the actuator test, the gauge needl e wi l l be
swept to the gauge cal i brati on poi nts on the gauge
scal e i n sequence i n order to confi rm the functi onal -
i ty of the gauge and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the engi ne cool ant
temperature sensor to determi ne the engi ne operat-
i ng temperature. The PCM then sends the proper
engi ne cool ant temperature messages to the i nstru-
ment cl uster. For further di agnosi s of the engi ne cool -
ant temperature gauge or the i nstrument cl uster
ci rcui try that control s the gauge, (Refer to 8 - ELEC-
AND TESTI NG). I f the i nstrument cl uster moves the
engi ne cool ant temperature gauge needl e to i ndi cate
a hi gh or cri ti cal engi ne temperature, i t may i ndi cate
that the engi ne or the engi ne cool i ng system requi res
servi ce. For proper di agnosi s of the engi ne cool ant
temperature sensor, the PCM, the PCI data bus, or
the el ectroni c message i nputs to the i nstrument cl us-
ter that control the engi ne cool ant temperature
DOOR AJ AR INDICATOR (Continued)
gauge, a DRBI I I scan tool i s requi red. Refer to the
FRONT FOG LAMP INDICATOR
DESCRIPTION
A front fog l amp i ndi cator i s standard equi pment
on al l i nstrument cl usters, but i s onl y functi onal on
vehi cl es equi pped wi th the opti onal front fog l amps.
The front fog l amp i ndi cator i s l ocated above the
engi ne temperature gauge and to the ri ght of the
speedometer i n the i nstrument cl uster. The front fog
l amp i ndi cator consi sts of a stenci l -l i ke cutout of the
Front Fog Li ght i n the opaque l ayer of the i nstru-
i bl e when i t i s not i l l umi nated. A green Li ght Emi t-
ti ng Di ode (LED) behi nd the cutout i n the opaque
l ayer of the overl ay causes the i con to appear i n
green through the transl ucent outer l ayer of the
overl ay when i t i s i l l umi nated from behi nd by the
LED, whi ch i s sol dered onto the i nstrument cl uster
el ectroni c ci rcui t board. When the exteri or l i ghti ng i s
turned On, the i l l umi nati on i ntensi ty of the front fog
l amp i ndi cator i s di mmabl e, whi ch i s adjusted usi ng
the panel l amps di mmer control ri ng on the l eft con-
trol stal k of the mul ti -functi on swi tch. The front fog
l amp i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The front fog l amp i ndi cator gi ves an i ndi cati on to
the vehi cl e operator whenever the front fog l amps
are i l l umi nated. Thi s i ndi cator i s control l ed by a
Body Control Modul e (BCM) over the Programmabl e
Communi cati ons I nterface (PCI ) data bus. The front
fog l amp i ndi cator Li ght Emi tti ng Di ode (LED) i s
ci rcui t, and that l ogi c wi l l al l ow thi s i ndi cator to
operate whenever the i nstrument cl uster recei ves a
battery current i nput on the fused B(+) ci rcui t.
Therefore, the LED can be i l l umi nated regardl ess of
the i gni ti on swi tch posi ti on. The LED onl y i l l umi -
nates when i t i s provi ded a path to ground by the
i nstrument cl uster transi stor. The i nstrument cl uster
wi l l turn on the front fog l amp i ndi cator for the fol -
l owi ng reasons:
Front Fog Lamp-On Message - Each ti me the
cl uster recei ves a front fog l amp-on message from the
BCM i ndi cati ng the front fog l amps are turned On,
the front fog l amp i ndi cator wi l l be i l l umi nated. The
recei ves a front fog l amp-off message from the BCM.
through the actuator test, the front fog l amp i ndi ca-
The BCM conti nual l y moni tors the exteri or l i ght-
i ng (mul ti -functi on) swi tch to determi ne the proper
outputs to the front fog l amp rel ay. The BCM then
sends the proper front fog l amp i ndi cator l amp-on
and l amp-off messages to the i nstrument cl uster. For
further di agnosi s of the front fog l amp i ndi cator or
the i nstrument cl uster ci rcui try that control s the
i ndi cator, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
proper di agnosi s of the front fog l amp system, the
BCM, the PCI data bus, or the el ectroni c message
i nputs to the i nstrument cl uster that control the
front fog l amp i ndi cator, a DRBI I I scan tool i s
requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
FUEL GAUGE
DESCRIPTION
A fuel gauge i s standard equi pment on al l i nstru-
ment cl usters. The fuel gauge i s l ocated i n the l eft
l ower corner of the i nstrument cl uster, to the l eft of
the tachometer. The fuel gauge consi sts of a movabl e
gauge needl e or poi nter control l ed by the i nstrument
cl uster ci rcui try and a fi xed 90 degree scal e on the
cl uster overl ay that reads l eft-to-ri ght from E (or
Empty) to F (or Ful l ). An I nternati onal Control and
Di spl ay Symbol i con for Fuel i s l ocated on the cl us-
ter overl ay, i n the center of the gauge di rectl y above
the hub of the gauge needl e. An arrowhead poi nted
to the l eft si de of the vehi cl e i s i mpri nted on the cl us-
ter overl ay next to the Fuel i con i n the fuel gauge
to provi de the dri ver wi th a remi nder as to the l oca-
ti on of the fuel fi l l er access. The fuel gauge graphi cs
are dark bl ue and bl ack agai nst a bei ge fi el d, except
for a si ngl e red graduati on at the far l eft (Empty)
end of the gauge scal e, maki ng them cl earl y vi si bl e
wi thi n the i nstrument cl uster i n dayl i ght. When i l l u-
mi nated from behi nd by the panel l amps di mmer
control l ed cl uster i l l umi nati on l i ghti ng wi th the exte-
ri or l amps turned On, the bl ue graphi cs appear bl ue
and the red graphi cs appear red. The orange gauge
needl e i s i nternal l y i l l umi nated. Gauge i l l umi nati on
i s provi ded by repl aceabl e i ncandescent bul b and
bul b hol der uni ts l ocated on the i nstrument cl uster
el ectroni c ci rcui t board. The fuel gauge i s servi ced as
a uni t wi th the i nstrument cl uster.
ENGINE TEMPERATURE GAUGE (Continued)
OPERATION
The fuel gauge gi ves an i ndi cati on to the vehi cl e
operator of the l evel of fuel i n the fuel tank. Thi s
gauge i s control l ed by the i nstrument cl uster ci rcui t
board based upon cl uster programmi ng and el ec-
fuel gauge i s an ai r core magneti c uni t that recei ves
battery current on the i nstrument cl uster el ectroni c
ci rcui t board through the fused i gni ti on swi tch out-
put (run-start) ci rcui t whenever the i gni ti on swi tch i s
i n the On or Start posi ti ons. The cl uster i s pro-
grammed to move the gauge needl e back to the l ow
end of the scal e after the i gni ti on swi tch i s turned to
the Off posi ti on. The i nstrument cl uster ci rcui try
control s the gauge needl e posi ti on and provi des the
fol l owi ng features:
Percent Tank Full Message - Each ti me the
cl uster recei ves a message from the PCM i ndi cati ng
the percent tank ful l , the cl uster moves the gauge
needl e to the rel ati ve fuel l evel posi ti on on the gauge
scal e. The PCM appl i es an al gori thm to the i nput
from the fuel tank sender to dampen gauge needl e
movement agai nst the negati ve effect that fuel sl osh-
i ng wi thi n the fuel tank can have on accurate i nputs
to the PCM.
Less Than 12.5 Percent Tank Full Message -
Each ti me the cl uster recei ves messages from the
PCM i ndi cati ng the percent tank ful l i s l ess than
12.5 (one-ei ghth), the gauge needl e i s moved to the
proper posi ti on on the gauge scal e and the l ow fuel
i ndi cator i s i l l umi nated. The l ow fuel i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves mes-
sages from the PCM i ndi cati ng that the percent tank
ful l i s greater than 12.5 (one-ei ghth), or unti l the
ever occurs fi rst.
Less Than Empty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves a message from
the PCM i ndi cati ng the percent tank ful l i s l ess than
empty, the gauge needl e i s moved to the far l eft (l ow)
end of the gauge scal e and the l ow fuel i ndi cator i s
i l l umi nated i mmedi atel y. Thi s message woul d i ndi -
cate that the fuel tank sender i nput to the PCM i s a
short ci rcui t.
More Than Full Percent Tank Full Message
- Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the percent tank ful l i s more than
ful l , the gauge needl e i s moved to the far l eft (l ow)
end of the gauge scal e and the l ow fuel i ndi cator i s
i l l umi nated i mmedi atel y. Thi s message woul d i ndi -
cate that the fuel tank sender i nput to the PCM i s an
open ci rcui t.
swept to the gauge cal i brati on poi nts on the gauge
scal e i n sequence i n order to confi rm the functi onal -
i ty of the gauge and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the fuel tank
sender i nput to determi ne the fuel l evel . The PCM
then appl i es an al gori thm to the i nput and sends the
proper percent tank ful l messages to the i nstrument
cl uster. For further di agnosi s of the fuel gauge or the
i nstrument cl uster ci rcui try that control s the gauge,
TER - DI AGNOSI S AND TESTI NG). For proper
di agnosi s of the fuel tank sender, the PCM, the PCI
i nstrument cl uster that control the fuel gauge, a
GATE AJ AR INDICATOR
DESCRIPTION
A gate ajar i ndi cator i s standard equi pment on al l
i nstrument cl usters. The gate ajar i ndi cator consi sts
of the word gate, whi ch appears i n pl ace of the
i t i s not i l l umi nated. The word gate appears i n the
cui t board. The gate ajar i ndi cator i s servi ced as a
OPERATION
The gate ajar i ndi cator gi ves an i ndi cati on to the
vehi cl e operator that the rear tai l gate may be open
or not compl etel y l atched. Thi s i ndi cator i s control l ed
by the i nstrument cl uster el ectroni c ci rcui t board
sages recei ved by the cl uster from the Body Control
Modul e (BCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The gate ajar i ndi ca-
tor functi on of the Vacuum Fl uorescent Di spl ay
(VFD) i s compl etel y control l ed by the i nstrument
cl uster l ogi c ci rcui t, and that l ogi c wi l l onl y al l ow
thi s i ndi cator to operate when the i nstrument cl uster
recei ves a battery current i nput on the fused i gni ti on
swi tch output (run-start) ci rcui t. Therefore, the VFD
gate ajar i ndi cator wi l l al ways be off when the i gni -
ti on swi tch i s i n any posi ti on except On or Start. The
FUEL GAUGE (Continued)
i nstrument cl uster wi l l turn on the gate ajar i ndi ca-
tor for the fol l owi ng reasons:
Gate Ajar Lamp-On Message - Each ti me the
cl uster recei ves a gate ajar l amp-on message from
the BCM i ndi cati ng that the rear tai l gate i s open or
not compl etel y l atched, the gate ajar i ndi cator wi l l be
i l l umi nated. I f the vehi cl e i s not movi ng when the
gate ajar l amp-on message i s recei ved, the VFD wi l l
repeatedl y and sequenti al l y cycl e i ts i ndi cati on i n
two second i nterval s wi th the odometer/tri p odometer
i nformati on, the gate ajar warni ng, and any other
acti ve warni ngs i ncl udi ng: door ajar, gl ass ajar, and
l ow washer fl ui d. I f the vehi cl e i s movi ng, or once the
cl uster of a non-movi ng vehi cl e recei ves an el ectroni c
vehi cl e speed message from the Powertrai n Control
Modul e (PCM) i ndi cati ng a speed greater than zero,
the warni ng sequence wi l l consi st of three compl ete
di spl ay cycl es, then revert to onl y the odometer/tri p
odometer di spl ay unti l the tai l gate ajar swi tch i s
cycl ed. The gate ajar i ndi cator wi l l al so be exti n-
gui shed when the cl uster recei ves a gate ajar l amp-
off message from the BCM, or i f the i gni ti on swi tch i s
The BCM conti nual l y moni tors the tai l gate ajar
swi tch that i s i ntegral to the tai l gate l atch to deter-
mi ne the status of the rear tai l gate. The BCM then
sends the proper gate ajar l amp-on and l amp-off mes-
sages to the i nstrument cl uster. For further di agnosi s
of the gate ajar i ndi cator or the i nstrument cl uster
ci rcui try that control s the i ndi cator, (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER - DI AGNO-
SI S AND TESTI NG). For proper di agnosi s of the tai l -
gate ajar swi tch and ci rcui t, the BCM, the PCI data
bus, or the el ectroni c message i nputs to the i nstru-
ment cl uster that control the gate ajar i ndi cator, a
GLASS AJ AR INDICATOR
DESCRIPTION
A gl ass ajar i ndi cator i s standard equi pment on al l
i nstrument cl usters. The gl ass ajar i ndi cator consi sts
of the word gl ass, whi ch appears i n pl ace of the
i t i s not i l l umi nated. The word gl ass appears i n the
cui t board. The gl ass ajar i ndi cator i s servi ced as a
OPERATION
The gl ass ajar i ndi cator gi ves an i ndi cati on to the
vehi cl e operator that the rear fl i p-up gl ass may be
open or not compl etel y l atched. Thi s i ndi cator i s con-
trol l ed by the i nstrument cl uster el ectroni c ci rcui t
Communi cati ons I nterface (PCI ) data bus. The gl ass
ajar i ndi cator functi on of the Vacuum Fl uorescent
Di spl ay (VFD) i s compl etel y control l ed by the i nstru-
the VFD gl ass ajar i ndi cator wi l l al ways be off when
the i gni ti on swi tch i s i n any posi ti on except On or
Start. The i nstrument cl uster wi l l turn on the gl ass
ajar i ndi cator for the fol l owi ng reasons:
Glass Ajar Lamp-On Message - Each ti me the
cl uster recei ves a gl ass ajar l amp-on message from
the BCM i ndi cati ng that the rear fl i p-up gl ass i s
open or not compl etel y l atched, the gl ass ajar i ndi ca-
tor wi l l be i l l umi nated. I f the vehi cl e i s not movi ng
when the gl ass ajar l amp-on message i s recei ved, the
VFD wi l l repeatedl y and sequenti al l y cycl e i ts i ndi ca-
ti on i n two second i nterval s wi th the odometer/tri p
odometer i nformati on, the gl ass ajar warni ng, and
any other acti ve warni ngs i ncl udi ng: door ajar, gate
ajar, and l ow washer fl ui d. I f the vehi cl e i s movi ng,
or once the cl uster of a non-movi ng vehi cl e recei ves
an el ectroni c vehi cl e speed message from the Power-
trai n Control Modul e (PCM) i ndi cati ng a speed
greater than zero, the warni ng sequence wi l l consi st
of three compl ete di spl ay cycl es, then revert to onl y
the odometer/tri p odometer di spl ay unti l the gl ass
ajar swi tch i s cycl ed. The gl ass ajar i ndi cator wi l l
al so be exti ngui shed when the cl uster recei ves a
gl ass ajar l amp-off message from the BCM, or i f the
ever occurs fi rst.
The BCM conti nual l y moni tors the gl ass ajar
swi tch that i s i ntegral to the fl i p-up gl ass l atch to
determi ne the status of the rear fl i p-up gl ass. The
BCM then sends the proper gl ass ajar l amp-on and
l amp-off messages to the i nstrument cl uster. For fur-
ther di agnosi s of the gl ass ajar i ndi cator or the
proper di agnosi s of the gl ass ajar swi tch and ci rcui t,
the BCM, the PCI data bus, or the el ectroni c mes-
GATE AJ AR INDICATOR (Continued)
sage i nputs to the i nstrument cl uster that control the
gl ass ajar i ndi cator, a DRBI I I scan tool i s requi red.
HIGH BEAM INDICATOR
DESCRIPTION
A hi gh beam i ndi cator l amp i s standard equi pment
on al l i nstrument cl usters. The hi gh beam i ndi cator
i s l ocated near the upper edge of the i nstrument cl us-
ter overl ay, between the tachometer and the speed-
ometer. The hi gh beam i ndi cator consi sts of a stenci l -
l i ke cutout of the I nternati onal Control and Di spl ay
Symbol i con for Hi gh Beam i n the opaque l ayer of
the i nstrument cl uster overl ay. The dark outer l ayer
of the overl ay prevents the i ndi cator from bei ng
cl earl y vi si bl e when the i t i s not i l l umi nated. A bl ue
Li ght Emi tti ng Di ode (LED) behi nd the cutout i n the
i n bl ue through the transl ucent outer l ayer of the
el ectroni c ci rcui t board. The hi gh beam i ndi cator i s
servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The hi gh beam i ndi cator gi ves an i ndi cati on to the
vehi cl e operator whenever the headl amp hi gh beams
are i l l umi nated. Thi s i ndi cator i s control l ed by a
Communi cati ons I nterface (PCI ) data bus. The hi gh
beam i ndi cator Li ght Emi tti ng Di ode (LED) i s com-
pl etel y control l ed by the i nstrument cl uster l ogi c ci r-
cui t, and that l ogi c wi l l al l ow thi s i ndi cator to
operate whenever the i nstrument cl uster recei ves a
battery current i nput on the fused B(+) ci rcui t.
Therefore, the LED can be i l l umi nated regardl ess of
the i gni ti on swi tch posi ti on. The LED onl y i l l umi -
wi l l turn on the hi gh beam i ndi cator for the fol l owi ng
reasons:
High Beam Headlamps-On Message - Each
ti me the cl uster recei ves a hi gh beam headl amps-on
message from the BCM i ndi cati ng the headl amp hi gh
beams are turned On, the hi gh beam i ndi cator wi l l
be i l l umi nated. The i ndi cator remai ns i l l umi nated
unti l the cl uster recei ves a hi gh beam headl amps-off
message from the BCM.
through the actuator test, the hi gh beam i ndi cator
outputs to the headl amp l ow beam and hi gh beam
rel ays. The BCM then sends the proper hi gh beam
i ndi cator l amp-on and l amp-off messages to the
i nstrument cl uster. For further di agnosi s of the hi gh
beam i ndi cator or the i nstrument cl uster ci rcui try
TESTI NG). For proper di agnosi s of the headl amp
system, the BCM, the PCI data bus, or the el ectroni c
the hi gh beam i ndi cator, a DRBI I I scan tool i s
mati on.
LOW FUEL INDICATOR
DESCRIPTION
A l ow fuel i ndi cator i s standard equi pment on al l
i nstrument cl usters. The l ow fuel i ndi cator i s l ocated
above the fuel gauge and to the l eft of the tachometer
i n the i nstrument cl uster. The l ow fuel i ndi cator con-
si sts of a stenci l -l i ke cutout of the I nternati onal Con-
trol and Di spl ay Symbol i con for Fuel i n the opaque
l ayer of the i nstrument cl uster overl ay. The dark
outer l ayer of the overl ay prevents the i ndi cator from
bei ng cl earl y vi si bl e when i t i s not i l l umi nated. An
amber Li ght Emi tti ng Di ode (LED) behi nd the cutout
i n the opaque l ayer of the overl ay causes the i con to
appear i n amber through the transl ucent outer l ayer
of the overl ay when i t i s i l l umi nated from behi nd by
the LED, whi ch i s sol dered onto the i nstrument cl us-
ter el ectroni c ci rcui t board. The l ow fuel i ndi cator i s
OPERATION
The l ow fuel i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the l evel of fuel i n the fuel
tank becomes l ow. Thi s i ndi cator i s control l ed by a
l ow fuel i ndi cator Li ght Emi tti ng Di ode (LED) i s
GLASS AJ AR INDICATOR (Continued)
turn on the l ow fuel i ndi cator for the fol l owi ng rea-
sons:
turned to the On posi ti on the l ow fuel i ndi cator i s
i l l umi nated for about three seconds as a bul b test.
Less Than 12.5 Percent Tank Full Message -
Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng that the percent tank ful l i s l ess
than 12.5 (one-ei ghth), the l ow fuel i ndi cator i s i l l u-
mi nated. The i ndi cator remai ns i l l umi nated unti l the
cl uster recei ves messages from the PCM i ndi cati ng
that the percent tank ful l has i ncreased to greater
than 12.5 (one-ei ghth). The PCM appl i es an al go-
ri thm to the i nput from the fuel tank sender to
dampen the i l l umi nati on of the l ow fuel i ndi cator
agai nst the negati ve effect that fuel sl oshi ng wi thi n
the fuel tank can have on accurate i nputs to the
PCM.
Less Than Empty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves a message from
the PCM i ndi cati ng the percent tank ful l i s l ess than
empty, the l ow fuel i ndi cator i s i l l umi nated i mmedi -
atel y. Thi s message woul d i ndi cate that the fuel tank
sender i nput to the PCM i s a short ci rcui t.
More Than Full Percent Tank Full Message
- Each ti me the cl uster recei ves a message from the
PCM i ndi cati ng the percent tank ful l i s more than
ful l , the l ow fuel i ndi cator i s i l l umi nated i mmedi -
atel y. Thi s message woul d i ndi cate that the fuel tank
sender i nput to the PCM i s an open ci rcui t.
Communication Error - I f the cl uster fai l s to
recei ve a percent tank ful l message for more than
about twel ve seconds, the cl uster control ci rcui try
wi l l i l l umi nate the l ow fuel i ndi cator unti l a new per-
cent tank ful l message i s recei ved, or unti l the i gni -
ti on swi tch i s turned to the Off posi ti on, whi chever
occurs fi rst.
through the actuator test, the l ow fuel i ndi cator wi l l
The PCM conti nual l y moni tors the fuel tank
sender i nput to determi ne the fuel l evel . The PCM
then appl i es an al gori thm to the i nput and sends the
proper percent tank ful l messages to the i nstrument
cl uster. For further di agnosi s of the l ow fuel i ndi cator
or the i nstrument cl uster ci rcui try that control s the
LED, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
proper di agnosi s of the fuel tank sender, the PCM,
the PCI data bus, or the el ectroni c message i nputs to
the i nstrument cl uster that control the l ow fuel i ndi -
cator, a DRBI I I scan tool i s requi red. Refer to the
LOW OIL PRESSURE
INDICATOR
DESCRIPTION
A l ow oi l pressure i ndi cator i s standard equi pment
on al l i nstrument cl usters. The l ow oi l pressure i ndi -
cator i s l ocated near the l ower edge of the i nstrument
cl uster, between the tachometer and the speedometer.
The l ow oi l pressure i ndi cator consi sts of a stenci l -
Symbol i con for Engi ne Oi l i n the opaque l ayer of
the i nstrument cl uster overl ay. The dark outer l ayer
of the overl ay prevents the i ndi cator from bei ng
el ectroni c ci rcui t board. The l ow oi l pressure i ndi ca-
tor i s servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The l ow oi l pressure i ndi cator gi ves an i ndi cati on
to the vehi cl e operator when the engi ne oi l pressure
i s l ow. Thi s i ndi cator i s control l ed by a transi stor on
the i nstrument cl uster el ectroni c ci rcui t board based
upon cl uster programmi ng and el ectroni c messages
recei ved by the cl uster from the Powertrai n Control
Modul e (PCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The l ow oi l pressure
l ow oi l pressure i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the l ow oi l pressure i ndi ca-
tor i s i l l umi nated as a bul b test. The i ndi cator wi l l
remai n i l l umi nated unti l the engi ne i s started
(engi ne speed i s greater than 450 rpm), or unti l the
ever occurs fi rst.
Engine Oil Pressure Low Message - Once the
engi ne has been started (engi ne speed has been
greater than 450 rpm), each ti me the cl uster recei ves
LOW FUEL INDICATOR (Continued)
three consecuti ve messages from the PCM i ndi cati ng
that the engi ne oi l pressure i s about 4 kPa or l ower
(about 0.6 psi or l ower), the l ow oi l pressure i ndi cator
i s i l l umi nated. The i ndi cator remai ns i l l umi nated
unti l the cl uster recei ves a si ngl e message from the
PCM i ndi cati ng that the engi ne oi l pressure i s about
76 kPa or hi gher (about 11 psi or hi gher), or unti l the
ever occurs fi rst. Once the cl uster moni tors and
engi ne speed of greater than 450 rpm, the cl uster
l ogi c wi l l i gnore engi ne speed i n determi ni ng l ow oi l
pressure i ndi cator operati on for the remai nder of the
current i gni ti on cycl e.
through the actuator test, the l ow oi l pressure i ndi -
The PCM conti nual l y moni tors the engi ne oi l pres-
sure sensor to determi ne the engi ne oi l pressure. The
PCM then sends the proper engi ne oi l pressure mes-
of the l ow oi l pressure i ndi cator or the i nstrument
cl uster ci rcui try that control s the LED, (Refer to 8 -
SI S AND TESTI NG). I f the i nstrument cl uster turns
on the i ndi cator after the bul b test, i t may i ndi cate
that the engi ne or the engi ne oi l i ng system requi res
servi ce. For proper di agnosi s of the engi ne oi l pres-
sure sensor, the PCM, the PCI data bus, or the el ec-
troni c message i nputs to the i nstrument cl uster that
control the l ow oi l pressure i ndi cator, a DRBI I I scan
tool i s requi red. Refer to the appropri ate di agnosti c
i nformati on.
MALFUNCTION INDICATOR
LAMP (MIL)
DESCRIPTION
A Mal functi on I ndi cator Lamp (MI L) i s standard
equi pment on al l i nstrument cl usters. The MI L i s
l ocated above the cool ant temperature gauge and to
the ri ght of the speedometer i n the i nstrument cl us-
ter. The MI L consi sts of a stenci l -l i ke cutout of the
Engi ne i n the opaque l ayer of the i nstrument cl us-
board. The MI L i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The Mal functi on I ndi cator Lamp (MI L) gi ves an
i ndi cati on to the vehi cl e operator when the Power-
trai n Control Modul e (PCM) has recorded a Di agnos-
ti c Troubl e Code (DTC) for an On-Board Di agnosti cs
I I (OBDI I ) emi ssi ons-rel ated ci rcui t or component
mal functi on. Thi s i ndi cator i s control l ed by a transi s-
tor on the i nstrument cl uster el ectroni c ci rcui t board
sages recei ved by the cl uster from the PCM over the
bus. The MI L Li ght Emi tti ng Di ode (LED) i s com-
pl etel y control l ed by the i nstrument cl uster l ogi c ci r-
cui t, and that l ogi c wi l l onl y al l ow thi s i ndi cator to
turn on the MI L for the fol l owi ng reasons:
turned to the On posi ti on the MI L i s i l l umi nated for
about seven seconds as a bul b test.
PCM Lamp-On Message - Each ti me the cl us-
ter recei ves a mal functi on i ndi cator l amp-on message
from the PCM, the i ndi cator wi l l be i l l umi nated. The
i ndi cator can be fl ashed on and off, or i l l umi nated
sol i d, as di ctated by the PCM message. For some
DTCs, i f a probl em does not recur, the PCM wi l l
send a l amp-off message automati cal l y. Other DTCs
may requi re that a faul t be repai red and the PCM be
reset before a l amp-off message wi l l be sent. For
more i nformati on on the PCM and the DTC set and
reset parameters, (Refer to 25 - EMI SSI ONS CON-
TROL - OPERATI ON).
no mal functi on i ndi cator l amp-on or l amp-off mes-
sage from the PCM for twenty consecuti ve seconds,
the MI L i s i l l umi nated by the i nstrument cl uster.
The i ndi cator remai ns control l ed and i l l umi nated by
the cl uster unti l a val i d mal functi on i ndi cator
l amp-on or l amp-off message i s recei ved from the
PCM.
through the actuator test, the MI L wi l l be turned on,
then off agai n duri ng the bul b check porti on of the
test to confi rm the functi onal i ty of the LED and the
cl uster control ci rcui try.
The PCM conti nual l y moni tors each of the many
fuel and emi ssi ons system ci rcui ts and sensors to
deci de whether the system i s i n good operati ng con-
LOW OIL PRESSURE INDICATOR (Continued)
di ti on. The PCM then sends the proper mal functi on
i ndi cator l amp-on or l amp-off messages to the i nstru-
ment cl uster. For further di agnosi s of the MI L or the
i nstrument cl uster ci rcui try that control s the LED,
TER - DI AGNOSI S AND TESTI NG). I f the i nstru-
ment cl uster turns on the MI L after the bul b test, i t
may i ndi cate that a mal functi on has occurred and
that the fuel and emi ssi ons system may requi re ser-
vi ce. For proper di agnosi s of the fuel and emi ssi ons
systems, the PCM, the PCI data bus, or the el ec-
control the MI L, a DRBI I I scan tool i s requi red.
ODOMETER
DESCRIPTION
An odometer and tri p odometer are standard
equi pment i n al l i nstrument cl usters. The odometer
and tri p odometer i nformati on are di spl ayed i n a
common el ectroni c, bl ue-green Vacuum Fl uorescent
Di spl ay (VFD), whi ch i s l ocated i n the l ower edge of
the speedometer di al face i n the i nstrument cl uster
and, when i l l umi nated, i s vi si bl e through a smal l
wi ndow cutout i n the cl uster overl ay. However, the
odometer and tri p odometer i nformati on are not di s-
pl ayed si mul taneousl y. The tri p odometer reset
swi tch on the i nstrument cl uster el ectroni c ci rcui t
board toggl es the di spl ay between odometer and tri p
odometer modes by depressi ng the odometer/tri p
odometer swi tch knob that extends through the l ower
edge of the cl uster l ens, just ri ght of the odometer
VFD. Both the odometer and tri p odometer i nforma-
ti on i s stored i n the i nstrument cl uster memory.
Al l odometer and tri p odometer di stance i nforma-
ti on i s stored i n the i nstrument cl uster. Thi s di stance
i nformati on can be i ncreased when the proper i nputs
are provi ded to the i nstrument cl uster, but the di s-
tance i nformati on cannot be decreased. The odometer
can di spl ay val ues up to 864,004 ki l ometers (536,870
mi l es). The odometer wi l l not rol l over, but wi l l l atch
at the maxi mum val ue. The tri p odometer can di s-
pl ay val ues up to 9999.9 ki l ometers (9999.9 mi l es)
before i t rol l s over to zero. The odometer di spl ay does
not have a deci mal poi nt and wi l l not show val ues
l ess than a ful l uni t (ki l ometer or mi l e), the tri p
odometer di spl ay does have a deci mal poi nt and wi l l
show tenths of a uni t (ki l ometer or mi l e). When the
tri p odometer i s acti ve, the word TRI P wi l l al so
i l l umi nate near the bottom of the VFD. The uni t of
measure for the odometer and tri p odometer di spl ay
i s not shown i n the VFD. I f the i nstrument cl uster
has a ki l ometers-per-hour pri mary speedometer
scal e, the odometer/tri p odometer regi sters ki l ome-
ters; and i f the cl uster features a mi l es-per-hour pri -
mary speedometer scal e, the odometer/tri p odometer
regi sters mi l es. I n thi s i nstrument cl uster, the odom-
eter/tri p odometer VFD i s al so used to di spl ay certai n
warni ng messages and di agnosti c i nformati on.
The odometer/tri p odometer has a Rental Car
mode, whi ch wi l l i l l umi nate the odometer i nforma-
ti on i n the VFD whenever the dri ver si de front door
i s opened wi th the i gni ti on swi tch i n the Off or
Accessory posi ti ons. Duri ng dayl i ght hours (exteri or
l amps Off) the VFD i s i l l umi nated at ful l bri ghtness
for cl ear vi si bi l i ty. At ni ght (exteri or l amps are On)
the i nstrument cl uster converts an el ectroni c di m-
mi ng l evel message recei ved from the Body Control
Modul e (BCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus to a di gi tal di mmi ng
l evel si gnal for control l i ng the l i ghti ng l evel of the
VFD. However, a Parade mode posi ti on of the panel
l amps di mmer control ri ng on the mul ti -functi on
swi tch l eft control stal k al l ows the VFD to be i l l umi -
nated at ful l bri ghtness i f the exteri or l amps are
turned On duri ng dayl i ght hours.
The VFD, the tri p odometer swi tch, and the tri p
odometer swi tch button are servi ced as a uni t wi th
the i nstrument cl uster.
OPERATION
The odometer and tri p odometer gi ve an i ndi cati on
to the vehi cl e operator of the di stance the vehi cl e has
travel ed. Thi s gauge i s control l ed by the i nstrument
cl uster el ectroni c ci rcui try based upon cl uster pro-
grammi ng and el ectroni c messages recei ved by the
cl uster from the Powertrai n Control Modul e (PCM)
(PCI ) data bus. The odometer and tri p odometer
i nformati on i s di spl ayed by the i nstrument cl uster
Vacuum Fl uorescent Di spl ay (VFD). The VFD wi l l
di spl ay the odometer i nformati on whenever the
dri ver si de front door i s opened wi th the i gni ti on
swi tch i n the Off or Accessory posi ti ons, and wi l l di s-
pl ay the l ast previ ousl y sel ected odometer or tri p
odometer i nformati on when the i gni ti on swi tch i s i n
the On or Start posi ti ons. The i nstrument cl uster ci r-
cui try control s the VFD and provi des the fol l owi ng
features:
Odometer/Trip Odometer Display Toggling -
Actuati ng the tri p odometer reset swi tch momen-
tari l y wi th the VFD i l l umi nated wi l l toggl e the di s-
pl ay between the odometer and tri p odometer
i nformati on. Each ti me the VFD i s i l l umi nated wi th
the i gni ti on swi tch i n the On or Start posi ti ons, the
di spl ay wi l l automati cal l y return to the l ast mode
previ ousl y sel ected (odometer or tri p odometer).
Trip Odometer Reset - When the tri p odome-
ter reset swi tch i s pressed and hel d for l onger than
about two seconds wi th the i gni ti ons swi tch i n the
MALFUNCTION INDICATOR LAMP (MIL) (Continued)
On or Start posi ti ons, the tri p odometer wi l l be reset
to 0.0 ki l ometers (mi l es). The VFD must be di spl ay-
i ng the tri p odometer i nformati on i n order for the
tri p odometer i nformati on to be reset.
Warning Display - The odometer or tri p odom-
eter i nformati on wi l l be toggl ed at two second i nter-
val s wi th a warni ng di spl ay when certai n moni tored
condi ti ons are acti ve. I f mul ti pl e condi ti ons are
acti ve, the VFD wi l l toggl e each acti ve warni ng and
the odometer/tri p odometer i nformati on at two sec-
ond i nterval s. Once the vehi cl e i s movi ng and a vehi -
cl e speed i nput i s recei ved by the i nstrument cl uster,
each acti ve warni ng wi l l be di spl ayed for three two-
second i nterval s before the VFD reverts to di spl ayi ng
onl y the sel ected odometer or tri p odometer i nforma-
ti on. The warni ngs and moni tored condi ti ons i ncl ude:
door - A door i s open or not ful l y l atched.
gate - The tai l gate i s open or not ful l y
l atched.
glass - The rear fl i p-up gl ass i s open or not
ful l y l atched.
lowash - The fl ui d l evel i n the washer reser-
voi r i s l ow.
no bus- The i nstrument cl uster can detect no
PCI bus communi cati on. Thi s message i s i l l umi nated
sol i d when there i s no PCI bus communi cati on, and
wi l l overri de the di spl ay of al l other acti ve warni ng
di spl ays.
recei ve a di stance message duri ng normal operati on,
i t wi l l hol d and di spl ay the l ast data recei ved unti l
the i gni ti on swi tch i s turned to the Off posi ti on. I f
the cl uster does not recei ve a di stance message
wi thi n one second after the i gni ti on swi tch i s turned
to the On posi ti on, i t wi l l di spl ay the l ast di stance
message stored i n the cl uster memory. I f the cl uster
i s unabl e to di spl ay di stance i nformati on due to an
error i nternal to the cl uster, error wi l l be di spl ayed
i n the VFD.
through the actuator test, the VFD wi l l step sequen-
ti al l y through a di spl ay of 111111 through 999999,
then di spl ay the cl uster software versi on number to
confi rm the functi onal i ty of the VFD and the cl uster
control ci rcui try.
The PCM conti nual l y moni tors the vehi cl e speed
pul se i nformati on recei ved from the Body Control
Modul e (BCM), then sends the proper di stance mes-
of the odometer/tri p odometer or the i nstrument cl us-
ter ci rcui try that control s these functi ons, (Refer to 8
- ELECTRI CAL/I NSTRUMENT CLUSTER - DI AG-
NOSI S AND TESTI NG). For proper di agnosi s of the
vehi cl e speed sensor, the BCM, the PCM, the PCI
i nstrument cl uster that control the odometer/tri p
odometer, a DRBI I I scan tool i s requi red. Refer to
the appropri ate di agnosti c i nformati on.
OVERDRIVE OFF INDICATOR
DESCRIPTION
An overdri ve off i ndi cator i s standard equi pment
on al l i nstrument cl usters, but i s onl y functi onal on
vehi cl es equi pped wi th the opti onal overdri ve auto-
mati c transmi ssi on. The overdri ve off i ndi cator i s
l ocated above the fuel gauge and to the l eft of the
tachometer i n the i nstrument cl uster. The overdri ve
off i ndi cator consi sts of a stenci l -l i ke cutout of the
text O/D OFF i n the opaque l ayer of the i nstrument
cl uster overl ay. The dark outer l ayer of the overl ay
prevents the i ndi cator from bei ng cl earl y vi si bl e
when i t i s not i l l umi nated. An amber Li ght Emi tti ng
the overl ay causes the O/D OFF text to appear i n
amber through the transl ucent outer l ayer of the
turned On, the i l l umi nati on i ntensi ty of the overdri ve
off i ndi cator i s di mmabl e, whi ch i s adjusted usi ng the
panel l amps di mmer control ri ng on the l eft control
stal k of the mul ti -functi on swi tch. The overdri ve off
cl uster.
OPERATION
The overdri ve off i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when the Off posi ti on of the
overdri ve off swi tch has been sel ected, di sabl i ng the
el ectroni cal l y control l ed overdri ve feature of the auto-
mati c transmi ssi on. Thi s i ndi cator i s control l ed by a
overdri ve off i ndi cator Li ght Emi tti ng Di ode (LED) i s
turn on the overdri ve off i ndi cator for the fol l owi ng
reasons:
Overdrive Off Lamp-On Message - Each ti me
the cl uster recei ves an overdri ve off l amp-on message
ODOMETER (Continued)
from the PCM i ndi cati ng that the Off posi ti on of the
overdri ve off swi tch has been sel ected, the overdri ve
off i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves an
overdri ve off l amp-off message from the PCM or unti l
the i gni ti on swi tch i s turned to the Off posi ti on,
through the actuator test, the overdri ve off i ndi cator
check porti on of the test i n order to confi rm the func-
ti onal i ty of the LED and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the overdri ve off
swi tch to determi ne the proper outputs to the auto-
mati c transmi ssi on. The PCM then sends the proper
overdri ve off l amp-on and l amp-off messages to the
i nstrument cl uster. For further di agnosi s of the over-
dri ve off i ndi cator or the i nstrument cl uster ci rcui try
TESTI NG). For proper di agnosi s of the overdri ve con-
trol system, the PCM, the PCI data bus, or the el ec-
control the overdri ve off i ndi cator, a DRBI I I scan
i nformati on.
REAR FOG LAMP INDICATOR
DESCRIPTION
A rear fog l amp i ndi cator i s standard equi pment on
al l i nstrument cl usters, but i s onl y functi onal on
vehi cl es equi pped wi th the opti onal rear fog l amps,
whi ch are avai l abl e onl y i n certai n markets where
they are requi red. The rear fog l amp i ndi cator i s
l ocated above the engi ne temperature gauge and to
ter. The rear fog l amp i ndi cator consi sts of a stenci l -
Symbol i con for Rear Fog Li ght i n the opaque l ayer
cl earl y vi si bl e when i t i s not i l l umi nated. An amber
Li ght Emi tti ng Di ode (LED) behi nd the cutout i n the
i n amber through the transl ucent outer l ayer of the
turned On, the i l l umi nati on i ntensi ty of the rear fog
l amp i ndi cator i s di mmabl e, whi ch i s adjusted usi ng
trol stal k of the mul ti -functi on swi tch. The rear fog
l amp i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The rear fog l amp i ndi cator gi ves an i ndi cati on to
the vehi cl e operator whenever the rear fog l amps are
i l l umi nated. Thi s i ndi cator i s control l ed by a transi s-
tor on the i nstrument cl uster el ectroni c ci rcui t board
messages recei ved by the cl uster from the Body Con-
trol Modul e (BCM) over the Programmabl e Commu-
ni cati ons I nterface (PCI ) data bus. The rear fog l amp
that l ogi c wi l l al l ow thi s i ndi cator to operate when-
ever the i nstrument cl uster recei ves a battery cur-
rent i nput on the fused B(+) ci rcui t. Therefore, the
LED can be i l l umi nated regardl ess of the i gni ti on
swi tch posi ti on. The LED onl y i l l umi nates when i t i s
provi ded a path to ground by the i nstrument cl uster
rear fog l amp i ndi cator for the fol l owi ng reasons:
Rear Fog Lamp-On Message - Each ti me the
cl uster recei ves a rear fog l amp-on message from the
BCM i ndi cati ng the rear fog l amps are turned On,
the rear fog l amp i ndi cator wi l l be i l l umi nated. The
recei ves a rear fog l amp-off message from the BCM.
through the actuator test, the rear fog l amp i ndi cator
outputs to the rear fog l amp rel ay. The BCM then
sends the proper rear fog l amp i ndi cator l amp-on and
l amp-off messages to the i nstrument cl uster. For fur-
ther di agnosi s of the rear fog l amp i ndi cator or the
proper di agnosi s of the rear fog l amp system, the
BCM, the PCI data bus, or the el ectroni c message
i nputs to the i nstrument cl uster that control the rear
fog l amp i ndi cator, a DRBI I I scan tool i s requi red.
SEATBELT INDICATOR
DESCRIPTION
A seatbel t i ndi cator i s standard equi pment on al l
i nstrument cl usters. The seatbel t i ndi cator i s l ocated
above the fuel gauge and to the ri ght of the tachom-
eter i n the i nstrument cl uster. The seatbel t i ndi cator
Control and Di spl ay Symbol i con for Seat Bel t i n
the opaque l ayer of the i nstrument cl uster overl ay.
OVERDRIVE OFF INDICATOR (Continued)
The dark outer l ayer of the overl ay prevents the i ndi -
cator from bei ng cl earl y vi si bl e when i t i s not i l l umi -
nated. A red Li ght Emi tti ng Di ode (LED) behi nd the
cutout i n the opaque l ayer of the overl ay causes the
i con to appear i n red through the transl ucent outer
l ayer of the overl ay when i t i s i l l umi nated from
i nstrument cl uster el ectroni c ci rcui t board. The seat-
bel t i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The seatbel t i ndi cator gi ves an i ndi cati on to the
vehi cl e operator of the status of the dri ver si de front
seatbel t. Thi s i ndi cator i s control l ed by a transi stor
on the i nstrument cl uster el ectroni c ci rcui t board
messages recei ved by the cl uster from the Ai rbag
Control Modul e (ACM) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus. The seatbel t
seatbel t i ndi cator for the fol l owi ng reasons:
Seatbelt Reminder Function - Each ti me the
i gni ti on swi tch output (run-start) ci rcui t, the i ndi ca-
tor wi l l be i l l umi nated as a seatbel t remi nder for
about seven seconds, or unti l the i gni ti on swi tch i s
Thi s remi nder functi on wi l l occur regardl ess of the
status of the el ectroni c seat bel t l amp-on or l amp-off
messages recei ved by the cl uster from the ACM.
Seat Belt Lamp-On Message - Fol l owi ng the
seatbel t remi nder functi on, each ti me the cl uster
recei ves a seat bel t l amp-on message from the ACM
i ndi cati ng the dri ver si de front seat bel t i s not fas-
tened wi th the i gni ti on swi tch i n the Start or On
posi ti ons, the i ndi cator wi l l be i l l umi nated. The seat-
bel t i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves a seat bel t l amp-off message, or unti l the
ever occurs fi rst.
through the actuator test, the seatbel t i ndi cator wi l l
The ACM conti nual l y moni tors the status of both
front seat bel t swi tches to determi ne the proper ai r-
bag system response to a frontal i mpact of the vehi -
cl e. The ACM then sends the proper seatbel t
i ndi cator l amp-on and l amp-off messages to the
i nstrument cl uster based upon the status of the
dri ver si de front seat bel t swi tch i nput. For further
di agnosi s of the seatbel t i ndi cator or the i nstrument
cl uster ci rcui try that control s the i ndi cator, (Refer to
8 - ELECTRI CAL/I NSTRUMENT CLUSTER - DI AG-
NOSI S AND TESTI NG). For proper di agnosi s of the
seatbel t swi tches, the ACM, the PCI data bus, or the
that control the seatbel t i ndi cator, a DRBI I I scan
i nformati on.
SECURITY INDICATOR
DESCRIPTION
A securi ty i ndi cator i s standard equi pment on al l
cl es equi pped wi th the opti onal Vehi cl e Theft Secu-
ri ty System (VTSS). The securi ty i ndi cator i s l ocated
near the l ower edge of the i nstrument cl uster bel ow
the tachometer and to the ri ght of the fuel gauge.
The securi ty i ndi cator consi sts of a smal l stenci l -l i ke
round cutout i n the opaque l ayer of the i nstrument
when i t i s not i l l umi nated. A red Li ght Emi tti ng
the overl ay causes the i ndi cator to appear i n red
through the transl ucent outer l ayer of the overl ay
when i t i s i l l umi nated from behi nd by the LED,
troni c ci rcui t board. The securi ty i ndi cator i s servi ced
as a uni t wi th the i nstrument cl uster.
OPERATION
The securi ty i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the Vehi cl e Theft Al arm (VTA)
porti on of the Vehi cl e Theft Securi ty System (VTSS)
i s armi ng or i s armed. Thi s i ndi cator i s control l ed on
the i nstrument cl uster ci rcui t board based upon a
hard wi red i nput to the cl uster from the Body Con-
trol Modul e (BCM) on the VTSS i ndi cator dri ver ci r-
cui t. The securi ty i ndi cator Li ght Emi tti ng Di ode
(LED) recei ves battery current on the i nstrument
cl uster el ectroni c ci rcui t board through the fused
B(+) ci rcui t at al l ti mes; therefore, the LED wi l l
remai n functi onal regardl ess of the i gni ti on swi tch
posi ti on. The LED onl y i l l umi nates when i t i s pro-
vi ded a path to ground by the BCM. The securi ty
SEATBELT INDICATOR (Continued)
i ndi cator wi l l be i l l umi nated for the fol l owi ng rea-
sons:
VTSS Indication - Duri ng the si xteen second
VTA pre-armi ng functi on, the BCM wi l l fl ash the
securi ty i ndi cator on and off repeatedl y at a steady,
fast rate to i ndi cate that the VTA i s i n the process of
armi ng. Fol l owi ng successful VTA armi ng, the BCM
fl ashes the securi ty i ndi cator on and off conti nuousl y
at a sl ower rate to i ndi cate that the VTA i s armed.
The securi ty i ndi cator conti nues fl ashi ng at the
sl ower rate unti l the VTA i s di sarmed.
The BCM provi des a hard wi red ground i nput to
the i nstrument cl uster ci rcui try through the VTSS
i ndi cator dri ver ci rcui t whenever the i gni ti on swi tch
i s i n the Off posi ti on and the VTA i s armi ng, armed,
or tri ggered. The VTSS i ndi cator dri ver ci rcui t
between the BCM and the i nstrument cl uster can be
di agnosed usi ng conventi onal di agnosti c tool s and
methods. However, for proper di agnosi s of the VTA
and the BCM, or the hard wi red i nputs to the i nstru-
ment cl uster that control the securi ty i ndi cator, a
SHIFT INDICATOR (TRANSFER
CASE)
DESCRIPTION
DESCRIPTION - PART TIME INDICATOR
A part ti me i ndi cator i s standard equi pment on al l
i nstrument cl usters. The part ti me i ndi cator i s
l ocated near the l ower edge of the tachometer di al
face i n the i nstrument cl uster. The part ti me i ndi ca-
tor consi sts of a stenci l -l i ke cutout of the words
PART TI ME i n the opaque l ayer of the i nstrument
when i t i s not i l l umi nated. An amber Li ght Emi tti ng
the overl ay causes the PART TI ME text to appear
turned On, the i l l umi nati on i ntensi ty of the part
ti me i ndi cator i s di mmabl e, whi ch i s adjusted usi ng
trol stal k of the mul ti -functi on swi tch. The part ti me
cl uster.
DESCRIPTION - FULL TIME INDICATOR
A ful l ti me i ndi cator i s standard equi pment on al l
cl es equi pped wi th the opti onal Sel ec-Trac four-wheel
dri ve system. The ful l ti me i ndi cator i s l ocated near
the l ower edge of the tachometer di al face i n the
i nstrument cl uster. The ful l ti me i ndi cator consi sts of
a stenci l -l i ke cutout of the words FULL TI ME i n
nated. A green Li ght Emi tti ng Di ode (LED) behi nd
the cutout i n the opaque l ayer of the cl uster overl ay
causes the FULL TI ME text to appear i n green
troni c ci rcui t board. When the exteri or l i ghti ng i s
turned On, the i l l umi nati on i ntensi ty of the ful l ti me
i ndi cator i s di mmabl e, whi ch i s adjusted usi ng the
panel l amps di mmer control ri ng on the l eft control
stal k of the mul ti -functi on swi tch. The ful l ti me i ndi -
cator i s servi ced as a uni t wi th the i nstrument cl us-
ter.
DESCRIPTION - FOUR LOW MODE INDICATOR
A four l ow mode i ndi cator i s standard equi pment
on al l i nstrument cl usters. The four l ow mode i ndi ca-
tor i s l ocated above the cool ant temperature gauge
and to the ri ght of the speedometer i n the i nstru-
ment cl uster. The four l ow mode i ndi cator consi sts of
a stenci l -l i ke cutout of the words 4 LO MODE i n
nated. An amber Li ght Emi tti ng Di ode (LED) behi nd
the cutout i n the opaque l ayer of the overl ay causes
the 4 LO MODE text to appear i n amber through
board. The four l ow mode i ndi cator i s servi ced as a
OPERATION
OPERATION - PART TIME INDICATOR
The part ti me i ndi cator gi ves an i ndi cati on to the
vehi cl e operator that a four-wheel dri ve part ti me
operati ng mode of the transfer case i s sel ected. On
vehi cl es equi pped wi th the standard Command-Trac
four-wheel dri ve system, the part ti me i ndi cator
l i ghts when the transfer case i s engaged i n the 4H or
4L posi ti ons. On vehi cl es equi pped wi th the opti onal
Sel ec-Trac four-wheel dri ve system, the part ti me
SECURITY INDICATOR (Continued)
i ndi cator l i ghts when the transfer case i s engaged i n
the 4 X 4 Part Ti me posi ti on. Thi s i ndi cator i s con-
trol l ed by a transi stor on the i nstrument cl uster el ec-
troni c ci rcui t board based upon the cl uster
I nterface (PCI ) data bus. The i nstrument cl uster
must be confi gured for the type of transfer case i n
the vehi cl e usi ng a DRBI I I scan tool i n order to pro-
vi de proper operati on of the part ti me i ndi cator. The
part ti me i ndi cator Li ght Emi tti ng Di ode (LED) i s
turn on the part ti me i ndi cator for the fol l owi ng rea-
sons:
Part Time Lamp-On Message - Each ti me the
cl uster recei ves a part ti me l amp-on message from
the PCM i ndi cati ng that a four-wheel dri ve part ti me
posi ti on of the transfer case has been sel ected, the
part ti me i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a part
ti me l amp-off message from the PCM or unti l the
ever occurs fi rst.
through the actuator test, the part ti me i ndi cator wi l l
The PCM conti nual l y moni tors the transfer case
swi tch to determi ne the dri vel i ne operati ng mode.
The PCM then sends the proper part ti me l amp-on
further di agnosi s of the part ti me i ndi cator or the
proper di agnosi s of the transfer case swi tch, the
PCM, the PCI data bus, or the el ectroni c message
i nputs to the i nstrument cl uster that control the part
ti me i ndi cator, a DRBI I I scan tool i s requi red. Refer
OPERATION - FULL TIME INDICATOR
The ful l ti me i ndi cator gi ves an i ndi cati on to the
vehi cl e operator that a four-wheel dri ve ful l ti me
operati ng mode of the transfer case i s sel ected. On
vehi cl es equi pped wi th the opti onal Sel ec-Trac four-
wheel dri ve system, the ful l ti me i ndi cator l i ghts
when the transfer case i s engaged i n the 4 X 4 Ful l
Ti me posi ti on. Thi s i ndi cator i s control l ed by a tran-
si stor on the i nstrument cl uster el ectroni c ci rcui t
i nstrument cl uster must be confi gured for the type of
transfer case i n the vehi cl e usi ng a DRBI I I scan
tool i n order to provi de proper operati on of the ful l
ti me i ndi cator. The ful l ti me i ndi cator Li ght Emi tti ng
Di ode (LED) i s compl etel y control l ed by the i nstru-
i s i n any posi ti on except On or Start. The LED onl y
i l l umi nates when i t i s provi ded a path to ground by
the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the ful l ti me i ndi cator for the fol -
l owi ng reasons:
Full Time Lamp-On Message - Each ti me the
cl uster recei ves a ful l ti me l amp-on message from the
PCM i ndi cati ng that a four-wheel dri ve ful l ti me
posi ti on of the transfer case has been sel ected, the
ful l ti me i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a ful l
ti me l amp-off message from the PCM or unti l the
ever occurs fi rst.
through the actuator test, the ful l ti me i ndi cator wi l l
The PCM then sends the proper ful l ti me l amp-on
further di agnosi s of the ful l ti me i ndi cator or the
proper di agnosi s of the transfer case swi tch, the
PCM, the PCI data bus, or the el ectroni c message
i nputs to the i nstrument cl uster that control the ful l
ti me i ndi cator, a DRBI I I scan tool i s requi red. Refer
OPERATION - FOUR LOW MODE INDICATOR
The four l ow mode i ndi cator gi ves an i ndi cati on to
the vehi cl e operator that a four-wheel dri ve l ow oper-
ati ng mode of the transfer case i s sel ected. On vehi -
cl es equi pped wi th the standard Command-Trac four-
SHIFT INDICATOR (TRANSFER CASE) (Continued)
wheel dri ve system, the four l ow mode i ndi cator
l i ghts when the transfer case i s engaged i n the 4L
posi ti on. On vehi cl es equi pped wi th the opti onal
Sel ec-Trac four-wheel dri ve system, the four l ow
mode i ndi cator l i ghts when the transfer case i s
engaged i n the 4 Lo posi ti on. Thi s i ndi cator i s con-
trol l ed by a transi stor on the i nstrument cl uster el ec-
troni c ci rcui t board based upon the cl uster
I nterface (PCI ) data bus. The i nstrument cl uster
must be confi gured for the type of transfer case i n
the vehi cl e usi ng a DRBI I I scan tool i n order to pro-
vi de proper operati on of the four l ow mode i ndi cator.
The four l ow mode i ndi cator Li ght Emi tti ng Di ode
(LED) i s compl etel y control l ed by the i nstrument
swi tch output (run-start) ci rcui t. Therefore, the LED
posi ti on except On or Start. The LED onl y i l l umi -
wi l l turn on the four l ow mode i ndi cator for the fol -
l owi ng reasons:
Four Low Mode Lamp-On Message - Each
ti me the cl uster recei ves a four l ow mode l amp-on
message from the PCM i ndi cati ng that a four-wheel
dri ve l ow posi ti on of the transfer case has been
sel ected, the four l ow mode i ndi cator wi l l be i l l umi -
nated. The i ndi cator remai ns i l l umi nated unti l the
cl uster recei ves a four l ow mode l amp-off message
from the PCM or unti l the i gni ti on swi tch i s turned
to the Off posi ti on, whi chever occurs fi rst.
through the actuator test, the four l ow mode i ndi ca-
The PCM then sends the proper four l ow mode
l amp-on and l amp-off messages to the i nstrument
cl uster. For further di agnosi s of the four l ow mode
i ndi cator or the i nstrument cl uster ci rcui try that con-
trol s the i ndi cator, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). For proper di agnosi s of the transfer case
swi tch, the PCM, the PCI data bus, or the el ectroni c
the four l ow mode i ndi cator, a DRBI I I scan tool i s
mati on.
SKIS INDICATOR
DESCRIPTION
A Sentry Key I mmobi l i zer System (SKI S) i ndi cator
i s standard equi pment on al l i nstrument cl usters, but
i s onl y operati onal on vehi cl es equi pped wi th the
opti onal SKI S. The SKI S i ndi cator i s l ocated above
the fuel gauge and to the l eft of the tachometer i n
the i nstrument cl uster. The SKI S i ndi cator consi sts
of a stenci l -l i ke cutout of a graphi cal representati on
or i con of a key that i s ci rcl ed and crossed-out i n the
opaque l ayer of the i nstrument cl uster overl ay. The
dark outer l ayer of the overl ay prevents the i ndi cator
from bei ng cl earl y vi si bl e when i t i s not i l l umi nated.
An amber Li ght Emi tti ng Di ode (LED) behi nd the
cutout i n the opaque l ayer of the overl ay causes the
i ndi cator to appear i n amber through the transl ucent
outer l ayer of the overl ay when i t i s i l l umi nated from
i nstrument cl uster el ectroni c ci rcui t board. The SKI S
cl uster.
OPERATION
The Sentry Key I mmobi l i zer System (SKI S) i ndi ca-
tor gi ves an i ndi cati on to the vehi cl e operator of the
status of the SKI S. Thi s i ndi cator i s control l ed by a
troni c messages recei ved by the cl uster from the Sen-
try Key I mmobi l i zer Modul e (SKI M) over the
bus. The SKI S i ndi cator Li ght Emi tti ng Di ode (LED)
i s compl etel y control l ed by the i nstrument cl uster
l ogi c ci rcui t, and that l ogi c wi l l onl y al l ow thi s i ndi -
cator to operate when the i nstrument cl uster recei ves
a battery current i nput on the fused i gni ti on swi tch
output (run-start) ci rcui t. Therefore, the LED wi l l
when i t i s swi tched to ground by the i nstrument cl us-
ter transi stor. The i nstrument cl uster wi l l turn on
the SKI S i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on, the SKI M tel l s the cl uster
to i l l umi nate the SKI S i ndi cator for about three sec-
onds as a bul b test.
SKIS Lamp-On Message - Each ti me the cl us-
ter recei ves a SKI S l amp-on message from the SKI M,
the SKI S i ndi cator wi l l be i l l umi nated. The i ndi cator
can be fl ashed on and off, or i l l umi nated sol i d, as di c-
tated by the SKI M message. For more i nformati on on
the SKI S and the SKI S i ndi cator control parameters,
(Refer to 8 - ELECTRI CAL/VEHI CLE THEFT SECU-
RI TY - OPERATI ON). The i ndi cator remai ns i l l umi -
nated unti l the cl uster recei ves a SKI S l amp-off
SHIFT INDICATOR (TRANSFER CASE) (Continued)
message from the SKI M or unti l the i gni ti on swi tch
i s turned to the Off posi ti on, whi chever occurs fi rst.
no SKI S l amp-on or l amp-off messages from the
SKI M for twenty consecuti ve seconds, the SKI S i ndi -
cator i s i l l umi nated by the i nstrument cl uster. The
i ndi cator remai ns control l ed and i l l umi nated by the
cl uster unti l a val i d SKI S l amp-on or l amp-off mes-
sage i s recei ved from the SKI M.
through the actuator test, the SKI S i ndi cator wi l l be
ti on of the test to confi rm the functi onal i ty of the
The SKI M performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the On posi ti on to deci de
whether the system i s i n good operati ng condi ti on
and whether a val i d key i s present i n the i gni ti on
l ock cyl i nder. The SKI M then sends the proper SKI S
l amp-on or l amp-off messages to the i nstrument cl us-
ter. For further di agnosi s of the SKI S i ndi cator or the
CLUSTER - DI AGNOSI S AND TESTI NG). I f the
i nstrument cl uster fl ashes the SKI S i ndi cator upon
i gni ti on On, or turns on the SKI S i ndi cator sol i d
after the bul b test, i t i ndi cates that a SKI S mal func-
ti on has occurred or that the SKI S i s i noperati ve. For
proper di agnosi s of the SKI S, the PCI data bus, or
the el ectroni c message i nputs to the i nstrument cl us-
ter that control the SKI S i ndi cator, a DRBI I I scan
i nformati on.
SPEEDOMETER
DESCRIPTION
A speedometer i s standard equi pment on al l i nstru-
ment cl usters. The speedometer i s l ocated to the
ri ght of the tachometer i n the i nstrument cl uster.
The speedometer consi sts of a movabl e gauge needl e
or poi nter control l ed by the i nstrument cl uster ci r-
cui try, and a fi xed 255 degree pri mary scal e on the
gauge di al face that reads l eft-to-ri ght ei ther from 0
to 120 mph, or from 0 to 240 km/h, dependi ng upon
the market for whi ch the vehi cl e i s manufactured.
Most model s al so have a smal l er secondary i nner
scal e on the gauge di al face that provi des the equi v-
al ent opposi te measurement uni ts from the pri mary
scal e. Text appeari ng on the cl uster overl ay just
bel ow the hub of the speedometer needl e abbrevi ates
the uni t of measure for the pri mary scal e fi rst (i .e.:
MPH or km/h), fol l owed by the uni t of measure for
the secondary scal e (i .e.: MPH or km/h). The speed-
ometer graphi cs are dark bl ue (pri mary scal e) and
l i ght bl ue (secondary scal e) agai nst a bei ge fi el d,
maki ng them cl earl y vi si bl e wi thi n the i nstrument
cl uster i n dayl i ght. When i l l umi nated from behi nd by
the panel l amps di mmer control l ed cl uster i l l umi na-
ti on l i ghti ng wi th the exteri or l amps turned On, both
the dark bl ue and l i ght bl ue graphi cs retai n thei r
bl ue col ors. The orange gauge needl e i s i nternal l y
i l l umi nated. Gauge i l l umi nati on i s provi ded by
repl aceabl e i ncandescent bul b and bul b hol der uni ts
l ocated on the i nstrument cl uster el ectroni c ci rcui t
board. The speedometer i s servi ced as a uni t wi th the
OPERATION
The speedometer gi ves an i ndi cati on to the vehi cl e
operator of the vehi cl e road speed. Thi s gauge i s con-
trol l ed by the i nstrument cl uster el ectroni c ci rcui t
speedometer i s an ai r core magneti c uni t that
recei ves battery current on the i nstrument cl uster
el ectroni c ci rcui t board through the fused i gni ti on
swi tch output (run-start) ci rcui t whenever the i gni -
ti on swi tch i s i n the On or Start posi ti ons. The cl us-
ter i s programmed to move the gauge needl e back to
the l ow end of the scal e after the i gni ti on swi tch i s
turned to the Off posi ti on. The i nstrument cl uster
ci rcui try control s the gauge needl e posi ti on and pro-
vi des the fol l owi ng features:
Vehicle Speed Message - Each ti me the cl us-
ter recei ves a vehi cl e speed message from the PCM i t
wi l l cal cul ate the correct vehi cl e speed readi ng and
posi ti on the gauge needl e at that speed posi ti on on
the gauge scal e. The cl uster wi l l recei ve a new vehi -
cl e speed message and reposi ti on the gauge poi nter
accordi ngl y about every 86 mi l l i seconds. The gauge
needl e wi l l conti nue to be posi ti oned at the actual
vehi cl e speed posi ti on on the gauge scal e unti l the
i gni ti on swi tch i s turned to the Off posi ti on.
recei ve a speedometer message, i t wi l l hol d the gauge
needl e at the l ast i ndi cati on for about si x seconds, or
whi chever occurs fi rst. I f a new speed message i s not
recei ved after about si x seconds, the gauge needl e
wi l l return to the far l eft (l ow) end of the scal e.
swept to several cal i brati on poi nts on the gauge scal e
i n sequence i n order to confi rm the functi onal i ty of
the gauge and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the vehi cl e speed
i nformati on recei ved from the Body Control Modul e
(BCM) to determi ne the vehi cl e road speed, then
SKIS INDICATOR (Continued)
sends the proper vehi cl e speed messages to the
i nstrument cl uster. For further di agnosi s of the
speedometer or the i nstrument cl uster ci rcui try that
control s the gauge, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG). For proper di agnosi s of the BCM, the PCM, the
PCI data bus, or the el ectroni c message i nputs to the
i nstrument cl uster that control the speedometer, a
TACHOMETER
DESCRIPTION
A tachometer i s standard equi pment on al l i nstru-
ment cl usters. The tachometer i s l ocated to the l eft of
the speedometer i n the i nstrument cl uster. The
tachometer consi sts of a movabl e gauge needl e or
poi nter control l ed by the i nstrument cl uster ci rcui try,
and a fi xed 255 degree scal e on the gauge di al face
that reads l eft-to-ri ght from 0 to 7 for gasol i ne
engi nes, or from 0 to 5 for di esel engi nes. The text
RPM X 1000 i mpri nted on the cl uster overl ay
di rectl y bel ow the hub of the tachometer needl e i den-
ti fi es that each number on the tachometer scal e i s to
be mul ti pl i ed by 1000 rpm. The gasol i ne engi ne
tachometer has a red zone begi nni ng at 5800 RPM,
whi l e the red zone for the di esel engi ne tachometer
begi ns at 4300 RPM. The tachometer graphi cs are
dark bl ue and red agai nst a bei ge fi el d, maki ng them
cl earl y vi si bl e wi thi n the i nstrument cl uster i n day-
l i ght. When i l l umi nated from behi nd by the panel
l amps di mmer control l ed cl uster i l l umi nati on l i ghti ng
wi th the exteri or l amps turned On, the dark bl ue
graphi cs appear bl ue and the red graphi cs appear
red. The orange gauge needl e i s i nternal l y i l l umi -
nated. Gauge i l l umi nati on i s provi ded by repl aceabl e
i ncandescent bul b and bul b hol der uni ts l ocated on
the i nstrument cl uster el ectroni c ci rcui t board. The
tachometer i s servi ced as a uni t wi th the i nstrument
cl uster.
OPERATION
The tachometer gi ves an i ndi cati on to the vehi cl e
operator of the engi ne speed. Thi s gauge i s control l ed
by the i nstrument cl uster el ectroni c ci rcui t board
sages recei ved by the cl uster from the Powertrai n
muni cati ons I nterface (PCI ) data bus. The tachome-
ter i s an ai r core magneti c uni t that recei ves battery
current on the i nstrument cl uster el ectroni c ci rcui t
board through the fused i gni ti on swi tch output (run-
start) ci rcui t whenever the i gni ti on swi tch i s i n the
On or Start posi ti ons. The cl uster i s programmed to
move the gauge needl e back to the l ow end of the
scal e after the i gni ti on swi tch i s turned to the Off
posi ti on. The i nstrument cl uster ci rcui try control s
the gauge needl e posi ti on and provi des the fol l owi ng
features:
Engine Speed Message - Each ti me the cl uster
recei ves an engi ne speed message from the PCM i t
wi l l cal cul ate the correct engi ne speed readi ng and
posi ti on the gauge needl e at that speed posi ti on on
the gauge scal e. The cl uster wi l l recei ve a new
engi ne speed message and reposi ti on the gauge
poi nter accordi ngl y about every 86 mi l l i seconds. The
gauge needl e wi l l conti nue to be posi ti oned at the
actual engi ne speed posi ti on on the gauge scal e unti l
the i gni ti on swi tch i s turned to the Off posi ti on.
recei ve an engi ne speed message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on for about si x sec-
onds, or unti l the i gni ti on swi tch i s turned to the Off
posi ti on, whi chever occurs fi rst. I f a new engi ne
speed message i s not recei ved after about si x sec-
onds, the gauge needl e wi l l return to the far l eft
(l ow) end of the scal e.
swept to several cal i brati on poi nts on the gauge scal e
i n sequence i n order to confi rm the functi onal i ty of
the gauge and the cl uster control ci rcui try.
The PCM conti nual l y moni tors the crankshaft posi -
ti on sensor to determi ne the engi ne speed, then
sends the proper engi ne speed messages to the
tachometer or the i nstrument cl uster ci rcui try that
control s the gauge, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG). For proper di agnosi s of the crankshaft posi ti on
sensor, the PCM, the PCI data bus, or the el ectroni c
the tachometer, a DRBI I I scan tool i s requi red.
TRANS TEMP INDICATOR
DESCRIPTION
A transmi ssi on over-temperature i ndi cator i s stan-
dard equi pment on al l i nstrument cl usters, but i s
onl y functi onal on vehi cl es equi pped wi th an opti onal
automati c transmi ssi on. The transmi ssi on over-tem-
perature i ndi cator i s l ocated near the l ower edge of
the i nstrument cl uster, between the tachometer and
the speedometer. The transmi ssi on over-temperature
i ndi cator consi sts of a stenci l -l i ke cutout of the words
TRANS TEMP i n the opaque l ayer of the i nstru-
SPEEDOMETER (Continued)
i bl e when i t i s not i l l umi nated. An amber Li ght
opaque l ayer of the overl ay causes the TRANS
TEMP text to appear i n amber through the transl u-
cent outer l ayer of the overl ay when the i ndi cator i s
board. The transmi ssi on over-temperature i ndi cator
i s servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The transmi ssi on over-temperature i ndi cator gi ves
an i ndi cati on to the vehi cl e operator when the trans-
mi ssi on fl ui d temperature i s excessi ve, whi ch may
l ead to accel erated transmi ssi on component wear or
fai l ure. Thi s i ndi cator i s control l ed by a transi stor on
the i nstrument cl uster el ectroni c ci rcui t board based
upon the cl uster programmi ng and el ectroni c mes-
muni cati ons I nterface (PCI ) data bus. The transmi s-
si on over-temperature i ndi cator Li ght Emi tti ng Di ode
(LED) i s compl etel y control l ed by the i nstrument
swi tch output (run-start) ci rcui t. Therefore, the LED
posi ti on except On or Start. The LED onl y i l l umi -
wi l l turn on the transmi ssi on over-temperature i ndi -
cator for the fol l owi ng reasons:
turned to the On posi ti on the transmi ssi on over-tem-
perature i ndi cator i s i l l umi nated for about three sec-
onds as a bul b test.
Trans Over-Temp Lamp-On Message - Each
ti me the cl uster recei ves a trans over-temp l amp-on
message from the PCM i ndi cati ng that the transmi s-
si on fl ui d temperature i s 135 C (275 F) or hi gher,
the i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a trans
over-temp l amp-off message from the PCM, or unti l
the i gni ti on swi tch i s turned to the Off posi ti on,
through the actuator test, the trans over-temp i ndi -
The PCM conti nual l y moni tors the transmi ssi on
temperature sensor to determi ne the transmi ssi on
operati ng condi ti on. The PCM then sends the proper
trans over-temp l amp-on and l amp-off messages to
the i nstrument cl uster. I f the i nstrument cl uster
turns on the transmi ssi on over-temperature i ndi cator
due to a hi gh transmi ssi on oi l temperature condi ti on,
i t may i ndi cate that the transmi ssi on and/or the
transmi ssi on cool i ng system are bei ng overl oaded or
that they requi re servi ce. For further di agnosi s of the
transmi ssi on over-temperature i ndi cator or the
proper di agnosi s of the transmi ssi on temperature
sensor, the PCM, the PCI data bus, or the el ectroni c
the transmi ssi on over-temperature i ndi cator, a
TURN SIGNAL INDICATOR
DESCRIPTION
Two turn si gnal i ndi cators, one ri ght and one l eft,
are standard equi pment on al l i nstrument cl usters.
The turn si gnal i ndi cators are l ocated near the upper
edge of the i nstrument cl uster, between the speedom-
eter and the tachometer. Each turn si gnal i ndi cator
Control and Di spl ay Symbol i con for Turn Warni ng
i n the opaque l ayer of the i nstrument cl uster overl ay.
The dark outer l ayer of the overl ay prevents these
i cons from bei ng cl earl y vi si bl e when they are not
i l l umi nated. A green Li ght-Emi tti ng Di ode (LED)
behi nd each cutout i n the opaque l ayer of the cl uster
overl ay causes the i ndi cator to appear i n green
troni c ci rcui t board. The turn si gnal i ndi cators are
OPERATION
The turn si gnal i ndi cators gi ve an i ndi cati on to the
vehi cl e operator that the turn si gnal (l eft or ri ght
i ndi cator fl ashi ng) or hazard warni ng (both l eft and
ri ght i ndi cators fl ashi ng) have been sel ected and are
operati ng. These i ndi cators are control l ed by two
i ndi vi dual hard wi red i nputs from the combi nati on
fl asher ci rcui try wi thi n the hazard swi tch to the
i nstrument cl uster el ectroni c ci rcui t board. Each turn
si gnal i ndi cator Li ght Emi tti ng Di ode (LED) i s
grounded on the i nstrument cl uster el ectroni c ci rcui t
board at al l ti mes; therefore, these i ndi cators remai n
functi onal regardl ess of the i gni ti on swi tch posi ti on.
Each LED wi l l onl y i l l umi nate when i t i s provi ded
battery current by the combi nati on fl asher ci rcui try
of the hazard swi tch.
TRANS TEMP INDICATOR (Continued)
The turn si gnal i ndi cators are connected i n paral l el
wi th the other turn si gnal ci rcui ts. Thi s arrangement
al l ows the turn si gnal i ndi cators to remai n func-
ti onal , regardl ess of the condi ti on of the other ci r-
cui ts i n the turn si gnal and hazard warni ng systems.
The combi nati on fl asher outputs of the hazard swi tch
to the i nstrument cl uster turn si gnal i ndi cator i nputs
can be di agnosed usi ng conventi onal di agnosti c tool s
and methods. (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/HAZARD SWI TCH -
DESCRI PTI ON) for more i nformati on on the combi -
nati on fl asher and hazard swi tch operati on.
WAIT-TO-START INDICATOR
DESCRIPTION
A wai t-to-start i ndi cator i s onl y found i n the
i nstrument cl usters of vehi cl es equi pped wi th an
opti onal di esel engi ne. The wai t-to-start i ndi cator i s
l ocated above the fuel gauge and to the l eft of the
tachometer i n the i nstrument cl uster. The wai t-to-
start i ndi cator consi sts of a stenci l -l i ke cutout of the
Di esel Preheat i n the opaque l ayer of the i nstru-
i bl e when i t i s not i l l umi nated. An amber Li ght
el ectroni c ci rcui t board. The wai t-to-start i ndi cator i s
OPERATION
The wai t-to-start i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when the di esel engi ne gl ow
pl ugs are energi zed i n thei r pre-heat operati ng mode.
Thi s i ndi cator i s control l ed by a transi stor on the
i nstrument cl uster el ectroni c ci rcui t board based
upon the cl uster programmi ng and el ectroni c mes-
muni cati ons I nterface (PCI ) data bus. The wai t-to-
start i ndi cator Li ght Emi tti ng Di ode (LED) i s
turn on the wai t-to-start i ndi cator for the fol l owi ng
reasons:
Wait-To-Start Lamp-On Message - Each ti me
the cl uster recei ves a wai t-to-start l amp-on message
from the PCM i ndi cati ng the gl ow pl ugs are heati ng
and the dri ver must wai t to start the engi ne, the
wai t-to-start i ndi cator wi l l be i l l umi nated. The i ndi -
cator remai ns i l l umi nated unti l the cl uster recei ves a
wai t-to-start l amp-off message, or unti l the i gni ti on
fi rst.
through the actuator test, the wai t-to-start i ndi cator
The PCM conti nual l y moni tors the ambi ent tem-
perature and the gl ow pl ug pre-heater ci rcui ts to
determi ne how l ong the gl ow pl ugs must be heated i n
the pre-heat operati ng mode. The PCM then sends
the proper wai t-to-start l amp-on and l amp-off mes-
of the wai t-to-start i ndi cator or the i nstrument cl us-
ter ci rcui try that control s the i ndi cator, (Refer to 8 -
SI S AND TESTI NG). For proper di agnosi s of the
gl ow pl ug pre-heater control ci rcui ts, the PCM, the
PCI data bus, or the el ectroni c message i nputs to the
i nstrument cl uster that control the wai t-to-start i ndi -
cator, a DRBI I I scan tool i s requi red. Refer to the
WASHER FLUID INDICATOR
DESCRIPTION
A washer fl ui d i ndi cator i s standard equi pment on
al l i nstrument cl usters. The washer fl ui d i ndi cator
consi sts of the text l owash, whi ch appears i n pl ace
of the odometer/tri p odometer i nformati on i n the Vac-
uum-Fl uorescent Di spl ay (VFD) of the i nstrument
cl uster. The VFD i s part of the cl uster el ectroni c ci r-
cui t board, and i s vi si bl e through a cutout l ocated
near the l ower edge of the speedometer di al face i n
the i nstrument cl uster. The dark outer l ayer of the
overl ay prevents the VFD from bei ng cl earl y vi si bl e
when i t i s not i l l umi nated. The text message
l owash appears i n the same bl ue-green col or and at
the same l i ghti ng l evel as the odometer/tri p odometer
i nformati on through the transl ucent outer l ayer of
the overl ay when i t i s i l l umi nated by the i nstrument
cl uster el ectroni c ci rcui t board. The washer fl ui d
cl uster.
TURN SIGNAL INDICATOR (Continued)
OPERATION
The washer fl ui d i ndi cator gi ves an i ndi cati on to
the vehi cl e operator that the fl ui d l evel i n the washer
reservoi r i s l ow. Thi s i ndi cator i s control l ed by the
i nstrument cl uster el ectroni c ci rcui t board based
upon cl uster programmi ng and a hard wi red i nput
recei ved by the cl uster from the washer fl ui d l evel
swi tch mounted on the washer reservoi r. The washer
fl ui d i ndi cator functi on of the Vacuum Fl uorescent
Di spl ay (VFD) i s compl etel y control l ed by the i nstru-
i s i n any posi ti on except On or Start. The i nstrument
cl uster wi l l turn on the washer fl ui d i ndi cator for the
fol l owi ng reasons:
Washer Fluid Level Switch Input - Each ti me
the cl uster detects ground on the l ow washer fl ui d
sense ci rcui t (washer fl ui d l evel swi tch cl osed =
washer fl ui d l evel l ow) the cl uster appl i es an al go-
ri thm to confi rm that the i nput i s correct and not the
resul t of fl ui d sl oshi ng i n the washer reservoi r. The
cl uster tests the status of the ci rcui t about seven mi l -
l i seconds after i gni ti on On, and about once every sec-
ond thereafter, then uses an i nternal counter to
count up or down. When the counter accumul ates
thi rty ground i nputs on the ci rcui t, the washer fl ui d
i ndi cator wi l l be i l l umi nated. I f the vehi cl e i s not
movi ng when the washer fl ui d l evel swi tch i nput
counter reaches thi rty, the VFD wi l l repeatedl y and
sequenti al l y cycl e i ts i ndi cati on i n two second i nter-
val s wi th the odometer/tri p odometer i nformati on,
the l ow washer fl ui d warni ng, and any other acti ve
warni ngs i ncl udi ng: door ajar, gate ajar, and gl ass
ajar. I f the vehi cl e i s movi ng, or once the cl uster of a
non-movi ng vehi cl e recei ves an el ectroni c vehi cl e
speed message from the Powertrai n Control Modul e
(PCM) i ndi cati ng a speed greater than zero, the
warni ng sequence wi l l consi st of three compl ete di s-
pl ay cycl es, then revert to onl y the odometer/tri p
odometer di spl ay. Once the washer fl ui d i ndi cator
warni ng has compl eted, the washer fl ui d i ndi cator i s
exti ngui shed and wi l l not repeat unti l the i gni ti on
swi tch i s cycl ed.
The i nstrument cl uster conti nual l y moni tors the
washer fl ui d l evel swi tch i n the washer reservoi r to
determi ne the status of the washer fl ui d l evel . For
further di agnosi s of the washer fl ui d i ndi cator or the
CLUSTER - DI AGNOSI S AND TESTI NG). The
washer fl ui d l evel swi tch and ci rcui ts can be di ag-
ods. The washer fl ui d l evel swi tch al so features a 3.3
ki l ohm di agnosti c resi stor connected i n paral l el
between the swi tch i nput and output to provi de the
cl uster wi th veri fi cati on that the l ow washer fl ui d
sense ci rcui t i s not open or shorted. Thi s i nput can
be moni tored usi ng a DRBI I I scan tool . Refer to the
DIAGNOSIS AND TESTING - WASHER FLUID
INDICATOR
The di agnosi s found here addresses an i noperati ve
washer fl ui d i ndi cator condi ti on. I f the probl em bei ng
di agnosed i s rel ated to i ndi cator accuracy, be certai n
to confi rm that the probl em i s wi th the i ndi cator or
washer fl ui d l evel swi tch i nput and not wi th a dam-
aged or empty washer fl ui d reservoi r, or i noperati ve
i nstrument cl uster i ndi cator control ci rcui try. I nspect
the washer fl ui d reservoi r for proper fl ui d l evel and
si gns of damage or di storti on that coul d affect
washer fl ui d l evel swi tch performance and perform
the i nstrument cl uster actuator test before you pro-
ceed wi th the fol l owi ng di agnosi s. I f no washer fl ui d
reservoi r or i nstrument cl uster control ci rcui try prob-
l em i s found, the fol l owi ng procedure wi l l hel p to
l ocate a short or open i n the washer fl ui d swi tch
sense ci rcui t. Refer to the appropri ate wi ri ng i nfor-
detai l s of wi re harness routi ng and retenti on, connec-
tor pi n-out i nformati on and l ocati on vi ews for the
PERSONAL INJURY.
INDICATOR DOES NOT ILLUMINATE WITH WASHER
RESERVOIR EMPTY
cabl e. Di sconnect the headl amp and dash wi re har-
ness connector for the washer fl ui d l evel swi tch from
the washer fl ui d l evel swi tch connector receptacl e.
WASHER FLUID INDICATOR (Continued)
i ty of the headl amp and dash wi re harness connector
for the washer fl ui d l evel swi tch and a good ground.
OK, repai r the open ground ci rcui t to ground (G111)
as requi red.
ment panel . Check for conti nui ty between the washer
fl ui d sense ci rcui t cavi ti es of the headl amp and dash
wi re harness connector for the washer fl ui d l evel
swi tch and the i nstrument panel wi re harness con-
nector (Connector C2) for the i nstrument cl uster. I f
OK, repl ace the faul ty washer fl ui d l evel swi tch. I f
not OK, repai r the open washer fl ui d swi tch sense
ci rcui t between the washer fl ui d l evel swi tch and the
i nstrument cl uster as requi red.
INDICATOR STAYS ILLUMINATED WITH WASHER
RESERVOIR FULL
cabl e. Di sconnect the headl amp and dash wi re har-
the washer fl ui d l evel swi tch connector receptacl e.
Check for conti nui ty between the ground ci rcui t ter-
mi nal and the washer fl ui d sense termi nal i n the
washer fl ui d l evel swi tch connector receptacl e. There
shoul d be no conti nui ty. I f OK, go to Step 2. I f not
OK, repl ace the faul ty washer fl ui d l evel swi tch.
ment panel . Check for conti nui ty between the washer
fl ui d sense ci rcui t cavi ty of the headl amp and dash
wi re harness connector for the washer fl ui d l evel
swi tch and a good ground. There shoul d be no conti -
nui ty. I f not OK, repai r the shorted washer fl ui d
swi tch sense ci rcui t between the washer fl ui d l evel
swi tch and the i nstrument cl uster as requi red.
WATER-IN-FUEL INDICATOR
DESCRIPTION
A water-i n-fuel i ndi cator i s onl y found i n the
i nstrument cl usters of vehi cl es equi pped wi th an
opti onal di esel engi ne. The water-i n-fuel i ndi cator i s
l ocated above the cool ant temperature gauge and to
ter. The water-i n-fuel i ndi cator consi sts of a stenci l -
Symbol i con for Water I n Fuel i n the opaque l ayer
overl ay when the i ndi cator i s i l l umi nated from
i nstrument cl uster el ectroni c ci rcui t board. The
water-i n-fuel i ndi cator i s servi ced as a uni t wi th the
OPERATION
The water-i n-fuel i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when there i s excessi ve water i n
the fuel system. Thi s i ndi cator i s control l ed by a
water-i n-fuel i ndi cator Li ght Emi tti ng Di ode (LED) i s
turn on the water-i n-fuel i ndi cator for the fol l owi ng
reasons:
turned to the On posi ti on the water-i n-fuel i ndi cator
i s i l l umi nated for about three seconds as a bul b test.
Water-In-Fuel Lamp-On Message - Each ti me
the cl uster recei ves a water-i n-fuel l amp-on message
from the PCM i ndi cati ng there i s excessi ve water i n
the di esel fuel system, the water-i n-fuel i ndi cator wi l l
be i l l umi nated. The i ndi cator remai ns i l l umi nated
unti l the cl uster recei ves a water-i n-fuel l amp-off
message, or unti l the i gni ti on swi tch i s turned to the
Off posi ti on, whi chever occurs fi rst.
through the actuator test, the water-i n-fuel i ndi cator
The PCM conti nual l y moni tors the water-i n-fuel
sensor to determi ne whether there i s excessi ve water
i n the di esel fuel . The PCM then sends the proper
water-i n-fuel l amp-on and l amp-off messages to the
water-i n-fuel i ndi cator or the i nstrument cl uster ci r-
cui try that control s the i ndi cator, (Refer to 8 - ELEC-
AND TESTI NG). For proper di agnosi s of the water-
i n-fuel -sensor, the PCM, the PCI data bus, or the
that control the water-i n-fuel i ndi cator, a DRBI I I
scan tool i s requi red. Refer to the appropri ate di ag-
nosti c i nformati on.
WASHER FLUID INDICATOR (Continued)
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . . . 1 LAMPS/LIGHTING - INTERIOR. . . . . . . . . . . . . . . 65
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - LAMPS/
LIGHTING - EXTERIOR . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS - LAMPS/LIGHTING -
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BACKUP LAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - BACKUP LAMP
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BRAKE LAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
CENTER HIGH MOUNTED STOP LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
COMBINATION FLASHER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DAYTIME RUNNING LAMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT FOG LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
FRONT FOG LAMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING - FRONT FOG
LAMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
FRONT FOG LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
ADJUSTMENTS
ADJUSTMENT - FRONT FOG LAMP UNIT . . . 25
FRONT LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
FRONT LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
FRONT POSITION LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
HAZARD SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
HEADLAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
HEADLAMP HIGH BEAM RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSIS AND TESTING - HEADLAMP
HIGH BEAM RELAY . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
KJ LAMPS 8L - 1
HEADLAMP LEVELING MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
HEADLAMP LEVELING SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
LEVELING SWITCH . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
HEADLAMP LOW BEAM RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DIAGNOSIS AND TESTING - HEADLAMP LOW
BEAM RELAY . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
HEADLAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
ADJUSTMENTS
ADJUSTMENT - HEADLAMP UNIT . . . . . . . . 42
LICENSE PLATE LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
LICENSE PLATE LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
MULTI-FUNCTION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53
PARK LAMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DIAGNOSIS AND TESTING - PARK LAMP
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56
REAR FOG LAMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DIAGNOSIS AND TESTING - REAR FOG
LAMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 57
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
REAR LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
REAR LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
REPEATER LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
REPEATER LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
TRAILER TOW CONNECTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
TRAILER TOW RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DIAGNOSIS AND TESTING - TRAILER TOW
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
TRAILER TOW WIRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 64
DESCRIPTION
The exteri or l i ghti ng system for thi s model
i ncl udes the fol l owi ng exteri or l amps (Fi g. 1):
Backup Lamps - The backup (or reverse) l amps
are i ntegral to the rear l amp uni ts mounted to the
back of the quarter panel on each si de of the tai l gate
at the rear of the vehi cl e.
Brake Lamps - The brake (or stop) l amps
i ncl ude a l amp that i s i ntegral to the rear l amp uni ts
mounted to the back of the quarter panel on each
si de of the tai l gate, and the Center Hi gh Mounted
Stop Lamp (CHMSL) that i s centered on the rear
edge of the roof panel above the fl i p-up gl ass openi ng
Daytime Running Lamps - Vehi cl es manufac-
tured for sal e i n Canada i l l umi nate the hi gh beam
fi l ament i n each headl amp bul b serves as the Day-
ti me Runni ng Lamps (DRL).
Front Fog Lamps - Opti onal front fog l amps
i ncl ude a si ngl e round front fog l amp uni t wi th an
adjustabl e refl ector and a removabl e bul b that i s
secured behi nd a dedi cated openi ng on each forward-
faci ng end of the front bumper fasci a.
Hazard Warning Lamps - The hazard warni ng
l amps i ncl ude al l of the ri ght and l eft turn si gnal
l amps.
Headlamps - A si ngl e round headl amp housi ng
wi th a fi xed l ens, an adjustabl e refl ector, and a si ngl e
removabl e hal ogen bul b i s secured to the gri l l e open-
i ng panel on each si de of the gri l l e openi ng at the
8L - 2 LAMPS/LIGHTING - EXTERIOR KJ
Fig. 1 Exterior Lamps
KJ LAMPS/LIGHTING - EXTERIOR 8L - 3
LAMPS/LIGHTING - EXTERIOR (Continued)
front of the vehi cl e. I n certai n markets where
requi red, a headl amp l evel i ng actuator motor i s
i ncl uded on each headl amp.
Park Lamps - The park l amps i ncl ude the front
park l amps and front si de marker l amps that are
i ntegral to the front l amp uni ts mounted at each end
of the bumper fasci a at the front of the vehi cl e, as
wel l as the rear park l amps and rear si de marker
l amps that are i ntegral to the rear l amp uni ts
si de of the tai l gate at the rear of the vehi cl e. The
park l amps i ncl ude a l i cense pl ate l amp or l amps,
dependi ng upon the requi rements of the market for
whi ch the vehi cl e i s manufactured. Vehi cl es wi th a
l i cense pl ate tub l ocated near the l eft end of the rear
bumper fasci a have a si ngl e l amp, whi l e vehi cl es
wi th a l i cense pl ate modul e l ocated on the spare ti re
carri er have two l i cense pl ate l amps. I n certai n mar-
kets where requi red, a front posi ti on l amp that i s
i ntegral to each headl amp uni t i s i l l umi nated i nstead
of the front park l amps and front si de marker l amps
i n the park l amps ci rcui t; and, a rectangul ar, red
refl ector i s l ocated on the rear bumper fasci a just
i nboard and bel ow each rear l amp uni t.
Rear Fog Lamps - Rear fog l amps are avai l -
abl e onl y i n certai n markets where they are requi red
equi pment. The rear fog l amps are i ntegral to the
rear l amp uni ts mounted to the back of the quarter
panel on each si de of the tai l gate at the rear of the
vehi cl e.
Turn Signal Lamps - The turn si gnal l amps
i ncl ude the front turn si gnal and front si de marker
l amps that are i ntegral to the front l amp uni ts
mounted at each end of the bumper fasci a at the
front of the vehi cl e, as wel l as rear turn si gnal l amps
that are i ntegral to the rear l amp uni ts mounted to
the back of the quarter panel on each si de of the tai l -
gate at the rear of the vehi cl e. I n certai n markets
where requi red, a repeater l amp uni t mounted to
each front fender just behi nd the front wheel openi ng
i s i l l umi nated i nstead of the front si de marker l amp
i n each turn si gnal l amp ci rcui t.
Other components of the exteri or l i ghti ng system
for thi s model i ncl ude:
Combination Flasher - An el ectroni c combi na-
ti on fl asher i s i ntegral to the hazard warni ng swi tch
i n the center of the i nstrument panel .
Backup Lamp Switch - Vehi cl es equi pped wi th
a manual transmi ssi on have a pl unger-type backup
l amp swi tch l ocated on the transmi ssi on housi ng. A
Transmi ssi on Range Sensor (TRS) i ntegral to the
sol enoi d pack on the val ve body of the opti onal el ec-
troni c automati c transmi ssi on performs the backup
l amp swi tch functi on on model s that are so equi pped.
Brake Lamp Switch - A pl unger-type brake
l amp swi tch i s l ocated on the steeri ng col umn sup-
port bracket under the i nstrument panel and actu-
ated by the brake pedal arm.
Body Control Module - The Body Control
Modul e (BCM) i s l ocated on the Juncti on Bl ock (JB)
under the dri ver si de outboard end of the i nstrument
panel . (Refer to 8 - ELECTRI CAL/ELECTRONI C
CONTROL MODULES/BODY CONTROL MODULE
- DESCRI PTI ON).
Daytime Running Lamp Relay - Vehi cl es
manufactured for sal e i n Canada use a sol i d state
Dayti me Runni ng Lamps (DRL) rel ay i nstal l ed i n the
Juncti on Bl ock (JB) i nstead of the conventi onal hi gh
beam rel ay.
Front Fog Lamp Relay - Vehi cl es equi pped
wi th the opti onal front fog l amps have a front fog
l amp rel ay l ocated i n the Juncti on Bl ock (JB).
Hazard Switch - The hazard swi tch i s l ocated
near the center of the i nstrument panel and i ncl udes
the i ntegral el ectroni c combi nati on fl asher ci rcui try
for the hazard warni ng system and the turn si gnal
system.
Headlamp Leveling Motor - A headl amp l ev-
el i ng actuator motor i s l ocated on the back of each
headl amp housi ng of vehi cl es manufactured for cer-
tai n markets where thi s equi pment i s requi red.
Headlamp Leveling Switch - A thumbwheel
actuated headl amp l evel i ng swi tch i s mounted i n the
dri ver si de i nboard i nstrument panel tri m bezel of
vehi cl es manufactured for certai n markets where thi s
equi pment i s requi red.
High Beam Relay - A hi gh beam rel ay i s
l ocated i n the Juncti on Bl ock (JB) of al l vehi cl es
except those that are manufactured for sal e i n Can-
ada. Canadi an vehi cl es have a sol i d state Dayti me
Runni ng Lamps (DRL) rel ay i n the JB i nstead of the
hi gh beam rel ay.
Low Beam Relay - A l ow beam rel ay i s l ocated
i n the Juncti on Bl ock (JB) of al l vehi cl es.
Multi-Function Switch - The mul ti -functi on
swi tch i s l ocated on the top of the steeri ng col umn,
just bel ow the steeri ng wheel . The mul ti -functi on
swi tch i ncl udes a l eft (l i ghti ng) control stal k and a
ri ght (wi per) control stal k. The l eft control stal k i s
dedi cated to provi di ng al most al l of the dri ver con-
1 - HEADLAMP UNIT (2)
2 - REPEATER LAMP UNIT (2)
3 - FRONT POSITION LAMP (2)
4 - FRONT LAMP UNIT (2)
5 - FRONT FOG LAMP (2)
6 - CENTER HIGH MOUNTED STOP LAMP UNIT
7 - REAR LAMP UNIT
8 - LICENSE PLATE LAMP UNIT
trol s for both the exteri or and i nteri or l i ghti ng sys-
tems.
Park Lamp Relay - A park l amp rel ay i s
l ocated i n the Juncti on Bl ock (JB) of al l vehi cl es.
Rear Fog Lamp Relay - Vehi cl es manufac-
tured for certai n markets where rear fog l amps are
requi red equi pment have a rear fog l amp rel ay
l ocated i n the Juncti on Bl ock (JB).
Trailer Tow Adapter - Vehi cl es equi pped wi th
a factory-i nstal l ed trai l er towi ng package have an
adapter provi ded that adapts the factory-i nstal l ed
heavy duty 7-way trai l er tow connector to a conven-
ti onal 4-way l i ght duty connector.
Trailer Tow Connector - Vehi cl es equi pped
wi th a factory-i nstal l ed trai l er towi ng package have a
heavy duty 7-way trai l er tow connector i nstal l ed i n a
bracket on the trai l er hi tch recei ver.
Trailer Tow Relays - Vehi cl es equi pped wi th a
factory-i nstal l ed trai l er towi ng package have a con-
nector bank contai ni ng four rel ays l ocated behi nd the
ri ght quarter tri m panel and over the ri ght rear
wheel housi ng. The four rel ays are used to suppl y
fused i gni ti on swi tch output (run), brake l amps, ri ght
turn si gnal , and l eft turn si gnal outputs to a trai l er
through the trai l er tow wi ri ng and connectors.
Hard wi red ci rcui try connects the exteri or l i ghti ng
system components to the el ectri cal system of the
vehi cl e. These hard wi red ci rcui ts are i ntegral to sev-
eral wi re harnesses, whi ch are routed throughout the
vehi cl e and retai ned by many di fferent methods.
These ci rcui ts may be connected to each other, to the
vehi cl e el ectri cal system and to the exteri or l i ghti ng
system components through the use of a combi nati on
of sol dered spl i ces, spl i ce bl ock connectors, and many
OPERATION
Fol l owi ng are paragraphs that bri efl y descri be the
operati on of each of the major exteri or l i ghti ng sys-
tems. The hard wi red ci rcui ts and components of the
exteri or l i ghti ng systems may be di agnosed and
may not prove concl usi ve i n the di agnosi s of the Body
Control Modul e (BCM), the El ectroMechani cal
I nstrument Cl uster (EMI C), the Powertrai n Control
Modul e (PCM), or the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus network. The most
rel i abl e, effi ci ent, and accurate means to di agnose
the BCM, the EMI C, the PCM, and the PCI data bus
network i nputs and outputs rel ated to the vari ous
exteri or l i ghti ng systems requi res the use of a
ti c i nformati on.
BACKUP LAMPS
The backup (or reverse) l amps have a path to
ground at al l ti mes through thei r connecti on to the
rear l i ghti ng wi re harness from a take out of the rear
body wi re harness wi th an eyel et termi nal connector
that i s secured by a ground screw to the base of the
ri ght D-pi l l ar behi nd the quarter tri m panel . The
backup l amps recei ve battery current from a fused
i gni ti on swi tch output (run) fuse i n the Juncti on
Bl ock (JB) on the back-up l amp feed ci rcui t onl y
when the backup l amp swi tch (manual transmi ssi on),
or backup l amp swi tch ci rcui t of the Transmi ssi on
Range Sensor (TRS - el ectroni c automati c transmi s-
si on) i s cl osed by the gearshi ft mechani sm wi thi n the
transmi ssi on.
BRAKE LAMPS
The brake (or stop) l amps have a path to ground at
al l ti mes through thei r connecti on to the rear l i ght-
i ng wi re harness from a take out of the rear body
wi re harness wi th an eyel et termi nal connector that
i s secured by a screw to the base of the ri ght D-pi l l ar
behi nd the quarter tri m panel . The Center Hi gh
Mounted Stop Lamp (CHMSL) has a path to ground
at al l ti mes through i ts connecti on to the rear body
wi re harness from a take out of the rear body wi re
secured by a ground screw to the dri ver si de D-pi l l ar
(l eft si de D-pi l l ar for l eft-hand dri ve, ri ght si de D-pi l -
l ar for ri ght-hand dri ve) behi nd the quarter tri m
panel . The brake l amps and CHMSL recei ve battery
current from a fused B(+) fuse i n the Juncti on Bl ock
(JB) on the brake l amp swi tch output ci rcui t onl y
when the brake l amp swi tch ci rcui t of the brake
l amp swi tch i s cl osed by the brake pedal arm.
DAYTIME RUNNING LAMPS
Vehi cl es manufactured for sal e i n Canada i l l umi -
nate the hi gh beam fi l ament at a reduced i ntensi ty
when the engi ne i s runni ng and the exteri or l amps
are turned off. Thi s feature i s enabl ed by the Body
Control Modul e (BCM) and a sol i d state Dayti me
Runni ng Lamps (DRL) rel ay, whi ch i s i nstal l ed i n the
Juncti on Bl ock (JB) and the hi gh beam rel ay i s omi t-
ted. When the BCM moni tors an engi ne speed si gnal
of greater than 450 RPM and the status of the exte-
ri or l i ghti ng swi tch i nput from the mul ti -functi on
swi tch i s Off, the BCM duty cycl es the DRL rel ay to
produce i l l umi nati on of the headl amp hi gh beam fi l -
aments at a reduced i ntensi ty. The BCM al so pro-
vi des normal headl amp hi gh beam operati on through
the DRL rel ay on vehi cl es so equi pped. When the
DRL rel ay i s energi zed, i t provi des battery current
from a fused B(+) fuse i n the JB to the headl amp
hi gh beam fi l ament through the DRL rel ay output
ci rcui t.
FRONT FOG LAMPS
Vehi cl es equi pped wi th opti onal front fog l amps
have a premi um Body Control Modul e (BCM), a front
fog l amp rel ay i nstal l ed i n the Juncti on Bl ock (JB),
and a front fog l amp swi tch i ntegral to the l eft (l i ght-
i ng) control stal k of the mul ti -functi on swi tch. The
front fog l amps have a path to ground at al l ti mes
through thei r connecti on to the front fasci a wi re har-
ness from two take outs of the headl amp and dash
wi re harness wi th eyel et termi nal connectors that
are secured by ground screws to the l eft i nner fender
shi el d i n the engi ne compartment. The BCM control s
front fog l amp operati on by moni tori ng the exteri or
l i ghti ng swi tch i nput from the mul ti -functi on swi tch,
then energi zi ng or de-energi zi ng the front fog l amp
rel ay control coi l ; and, by sendi ng the appropri ate
el ectroni c message to the i nstrument cl uster over the
bus to turn the front fog l amp i ndi cator on or off.
When the front fog l amp rel ay i s energi zed, i t pro-
vi des battery current from a fused B(+) fuse i n the
JB to the front fog l amps through the front fog l amp
rel ay output ci rcui t. The BCM provi des a battery
saver (l oad sheddi ng) feature for the front fog l amps,
whi ch wi l l turn these l amps off i f they are l eft on for
more than about ei ght mi nutes wi th the i gni ti on
swi tch i n the Off posi ti on. I n certai n markets where
requi red, the front fog l amps are al so turned off by
the BCM whenever the headl amp hi gh beams are
sel ected. Each front fog l amp i ncl udes an i ntegral
adjustment screw to be used for stati c ai mi ng the fog
l amp beams.
HAZARD WARNING LAMPS
Wi th the hazard swi tch i n the On posi ti on, the
hazard warni ng system i s acti vated causi ng the haz-
ard swi tch button i l l umi nati on l amp, the ri ght and
l eft turn si gnal i ndi cators, and the ri ght and l eft turn
si gnal l amps to fl ash on and off. When the hazard
warni ng system i s acti vated, the ci rcui try wi thi n the
hazard swi tch and el ectroni c combi nati on fl asher
uni t wi l l repeatedl y energi ze and de-energi ze two
i nternal rel ays that swi tch battery current from a
fused B(+) fuse i n the Juncti on Bl ock (JB) to the
ri ght si de and l eft si de turn si gnal i ndi cators, and
turn si gnal l amps through the ri ght and l eft turn si g-
nal ci rcui ts. The fl ashi ng of the hazard swi tch button
i l l umi nati on l amp i s performed i nternal l y by the haz-
ard swi tch and combi nati on fl asher uni t ci rcui t
board. The hazard warni ng l amps can al so be ener-
gi zed by the Body Control Modul e (BCM) through a
hazard l amp control ci rcui t i nput to the hazard
swi tch and combi nati on fl asher uni t.
HEADLAMPS
The headl amp system i ncl udes the Body Control
Modul e (BCM), a l ow beam rel ay i nstal l ed i n the
Juncti on Bl ock (JB), a hi gh beam rel ay i nstal l ed i n
the JB (except Canada), a sol i d state Dayti me Run-
ni ng Lamps (DRL) rel ay i nstal l ed i n the JB (Canada
onl y), and the exteri or l i ghti ng (headl amp and di m-
mer) swi tches i ntegral to the l eft (l i ghti ng) control
stal k of the mul ti -functi on swi tch. The headl amp
bul bs have a path to ground at al l ti mes through
thei r connecti on to the gri l l e openi ng rei nforcement
wi re harness from two take outs of the headl amp and
dash wi re harness wi th eyel et termi nal connectors
that are secured by ground screws to the l eft i nner
fender shi el d i n the engi ne compartment. The BCM
control s the headl amp operati on by moni tori ng the
exteri or l i ghti ng swi tch i nputs from the mul ti -func-
ti on swi tch, then energi zi ng or de-energi zi ng the con-
trol coi l s of the l ow beam rel ay, the hi gh beam rel ay,
or the sol i d state ci rcui try of the DRL rel ay; and, by
sendi ng the appropri ate el ectroni c message to the
i nstrument cl uster over the Programmabl e Commu-
ni cati ons I nterface (PCI ) data bus to turn the hi gh
beam i ndi cator on or off. When each respecti ve rel ay
i s energi zed, i t provi des battery current from a fused
B(+) fuse i n the Power Di stri buti on Center (PDC)
through a rel ay (l ow beam, hi gh beam, or DRL) out-
put ci rcui t and four separate fuses i n the JB through
i ndi vi dual fused ri ght and l eft, l ow and hi gh beam
output ci rcui ts to the appropri ate headl amp bul b fi l -
aments. The BCM provi des a battery saver (l oad
sheddi ng) feature for the headl amps, whi ch wi l l turn
these l amps off i f they are l eft on for more than
about ei ght mi nutes wi th the i gni ti on swi tch i n the
Off posi ti on; and, a headl amp del ay feature wi th a
DRBI I I scan tool programmabl e del ay i nterval .
Each headl amp i ncl udes an i ntegral adjustment
screw to be used for stati c ai mi ng of the headl amp
beams.
HEADLAMP LEVELING
I n certai n markets where requi red, a headl amp
l evel i ng system i s provi ded on the vehi cl e. The head-
l amp l evel i ng system i ncl udes uni que headl amp uni ts
equi pped wi th a headl amp l evel i ng actuator motor,
and a rotary thumbwheel actuated headl amp l evel i ng
swi tch on the i nstrument panel . The headl amp l evel -
i ng system al l ows the headl amp beams to be
adjusted to one of four verti cal posi ti ons to compen-
sate for changes i n i ncl i nati on caused by the l oadi ng
of the vehi cl e suspensi on. The actuator motors are
mechani cal l y connected through an i ntegral pushrod
to an adjustabl e headl amp refl ector. The headl amp
l evel i ng swi tch i s a resi stor mul ti pl exed uni t that
provi des one of four vol tage outputs to the headl amp
l evel i ng motors. The headl amp l evel i ng motors wi l l
move the headl amps to the sel ected posi ti on based
upon the vol tage i nput recei ved from the swi tch. The
headl amp l evel i ng motors and swi tch have a path to
ground at al l ti mes. The headl amp l evel i ng compo-
nents operate on battery current recei ved through
the fused park l amp rel ay output ci rcui t so that the
system wi l l onl y operate when the exteri or l i ghti ng i s
turned on.
PARK LAMPS
The park l amps system i ncl udes the Body Control
Modul e (BCM), a park l amp rel ay i nstal l ed i n the
Juncti on Bl ock (JB), and the exteri or l i ghti ng swi tch
i ntegral to the l eft (l i ghti ng) control stal k of the
mul ti -functi on swi tch. The front park l amp and si de
marker or, i f equi pped, the front posi ti on l amp bul bs
each have a path to ground at al l ti mes through thei r
connecti ons to the gri l l e openi ng rei nforcement wi re
harness from two take outs of the headl amp and
fender shi el d i n the engi ne compartment. The rear
park l amp bul bs and l i cense pl ate l amp have a path
to ground at al l ti mes through thei r connecti on to the
BCM control s the park l amp operati on by moni tori ng
the exteri or l i ghti ng swi tch i nputs from the mul ti -
functi on swi tch, then energi zi ng or de-energi zi ng the
control coi l of the park l amp rel ay. When the park
l amp rel ay i s energi zed, i t provi des battery current
from a fused B(+) fuse i n the Power Di stri buti on
Center (PDC) through a park l amp rel ay output ci r-
cui t and a separate fuse i n the JB through a fused
park l amp rel ay output ci rcui t to the appropri ate
l amp bul b fi l aments. The BCM provi des a battery
saver (l oad sheddi ng) feature for the park l amps,
swi tch i n the Off posi ti on.
REAR FOG LAMPS
Rear fog l amps are i nstal l ed on vehi cl es manufac-
tured for certai n markets where they are requi red.
The rear fog l amp system i ncl udes a premi um Body
Control Modul e (BCM), a rear fog l amp rel ay
i nstal l ed i n the Juncti on Bl ock (JB), and a rear fog
l amp swi tch i ntegral to the l eft (l i ghti ng) control
stal k of the mul ti -functi on swi tch. The rear fog l amps
have a path to ground at al l ti mes through thei r con-
necti on to the rear l i ghti ng wi re harness from a take
out of the rear body wi re harness wi th an eyel et ter-
mi nal connector that i s secured by a ground screw to
the base of the ri ght D-pi l l ar behi nd the quarter tri m
panel . The BCM control s rear fog l amp operati on by
moni tori ng the exteri or l i ghti ng swi tch i nput from
the mul ti -functi on swi tch, then energi zi ng or de-ener-
gi zi ng the rear fog l amp rel ay control coi l ; and, by
ni cati ons I nterface (PCI ) data bus to turn the rear
fog l amp i ndi cator on or off. When the rear fog l amp
rel ay i s energi zed, i t provi des battery current from a
fused B(+) fuse i n the JB to the rear fog l amps
through the rear fog l amp rel ay output ci rcui t. The
BCM provi des a battery saver (l oad sheddi ng) feature
for the rear fog l amps, whi ch wi l l turn these l amps
off i f they are l eft on for more than about ei ght mi n-
utes wi th the i gni ti on swi tch i n the Off posi ti on.
TURN SIGNAL LAMPS
When the l eft control stal k of the mul ti -functi on
swi tch i s moved up (ri ght turn) or down (l eft turn),
the turn si gnal system i s acti vated causi ng the
sel ected ri ght or l eft turn si gnal i ndi cator, and ri ght
or l eft turn si gnal l amps to fl ash on and off. When
the turn si gnal system i s acti vated, the ci rcui try
wi thi n the turn si gnal swi tch and the hazard swi tch/
el ectroni c combi nati on fl asher uni t wi l l repeatedl y
energi ze and de-energi ze one of two i nternal rel ays
that swi tch battery current from a fused i gni ti on
swi tch output (run) fuse i n the Juncti on Bl ock (JB) to
the ri ght si de or l eft si de turn si gnal i ndi cators and
turn si gnal l amps through the ri ght or l eft turn si g-
nal ci rcui ts. The El ectroMechani cal I nstrument Cl us-
ter (EMI C) chi me tone generator wi l l generate an
audi bl e turn si gnal cancel warni ng each ti me the
vehi cl e i s dri ven for a di stance of about 3.2 ki l ome-
ters (about two mi l es) wi th a turn si gnal i ndi cator
fl ashi ng. The EMI C uses Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus di stance messages
from the Powertrai n Control Modul e (PCM) and a
hard wi red i nput from the turn si gnal swi tch ci r-
cui try of the mul ti -functi on swi tch to determi ne when
to sound the turn si gnal cancel warni ng.
DIAGNOSIS AND TESTING - LAMPS/LIGHTING
- EXTERIOR
The hard wi red ci rcui ts and components of the
ti c i nformati on.
When di agnosi ng the exteri or l i ghti ng ci rcui ts,
remember that hi gh generator output can burn out
bul bs rapi dl y and repeatedl y; and, that di m or fl i ck-
eri ng bul bs can be caused by l ow generator output or
poor battery condi ti on. I f one of these symptoms i s a
probl em on the vehi cl e bei ng di agnosed, be certai n to
di agnose and repai r the battery and chargi ng system
as requi red. Al so keep i n mi nd that a good ground i s
necessary for proper l i ghti ng operati on. I f a l i ghti ng
probl em i s bei ng di agnosed that i nvol ves mul ti pl e
symptoms, systems, or components the probl em can
often be traced to a l oose, corroded, or open ground.
For compl ete ci rcui t di agrams, refer to the appropri -
ate wi ri ng i nformati on. The wi ri ng i nformati on
PERSONAL INJURY.
BACKUP LAMPS
BACKUP LAMP DOES
NOT ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace backup lamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace backup lamp bulb as
required.
3. Faulty switch. 3. Test and replace backup lamp switch
(manual transmission) or transmission
range sensor (automatic transmission) as
required.
4. Faulty ground circuit. 4. Test and repair backup lamp ground
circuit as required.
5. Faulty feed circuit. 5. Test and repair open back-up lamp feed
BACKUP LAMP DOES
NOT EXTINGUISH
required.
2. Faulty feed circuit. 2. Test and repair shorted back-up lamp
feed circuit as required.
BRAKE LAMPS
BRAKE LAMP DOES NOT
ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace brake lamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace brake lamp bulb as
required.
3. Faulty switch. 3. Test and replace brake lamp switch as
required.
4. Faulty ground circuit. 4. Test and repair brake lamp ground circuit
as required.
5. Faulty feed circuit. 5. Test and repair open brake lamp switch
output circuit as required.
BRAKE LAMP DOES NOT
EXTINGUISH
required.
2. Faulty feed circuit. 2. Test and repair shorted brake lamp
switch output circuit as required.
Before performi ng the fol l owi ng tests, determi ne
whether the headl amp l ow and hi gh beams operate.
I f the headl amp hi gh and l ow beams are al so i noper-
ati ve, di agnose and repai r that probl em before
attempti ng to repai r the Dayti me Runni ng Lamps.
DAYTIME RUNNING
LAMPS WILL NOT
ILLUMINATE
1. High beam relay installed. 1. Remove high beam relay as required.
2. Faulty or missing DRL relay. 2. Replace DRL relay with a known good
unit and check operation. Replace DRL
relay as required.
3. Incorrect BCM programming. 3. Use a DRBIII scan tool to check and
program correct country code into BCM as
required.
4. Faulty BCM inputs or outputs. 4. Use a DRBIII scan tool to test the BCM
inputs or outputs. Refer to the appropriate
diagnostic information.
FRONT FOG LAMPS
FRONT FOG LAMP DOES
NOT ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace front fog lamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace front fog lamp bulb as
required.
3. Faulty or missing relay. 3. Test and replace front fog lamp relay as
required.
4. Faulty switch. 4. Test and replace multi-function switch as
required.
5. Faulty ground circuit. 5. Test and repair front fog lamp ground
6. Faulty feed circuit. 6. Test and repair open front fog lamp relay
inputs and outputs. Refer to the appropriate
FRONT FOG LAMP DOES
NOT EXTINGUISH
1. Faulty relay. 1. Test and replace front fog lamp relay as
required.
required.
3. Faulty feed circuit. 3. Test and repair shorted front fog lamp
relay output circuit as required.
Before performi ng the fol l owi ng tests, confi rm
whether the l eft and ri ght turn si gnal s operate sati s-
factori l y. I f the turn si gnal s are i noperati ve or oper-
ate i mproperl y, di agnose and repai r that probl em
before attempti ng to repai r the Hazard Warni ng
Lamps.
HAZARD WARNING
LAMPS DO NOT FLASH
1. Faulty or missing fuse. 1. Test and replace hazard warning fuse as
required.
2. Faulty ground circuit. 2. Test and repair hazard switch ground
3. Faulty feed circuit. 3. Test and repair open hazard switch fused
B(+) circuit as required.
4. Faulty switch/flasher. 4. Replace hazard switch/combination
flasher with a known good unit and check
operation. Replace hazard switch/
combination flasher unit if required.
HEADLAMPS
HEADLAMP DOES NOT
ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace headlamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace headlamp bulb as
required.
3. Faulty or missing relay. 3. Test and replace low beam or high beam
relay as required. (Note: Vehicles with a DRL
relay do not use a high beam relay. The DRL
relay cannot be tested. Replace DRL relay
with a known good unit and check operation.
Replace DRL relay as required.)
required.
5. Faulty ground circuit. 5. Test and repair open headlamp ground
6. Faulty feed circuit. 6. Test and repair open headlamp low beam,
high beam, or DRL relay output circuit as
required.
HEADLAMP DOES NOT
EXTINGUISH
1. Faulty relay. 1. Test and replace low beam or high beam
required.
3. Faulty feed circuit. 3. Test and repair shorted headlamp low
beam, high beam, or DRL relay output circuit
as required.
HEADLAMPS WILL NOT
SWITCH FROM HIGH TO
LOW BEAMS, OR FROM
LOW TO HIGH BEAMS
required.
HEADLAMP LEVELING
whether the park l amps operate sati sfactori l y. I f the
park l amps are i noperati ve, di agnose and repai r that
probl em before attempti ng to repai r the Headl amp
Level i ng System.
ONE LEVELING MOTOR
IS INOPERATIVE
1. Faulty ground circuit. 1. Test and repair open leveling motor
ground circuit as required.
2. Faulty feed circuit. 2. Test and repair open leveling motor feed
3. Faulty signal circuit. 3. Test and repair open headlamp adjust
signal circuit as required.
4. Faulty motor. 4. Test and replace headlamp leveling
motor as required.
BOTH LEVELING
MOTORS ARE
INOPERATIVE
1. Faulty switch ground circuit. 1. Test and repair open leveling switch
2. Faulty motor ground circuit. 2. Test and repair open leveling motor
3. Faulty switch feed circuit. 3. Test and repair open leveling switch feed
4. Faulty motor feed circuit. 4. Test and repair open leveling motor feed
5. Faulty signal circuit. 5. Test and repair open or shorted leveling
motor signal circuit as required.
6. Faulty switch. 6. Test and replace leveling switch as
required.
7. Faulty motors. 7. Test and replace leveling motors as
required.
PARK LAMPS
PARK LAMP DOES NOT
ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace park lamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace park lamp bulb as
required.
3. Faulty or missing relay. 3. Test and replace park lamp relay as
required.
required.
5. Faulty ground circuit. 5. Test and repair open park lamp ground
6. Faulty feed circuit. 6. Test and repair open park lamp relay
PARK LAMP DOES NOT
EXTINGUISH
1. Faulty relay. 1. Test and replace park lamp relay as
required.
required.
3. Faulty feed circuit. 3. Test and repair shorted park lamp relay
REAR FOG LAMPS
REAR FOG LAMP DOES
NOT ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace rear fog lamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace rear fog lamp bulb as
required.
3. Faulty or missing relay. 3. Test and replace rear fog lamp relay as
required.
required.
5. Faulty ground circuit. 5. Test and repair open rear fog lamp
6. Faulty feed circuit. 6. Test and repair open rear fog lamp relay
REAR FOG LAMP DOES
NOT EXTINGUISH
1. Faulty relay. 1. Test and replace rear fog lamp relay as
required.
required.
3. Faulty feed circuit. 3. Test and repair shorted rear fog lamp
TURN SIGNAL LAMPS
ONE TURN SIGNAL LAMP
DOES NOT ILLUMINATE
1. Faulty or missing bulb. 1. Test and replace turn signal bulb as
required.
2. Faulty ground circuit. 2. Test and repair open ground circuit as
required.
3. Faulty feed circuit. 3. Test and repair open right or left turn
ALL RIGHT SIDE AND/OR
ALL LEFT SIDE TURN
SIGNAL LAMPS DO NOT
FLASH
1. Faulty sense circuit. 1. Test and repair open right or left turn
switch sense circuit as required.
required.
3. Faulty flasher. 3. Replace hazard switch/combination
combination flasher unit as required.
4. Faulty signal circuit. 4. Test and repair open right or left turn
ALL RIGHT SIDE OR ALL
LEFT SIDE TURN
SIGNALS FLASH TOO
RAPIDLY (MORE THAN
100 FLASHES PER
MINUTE)
1. Faulty or missing bulb. 1. Test and replace faulty bulb as required.
required.
3. Faulty signal circuit 3. Test and repair open right or left turn
EXTERIOR
BULB SPECIFICATIONS
LAMP BULB
Backup 3157 P27/7W
Brake 3157 P27/7W
Center High Mounted
Stop
921/W16W
Front Fog 9145
Front Park 3157 P27/7W
Front Position W5W
Front Side Marker 168
Front Turn 3157 P27/7W
Headlamp (North
America)
9007QL
Headlamp (Rest-Of-
World)
H-4 W0W6
License Plate (North
America)
168
License Plate (Rest-Of-
World)
W5W
Rear Fog 3157 P27/7W
Rear Park/Tail 3157 P27/7W
Rear Turn 3157 P27/7W
Side Repeater W5W
BACKUP LAMP SWITCH
DESCRIPTION
Vehi cl es equi pped wi th a manual transmi ssi on
have a normal l y open, spri ng-l oaded pl unger type
back-up l amp swi tch (Fi g. 2). The backup l amp
swi tch i s l ocated i n a threaded hol e on the si de of the
manual transmi ssi on housi ng, beneath the fl oor
panel of the vehi cl e. The backup l amp swi tch has a
threaded body and a hex formati on near the pl unger
end of the swi tch, and an i ntegral connector recepta-
cl e at the opposi te end of the swi tch. When i nstal l ed,
onl y the connector receptacl e and the hex formati on
are vi si bl e on the outsi de of the transmi ssi on hous-
i ng. Vehi cl es wi th an opti onal el ectroni c automati c
transmi ssi on have a Transmi ssi on Range Sensor
(TRS) that i s used to perform several functi ons,
i ncl udi ng that of the backup l amp swi tch. The TRS i s
descri bed i n further detai l el sewhere i n thi s servi ce
i nformati on. The backup l amp swi tch cannot be
enti re swi tch uni t must be repl aced.
OPERATION
The backup l amp swi tch control s the fl ow of bat-
tery current to the backup l amp bul bs at the back of
the vehi cl e through an output on the back-up l amp
feed ci rcui t. The swi tch pl unger i s mechani cal l y actu-
ated by the gearshi ft mechani sm wi thi n the trans-
mi ssi on, whi ch wi l l depress the swi tch pl unger and
cl ose the swi tch contacts whenever the reverse gear
has been sel ected. The swi tch recei ves battery cur-
rent through a fuse i n the Juncti on Bl ock (JB) on a
fused i gni ti on swi tch output (run) ci rcui t whenever
the i gni ti on swi tch i s i n the On posi ti on. A take out
of the engi ne wi re harness connects the backup l amp
swi tch to the vehi cl e el ectri cal system. The backup
l amp swi tch and ci rcui ts can be tested usi ng conven-
ti onal di agnosti c tool s and methods.
SWITCH
cabl e.
(3) Locate and di sconnect the engi ne wi re harness
connector for the backup l amp swi tch from the
swi tch connector receptacl e.
(4) Check for conti nui ty between the two termi nal
pi ns i n the backup l amp swi tch connector receptacl e.
(a) Wi th the gear sel ector l ever i n the Reverse
posi ti on, there shoul d be conti nui ty.
(b) Wi th the gear sel ector l ever i n any posi ti on
other than Reverse, there shoul d be no conti nui ty.
Fig. 2 Backup Lamp Switch - Typical
1 - MANUAL TRANSMISSION
2 - BACKUP LAMP SWITCH
3 - ENGINE WIRE HARNESS
BRAKE LAMP SWITCH
DESCRIPTION
The brake l amp swi tch i s a three ci rcui t, spri ng-
l oaded pl unger actuated swi tch that i s secured to the
steeri ng col umn support bracket under the dri ver
si de of the i nstrument panel (Fi g. 3). The brake l amp
swi tch i s contai ned wi thi n a rectangul ar mol ded pl as-
ti c housi ng wi th an i ntegral connector receptacl e fea-
turi ng si x termi nal pi ns and a red pl asti c Connector
Posi ti on Assurance (CPA) l ock. The swi tch i s con-
nected to the vehi cl e el ectri cal system through a ded-
i cated take out and connector of the i nstrument
panel wi re harness. The swi tch pl unger extends
through a mounti ng col l ar on one end of the swi tch
housi ng. The pl unger has a one ti me tel escopi ng sel f-
adjustment feature that i s achi eved after the swi tch
i s i nstal l ed by movi ng an adjustment rel ease l ever on
the opposi te end of the swi tch housi ng cl ockwi se,
unti l i t l ocks i n a posi ti on that i s paral l el to the con-
nector receptacl e. The brake l amp swi tch sel f-adjust-
ment i s a one ti me feature. Once the feature has
been used, the swi tch cannot be readjusted. A DO
NOT RE-I NSTALL warni ng i s mol ded i nto the
swi tch housi ng bel ow the connector receptacl e.
An i nstal l ed brake l amp swi tch cannot be read-
justed or repai red. I f the swi tch i s damaged, faul ty,
or removed from i ts mounti ng posi ti on for any rea-
son, i t must be repl aced wi th a new uni t.
OPERATION
The brake l amp swi tch control s three di fferent ci r-
cui ts, one normal l y open and two normal l y cl osed.
These ci rcui ts are descri bed as fol l ows:
Brake Lamp Switch Circuit - A normal l y
open brake l amp swi tch ci rcui t recei ves battery cur-
rent on a fused B(+) ci rcui t from a fuse i n the Junc-
ti on Bl ock (JB), and suppl i es battery current to the
brake l amps and the Control l er Anti l ock Brake
(CAB) on a brake l amp swi tch output ci rcui t when
the brake pedal i s depressed (brake l amp swi tch
pl unger rel eased).
Brake Lamp Switch Signal Circuit - A nor-
mal l y cl osed brake l amp swi tch si gnal ci rcui t recei ves
a path to ground through a spl i ce bl ock l ocated i n the
i nstrument panel wi re harness wi th an eyel et termi -
nal connector that i s secured by a nut to a ground
stud on the dri ver si de i nstrument panel end bracket
near the Juncti on Bl ock (JB). Thi s ci rcui t suppl i es a
ground i nput to the Powertrai n Control Modul e
(PCM) on a brake l amp swi tch sense ci rcui t when the
brake pedal i s rel eased (brake l amp swi tch pl unger i s
depressed).
Speed Control Circuit - A normal l y cl osed
speed control ci rcui t recei ves battery current from
the Powertrai n Control Modul e on a speed control
suppl y ci rcui t, and suppl i es battery current to the
speed control servo sol enoi ds (dump, vacuum, and
vent) on a speed control brake swi tch output ci rcui t
when the speed control system i s turned on and the
depressed).
Conceal ed wi thi n the brake l amp swi tch housi ng
the components of the sel f-adjusti ng brake swi tch
pl unger consi st of a two-pi ece tel escopi ng pl unger, a
spl i t pl unger l ocki ng col l ar, and a rel ease wedge. The
rel ease l ever has an i ntegral shaft wi th a wedge that
spreads the pl unger l ocki ng col l ar to an open or
rel eased posi ti on. After the swi tch i s i nstal l ed and
the brake pedal i s rel eased, the pl unger tel escopes to
the correct adjustment posi ti on. When the rel ease
l ever i s moved to the rel ease posi ti on, the wedge i s
di sengaged from the l ocki ng col l ar causi ng the col l ar
to appl y a cl ampi ng pressure to the two pl unger
hal ves fi xi ng the pl unger l ength.
The brake l amp swi tch can be di agnosed usi ng con-
venti onal di agnosti c tool s and methods.
Fig. 3 Brake Lamp Switch
2 - BRAKE LAMP SWITCH
3 - PLUNGER
4 - COLLAR
5 - LEVER
SWITCH
PERSONAL INJURY.
cabl e. Di sconnect the i nstrument panel wi re harness
connector for the brake l amp swi tch from the swi tch
connector receptacl e.
(2) Usi ng an ohmmeter, perform the conti nui ty
tests at the termi nal pi ns i n the brake l amp swi tch
connector receptacl e (Fi g. 4) as shown i n the Brake
Lamp Swi tch Tests tabl e.
BRAKE LAMP SWITCH TESTS
PLUNGER POSITION CONTINUITY BETWEEN
Released (Extended) Pins 1 & 2
Compressed (Retracted) Pins 3 & 4, 5 & 6
(3) I f the swi tch fai l s any of the conti nui ty tests,
repl ace the faul ty brake l amp swi tch as requi red.
REMOVAL
PERSONAL INJURY.
cabl e.
connector receptacl e (Fi g. 5).
(3) Grasp the brake l amp swi tch housi ng fi rml y
and rotate the swi tch countercl ockwi se about 30
degrees to al i gn the tabs on the l ocki ng col l ar wi th
the keyed mounti ng hol e i n the steeri ng col umn sup-
port bracket.
(4) Pul l the swi tch strai ght back from the mount-
i ng hol e to remove i t from the steeri ng col umn sup-
port bracket.
Fig. 4 Brake Lamp Switch Terminal Identification
1 - TERMINAL PINS
2 - PLUNGER TEST POSITIONS
Fig. 5 Brake Lamp Switch Remove/Install
1 - STEERING COLUMN SUPPORT
3 - LEVER
5 - BRAKE PEDAL ARM
BRAKE LAMP SWITCH (Continued)
(5) Di scard the removed brake l amp swi tch.
CAUTION: Always replace a removed brake lamp
switch with a new unit. This is a one time compo-
nent and is not intended for reinstallation.
INSTALLATION
PERSONAL INJURY.
(1) Whi l e hol di ng the brake pedal depressed, al i gn
the tabs on the brake l amp swi tch l ocki ng col l ar wi th
port bracket (Fi g. 5).
(2) Sti l l hol di ng the brake pedal depressed, i nsert
the tabs on the brake l amp swi tch housi ng through
port bracket unti l the swi tch i s fi rml y seated agai nst
the bracket.
(3) Sti l l hol di ng the brake pedal depressed, rotate
the swi tch cl ockwi se about 30 degrees to l ock the
tabs on the brake l amp swi tch l ocki ng col l ar to the
keyed mounti ng hol e i n the steeri ng col umn support
bracket.
(4) Rel ease the brake pedal .
CAUTION: Do not pull up on the brake pedal before
the switch plunger adjustment has been completed.
(5) Rotate the pl unger adjustment rel ease l ever
cl ockwi se unti l i t l ocks i nto pl ace paral l el to the
brake l amp swi tch connector receptacl e. Thi s acti on
wi l l set the swi tch pl unger l ength to a fi nal adjust-
ment posi ti on and cannot be undone. I f not per-
formed properl y the fi rst ti me, a new brake l amp
swi tch must be i nstal l ed.
connector for the brake l amp swi tch to the swi tch
CENTER HIGH MOUNTED
STOP LAMP BULB
REMOVAL
cabl e.
(2) Remove the Center Hi gh Mounted Stop Lamp
(CHMSL) uni t from the roof panel . (Refer to 8 -
CENTER HI GH MOUNTED STOP LAMP UNI T -
REMOVAL).
(3) Fi rml y grasp the socket on the back of the
CHMSL uni t housi ng.
(4) Rotate the socket on the back of the CHMSL
uni t housi ng countercl ockwi se about 30 degrees (Fi g.
6).
(5) Pul l the socket and bul b strai ght out of the
back of CHMSL uni t housi ng.
(6) Pul l the bul b strai ght out of the CHMSL uni t
socket.
Fig. 6 Center High Mounted Stop Lamp Bulb
Remove/Install
1 - CHMSL UNIT
2 - BULB
3 - SOCKET
4 - BODY WIRE HARNESS CONNECTOR
INSTALLATION
may overheat and cause damage to the lamp, the
socket and/or the lamp wiring.
(1) Al i gn the base of the bul b wi th the receptacl e
i n the Center Hi gh Mounted Stop Lamp (CHMSL)
uni t socket.
(2) Push the bul b strai ght i nto the CHMSL uni t
socket unti l i t i s fi rml y seated.
(3) Al i gn the socket and bul b wi th the socket open-
i ng on the back of CHMSL uni t housi ng.
(4) Push the socket and bul b strai ght i nto the
CHMSL uni t housi ng unti l i t i s fi rml y seated (Fi g. 6).
uni t housi ng cl ockwi se about 30 degrees.
(6) Rei nstal l the CHMSL uni t onto the roof panel .
(Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG -
EXTERI OR/CENTER HI GH MOUNTED STOP
LAMP UNI T - I NSTALLATI ON).
CENTER HIGH MOUNTED
STOP LAMP UNIT
REMOVAL
cabl e.
(2) Remove the two screws that secure the Center
Hi gh Mounted Stop Lamp (CHMSL) uni t to the rear
of the roof panel (Fi g. 7).
(3) Pul l the CHMSL uni t away from the roof panel
far enough to access and di sconnect the wi re harness
connector for the CHMSL uni t from the l amp socket
pi gtai l wi re.
(4) Remove the CHMSL uni t from the roof panel .
INSTALLATION
(1) Posi ti on the Center Hi gh Mounted Stop Lamp
(CHMSL) uni t to the roof panel .
(2) Reconnect the wi re harness connector for the
CHMSL uni t to the l amp socket pi gtai l wi re (Fi g. 7).
(3) Posi ti on the CHMSL uni t i nto the roof panel
openi ng.
(4) I nstal l and ti ghten the two screws that secure
the CHMSL uni t to the rear of the roof panel .
Ti ghten the screws to 2 Nm (21 i n. l bs.).
COMBINATION FLASHER
DESCRIPTION
The combi nati on fl asher for thi s model i s i ntegral
to the hazard swi tch l ocated i n the center of the
i nstrument panel , just above the radi o. The combi na-
ti on fl asher i s a smart rel ay that functi ons as both
the turn si gnal system and the hazard warni ng sys-
tem fl asher. The combi nati on fl asher contai ns acti ve
el ectroni c I ntegrated Ci rcui try (I C) el ements. Thi s
fl asher i s desi gned to handl e the current fl ow
requi rements of the factory-i nstal l ed l i ghti ng. I f sup-
pl emental l i ghti ng i s added to the turn si gnal l amp
ci rcui ts, such as when towi ng a trai l er wi th l i ghts,
the combi nati on fl asher wi l l automati cal l y try to
compensate to keep the fl ash rate the same.
The combi nati on fl asher cannot be repai red or
adjusted and, i f faul ty or damaged, the hazard swi tch
uni t must be repl aced.
OPERATION
The combi nati on fl asher has the fol l owi ng i nputs and
outputs: fused B(+), fused i gni ti on swi tch output, ri ght
turn si gnal sense, l eft turn si gnal sense, and one output
each for the ri ght and l eft turn si gnal ci rcui ts. The com-
bi nati on fl asher al so recei ves an i nternal i nput through
the cl osed contacts of the hazard swi tch and, on vehi cl es
equi pped wi th the opti onal Vehi cl e Theft Securi ty Sys-
tem (VTSS), the fl asher recei ves an i nput from the Body
Control Modul e (BCM) i n order to fl ash the turn si gnal
l amps as an opti cal al ert feature of that system. Con-
Fig. 7 Center High Mounted Stop Lamp Remove/
Install
1 - ROOF PANEL
3 - BULB SOCKET
4 - CHMSL
5 - SCREW (2)
6 - PLASTIC NUT (2)
CENTER HIGH MOUNTED STOP LAMP BULB (Continued)
stant battery vol tage i s suppl i ed to the fl asher so that i t
can perform the hazard warni ng functi on, and i gni ti on
swi tched battery vol tage i s suppl i ed for the turn si gnal
functi on. The I ntegrated Ci rcui t (I C) wi thi n the combi -
nati on fl asher contai ns the l ogi c that control s the
fl asher operati on and the fl ash rate. The I C recei ves
separate sense ground i nputs from the mul ti -functi on
swi tch for the ri ght and l eft turn si gnal s, and from the
hazard swi tch contacts or the BCM for the hazard
warni ng si gnal s. A speci al desi gn feature of the combi -
nati on fl asher al l ows i t to sense that a turn si gnal ci r-
cui t or bul b i s not operati ng, and provi de the dri ver an
i ndi cati on of the condi ti on by fl ashi ng the remai ni ng
bul bs i n the affected ci rcui t at a hi gher rate (120 fl ash-
es-per-mi nute or hi gher). Conventi onal fl ashers ei ther
conti nue fl ashi ng at thei r typi cal rate (heavy-duty type),
or di sconti nue fl ashi ng the affected ci rcui t enti rel y
(standard-duty type).
Because of the acti ve el ectroni c el ements wi thi n
the combi nati on fl asher, i t cannot be tested wi th con-
venti onal automoti ve el ectri cal test equi pment. I f the
combi nati on fl asher i s bel i eved to be faul ty, test the
turn si gnal and hazard warni ng system. Then
repl ace the hazard swi tch wi th a known good uni t to
confi rm system operati on.
DAYTIME RUNNING LAMP
RELAY
DESCRIPTION
The Dayti me Runni ng Lamp (DRL) rel ay (Fi g. 8) i s
a sol i d state rel ay that i s used onl y on vehi cl es man-
ufactured for sal e i n Canada. The DRL rel ay features
a di e cast al umi num housi ng wi th i ntegral cool i ng
fi ns that act as a heat si nk for the sol i d state DRL
ci rcui try. Four mal e spade termi nal s extend from the
base of the rel ay through a potti ng materi al that
encl oses and protects the DRL ci rcui try. Al though the
DRL rel ay has four termi nal s that are l ai d out i n a
footpri nt that i s si mi l ar to that of a conventi onal
I nternati onal Standards Organi zati on (I SO) rel ay, a
standard I SO rel ay shoul d never be i nstal l ed i n pl ace
of the DRL rel ay. The DRL rel ay i s i nstal l ed i n the
Juncti on Bl ock (JB) on the dri ver si de outboard end
of the i nstrument panel . Vehi cl es equi pped wi th thi s
rel ay do not have a headl amp hi gh beam rel ay
i nstal l ed i n the JB.
The DRL rel ay cannot be adjusted or repai red and,
i f faul ty or damaged, the uni t must be repl aced.
OPERATION
The Dayti me Runni ng Lamp (DRL) rel ay i s a sol i d
state rel ay that control s the fl ow of battery current
to the hi gh beam fi l aments of both headl amp bul bs
based upon a duty cycl ed control i nput recei ved from
the Body Control Modul e (BCM) of vehi cl es equi pped
wi th the DRL feature. By cycl i ng the DRL rel ay out-
put, the BCM control s the i l l umi nati on i ntensi ty of
the hi gh beam fi l aments. The DRL rel ay termi nal s
are connected to the vehi cl e el ectri cal system through
a connector receptacl e i n the Juncti on Bl ock (JB).
The i nputs and outputs of the DRL rel ay i ncl ude:
Battery Current Input - The DRL rel ay
recei ves battery current on a fused B(+) ci rcui t from
a fuse i n the Power Di stri buti on Center (PDC).
Ground Input - The DRL rel ay recei ves a path
to ground through a spl i ce bl ock l ocated i n the
near the Juncti on Bl ock (JB).
Control Input - The DRL rel ay control i nput i s
recei ved from the BCM and/or the momentary opti cal
horn (fl ash-to-pass) output of the mul ti -functi on
swi tch through a hi gh beam rel ay control ci rcui t.
Control Output - The DRL rel ay suppl i es bat-
tery current output to the headl amp hi gh beam fi l a-
ments through the hi gh beam rel ay output ci rcui t.
Because of acti ve el ectroni c el ements wi thi n the
DRL rel ay, i t cannot be tested wi th conventi onal
automoti ve el ectri cal test equi pment. I f the DRL
rel ay i s bel i eved to be faul ty, repl ace the rel ay wi th a
known good uni t to confi rm system operati on.
Fig. 8 Daytime Running Lamp Relay
1 - DRL RELAY
2 - HEAT SINK
3 - POTTING MATERIAL
4 - TERMINAL (4)
COMBINATION FLASHER (Continued)
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Remove the end cap from the dri ver si de out-
board end of the i nstrument panel . (Refer to 23 -
PANEL END CAP - REMOVAL).
(3) Remove the Dayti me Runni ng Lamp (DRL)
rel ay by graspi ng i t fi rml y and pul l i ng i t strai ght out
from the receptacl e i n the Juncti on Bl ock (JB) (Fi g.
9).
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the Dayti me Runni ng Lamp (DRL)
rel ay to the proper receptacl e i n the Juncti on Bl ock
(JB) (Fi g. 9).
(2) Al i gn the DRL rel ay termi nal s wi th the termi -
nal cavi ti es i n the JB receptacl e.
(3) Push fi rml y and evenl y on the top of the DRL
rel ay unti l the termi nal s are ful l y seated i n the ter-
mi nal cavi ti es i n the JB receptacl e.
(4) Rei nstal l the end cap onto the dri ver si de out-
PANEL END CAP - I NSTALLATI ON).
FRONT FOG LAMP BULB
REMOVAL
(1) Turn the front wheel s ful l l ock i n the di recti on
of the fog l amp bul b that i s to be changed.
cabl e.
(3) Reach i nto the front wheel openi ng to unsnap
and l i ft the cover over the access hol e at the front of
the front wheel house spl ash shi el d (Fi g. 10).
(4) Reach through the access hol e and fi rml y grasp
the socket on the back of the front fog l amp uni t
housi ng.
(5) Rotate the socket on the back of the front fog
l amp uni t housi ng countercl ockwi se about 30
degrees.
CAUTION: Do not contaminate the bulb glass by
touching it with your fingers or by allowing it to
contact other oily surfaces. Shortened bulb life will
result.
Fig. 9 Junction Block - Outboard Side (RHD Shown
- Rotate 180for LHD)
1 - JB/BCM CONNECTOR
2 - HIGH BEAM RELAY
3 - DRL RELAY
DAYTIME RUNNING LAMP RELAY (Continued)
front fog l amp uni t housi ng and through the access
hol e i nto the front wheel openi ng area.
(7) Pul l the bul b strai ght out of the front fog l amp
uni t socket.
INSTALLATION
result.
i n the front fog l amp uni t socket.
(2) Push the bul b strai ght i nto the front fog l amp
uni t socket unti l i t i s fi rml y seated.
(3) Posi ti on the socket and bul b through the access
hol e i n the front wheel house spl ash shi el d and al i gn
i t wi th the socket openi ng on the back of the front
fog l amp uni t housi ng (Fi g. 10).
front fog l amp uni t housi ng unti l i t i s fi rml y seated.
l amp uni t housi ng cl ockwi se about 30 degrees.
(6) Lower and snap shut the access cover over the
hol e at the front of the front wheel house spl ash
shi el d.
DESCRIPTION
The front fog l amp rel ay i s l ocated i n the Juncti on
Bl ock (JB) on the dri ver si de outboard end of the
i nstrument panel i n the passenger compartment of
the vehi cl e. The front fog l amp rel ay i s a conven-
ti onal I nternati onal Standards Organi zati on (I SO)
mi cro rel ay (Fi g. 11). Rel ays conformi ng to the I SO
ti ons. The rel ay i s contai ned wi thi n a smal l ,
rectangul ar, mol ded pl asti c housi ng and i s connected
to al l of the requi red i nputs and outputs by fi ve i nte-
gral mal e spade-type termi nal s that extend from the
bottom of the rel ay base.
The front fog l amp rel ay cannot be adjusted or
repai red and, i f faul ty or damaged, the uni t must be
repl aced.
OPERATION
The front fog l amp rel ay i s an el ectromechani cal
swi tch that uses a l ow current i nput from the Body
Control Modul e (BCM) to control a hi gh current out-
put to the front fog l amps. The movabl e common feed
contact poi nt i s hel d agai nst the fi xed normal l y
cl osed contact poi nt by spri ng pressure. When the
rel ay coi l i s energi zed, an el ectromagneti c fi el d i s
produced by the coi l wi ndi ngs. Thi s el ectromagneti c
fi el d draws the movabl e rel ay contact poi nt away
from the fi xed normal l y cl osed contact poi nt, and
hol ds i t agai nst the fi xed normal l y open contact
Fig. 10 Front Fog Lamp Bulb Remove/Install
1 - FRONT WHEELHOUSE SPLASH SHIELD
2 - ACCESS HOLE
3 - SOCKET
4 - BULB Fig. 11 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
FRONT FOG LAMP BULB (Continued)
poi nt. When the rel ay coi l i s de-energi zed, spri ng
pressure returns the movabl e contact poi nt back
agai nst the fi xed normal l y cl osed contact poi nt. A
resi stor i s connected i n paral l el wi th the rel ay coi l i n
the rel ay, and hel ps to di ssi pate vol tage spi kes and
el ectromagneti c i nterference that can be generated as
the el ectromagneti c fi el d of the rel ay coi l col l apses.
The front fog l amp rel ay termi nal s are connected
to the vehi cl e el ectri cal system through a connector
receptacl e i n the Juncti on Bl ock (JB). The i nputs and
outputs of the front fog l amp rel ay i ncl ude:
Common Feed Terminal - The common feed
termi nal (30) recei ves battery current at al l ti mes
from a fuse i n the JB through a fused B(+) ci rcui t.
Coil Ground Terminal - The coi l ground termi -
nal (85) i s connected to a control output of the pre-
mi um Body Control Modul e (BCM) through a front
fog l amp rel ay control ci rcui t. The BCM control s
front fog l amp operati on by control l i ng a ground path
through thi s ci rcui t.
Coil Battery Terminal - The coi l battery ter-
mi nal (86) recei ves battery current at al l ti mes from
a fuse i n the JB through a fused B(+) ci rcui t.
Normally Open Terminal - The normal l y open
termi nal (87) i s connected to the front fog l amps
through a front fog l amp rel ay output ci rcui t and
provi des battery current to the front fog l amps when-
ever the rel ay i s energi zed.
Normally Closed Terminal - The normal l y
cl osed termi nal (87A) i s not connected i n thi s appl i -
cati on.
The front fog l amp rel ay can be di agnosed usi ng
conventi onal di agnosti c tool s and methods.
DIAGNOSIS AND TESTING - FRONT FOG LAMP
RELAY
The front fog l amp rel ay (Fi g. 12) i s l ocated i n the
Juncti on Bl ock (JB) under the dri ver si de outboard
end of the i nstrument panel . Refer to the appropri ate
wi ri ng i nformati on. The wi ri ng i nformati on i ncl udes
and grounds.
PERSONAL INJURY.
(1) Remove the front fog l amp rel ay from the JB.
EXTERI OR/FRONT FOG LAMP RELAY - REMOV-
AL).
4. I f not OK, repl ace the faul ty rel ay.
and 30. I f OK, rei nstal l the rel ay and use a DRBI I I
scan tool to perform further testi ng. Refer to the
Fig. 12 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
FRONT FOG LAMP RELAY (Continued)
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - REMOVAL).
(3) Remove the front fog l amp rel ay by graspi ng i t
fi rml y and pul l i ng i t strai ght out from the receptacl e
i n the Juncti on Bl ock (JB) (Fi g. 13).
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the front fog l amp rel ay to the proper
receptacl e i n the Juncti on Bl ock (JB) (Fi g. 13).
(2) Al i gn the front fog l amp rel ay termi nal s wi th
the termi nal cavi ti es i n the JB receptacl e.
(3) Push fi rml y and evenl y on the top of the front
fog l amp rel ay unti l the termi nal s are ful l y seated i n
(4) Rei nstal l the steeri ng col umn openi ng cover
onto the i nstrument panel . (Refer to 23 - BODY/I N-
I NG COVER - I NSTALLATI ON).
Fig. 13 Junction Block - Inboard Side (LHD Shown -
Rotate 180for RHD)
1 - PASSENGER DOOR UNLOCK RELAY
2 - JB C3 CONNECTOR RECEPTACLE
3 - LOW BEAM RELAY
4 - CIRCUIT BREAKER #1
7 - DOOR LOCK RELAY
8 - DEFOGGER RELAY
9 - SPARE
10 - FRONT FOG LAMP RELAY
11 - HORN RELAY
12 - SPARE
13 - SPARE
14 - REAR FOG LAMP RELAY
15 - PARK LAMP RELAY
16 - DRIVER DOOR UNLOCK RELAY
FRONT FOG LAMP UNIT
REMOVAL
cabl e.
(4) Reach through the access hol e to remove the
three screws that secure the front fog l amp uni t to
the front bumper fasci a.
(5) From the front of the vehi cl e, pul l the front fog
l amp uni t out of the front bumper fasci a far enough
to access and di sconnect the wi re harness connector
for the front fog l amp uni t from the l amp socket con-
nector receptacl e (Fi g. 15).
(6) Remove the front fog l amp uni t from the front
bumper fasci a.
INSTALLATION
(1) Posi ti on the front fog l amp uni t to the front
bumper fasci a.
front fog l amp to the l amp socket connector recepta-
cl e (Fi g. 15).
(3) Posi ti on the front fog l amp uni t i nto the front
bumper fasci a.
(4) Reach i nto the front wheel openi ng and
through the access hol e to i nstal l and ti ghten the
three screws that secure the front fog l amp uni t
housi ng to the front bumper fasci a (Fi g. 14). Ti ghten
the screws to 3 Nm (25 i n. l bs.).
(5) Lower and snap shut the cover over the access
shi el d.
(7) Confi rm proper front fog l amp uni t al i gnment.
EXTERI OR/FRONT FOG LAMP UNI T - ADJUST-
MENTS).
ADJ USTMENTS
ADJUSTMENT - FRONT FOG LAMP UNIT
VEHICLE PREPARATION FOR FOG LAMP ALIGNMENT
(1) Repai r or repl ace any faul ty or damaged com-
ponents that coul d hi nder proper l amp al i gnment.
(2) Veri fy proper ti re i nfl ati on.
(3) Cl ean the front fog l amp l enses.
(4) Veri fy that the cargo area i s not heavi l y l oaded.
(5) The fuel tank shoul d be Ful l . Add 2.94 ki l o-
grams (6.5 pounds) of wei ght over the fuel tank for
each esti mated gal l on of mi ssi ng fuel .
FOG LAMP ALIGNMENT
Prepare an al i gnment screen as i l l ustrated. A prop-
erl y al i gned front fog l amp wi l l project a pattern on
the al i gnment screen 100 mi l l i meters (4 i nches)
bel ow the fog l amp centerl i ne and strai ght ahead of
the l amp.
Fig. 14 Front Fog Lamp Unit Remove/Install
1 - FRONT FOG LAMP UNIT
2 - SCREW (3)
4 - FRONT BUMPER FASCIA
5 - ACCESS HOLE
Fig. 15 Front Fog Lamp Unit
1 - ADJUSTING SCREW
2 - MOUNTING BRACKET
3 - HOUSING
4 - SOCKET & BULB
5 - LENS
(1) Posi ti on the vehi cl e on a l evel surface perpen-
di cul ar to a fl at wal l 7.62 meters (25 feet) away from
the front of the front fog l amp l ens (Fi g. 16). I f nec-
essary, tape a l i ne on the fl oor 7.62 meters (25 feet)
away from and paral l el to the wal l .
(2) Measure up on the wal l 1.27 meters (5 feet)
from the fl oor and tape a verti cal l i ne on the al i gn-
ment screen at the centerl i ne of the vehi cl e. Si ght
al ong the centerl i ne of the vehi cl e (from the rear of
the vehi cl e forward) to veri fy the accuracy of the cen-
terl i ne pl acement.
(3) Rock the vehi cl e from si de-to-si de three ti mes
to al l ow the suspensi on to stabi l i ze, then jounce the
front suspensi on three ti mes by pushi ng downward
on the front bumper and rel easi ng. Measure the di s-
tance from the center of the front fog l amp l ens to
the fl oor. Transfer thi s measurement to the al i gn-
ment screen and tape a hori zontal l i ne on the wal l at
thi s mark. Thi s l i ne wi l l be used for up-and-down
adjustment reference.
(4) Measure the di stance from the centerl i ne of the
vehi cl e to the center of each front fog l amp bei ng
al i gned. Transfer these measurements to the al i gn-
ment screen and tape a verti cal l i ne thi s di stance to
each si de of the vehi cl e centerl i ne. These l i nes wi l l be
used for l eft/ri ght reference.
(5) Rotate the front fog l amp adjusti ng screws to
adjust the beam hei ght as requi red (Fi g. 17).
FRONT LAMP BULB
REMOVAL
The front l amp uni t may contai n ei ther one or two
bul bs, dependi ng upon the market for whi ch the
vehi cl e was manufactured. The servi ce procedures for
one bul b or for both bul bs i s the same, onl y the bul b
si zes and types may di ffer. Be certai n any removed
bul b i s repl aced wi th the same bul b si ze and type
that was removed.
cabl e.
(2) Remove the front l amp uni t from the front
bumper fasci a. (Refer to 8 - ELECTRI CAL/LAMPS/
Fig. 16 Front Fog Lamp Alignment - Typical
1 - VEHICLE CENTERLINE
2 - CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS
3 - HIGH-INTENSITY AREA
4 - FLOOR TO CENTER OF FOG LAMP LENS
5 - 100 MILLIMETERS (4 INCHES)
6 - 7.62 METERS (25 FEET)
7 - FRONT OF FOG LAMP
FRONT FOG LAMP UNIT (Continued)
LI GHTI NG - EXTERI OR/FRONT LAMP UNI T -
REMOVAL).
front l amp uni t housi ng for the bul b that i s bei ng
removed (Fi g. 18).
(4) Rotate the socket on the back of the front l amp
uni t housi ng countercl ockwi se about 30 degrees.
back of the front l amp uni t housi ng.
(6) Pul l the bul b strai ght out of the front l amp
uni t socket.
INSTALLATION
i n the front l amp uni t socket.
(2) Push the bul b strai ght i nto the front l amp uni t
i ng on the back of the front l amp uni t housi ng (Fi g.
18).
front l amp uni t housi ng unti l i t i s fi rml y seated.
(6) Rei nstal l the front l amp uni t i nto the front
I NSTALLATI ON).
FRONT LAMP UNIT
REMOVAL
cabl e.
(2) Remove the screw that secures the outboard
end of the front l amp uni t to the front bumper fasci a
(Fi g. 19).
(3) Pul l the outboard end of the front l amp uni t
away from the front bumper fasci a far enough to di s-
Fig. 17 Front Fog Lamp Adjusting Screw
2 - ADJUSTING SCREW
Fig. 18 Front Lamp Bulb Remove/Install
1 - FRONT LAMP UNIT
2 - SIDE MARKER SOCKET
3 - FRONT FASCIA
4 - HEADLAMP & DASH WIRE HARNESS
5 - MOUNTING TAB
6 - PARK/TURN SIGNAL SOCKET
Fig. 19 Front Lamp Unit Remove/Install
1 - FRONT LAMP UNIT
3 - SCREW (1)
FRONT LAMP BULB (Continued)
engage the tab on the i nboard end of the front l amp
uni t housi ng from the receptacl e i n the fasci a.
(4) Pul l the front l amp uni t away from the front
bumper fasci a far enough to access and di sconnect
the wi re harness connector(s) for the front l amp uni t
from the l amp socket pi gtai l wi re(s).
bumper fasci a.
INSTALLATION
(1) Posi ti on the front l amp uni t to the front
bumper fasci a.
(2) Reconnect the wi re harness connector(s) for the
front l amp uni t to the l amp socket pi gtai l wi re(s).
(3) Engage the tab on the i nboard end of the front
l amp uni t housi ng i nto the receptacl e i n the front
bumper fasci a.
(4) Posi ti on the outboard end of the front l amp
uni t housi ng to the front bumper fasci a.
(5) I nstal l and ti ghten the screw that secures the
outboard end of the front l amp uni t housi ng to the
front bumper fasci a (Fi g. 19). Ti ghten the screw to 2
Nm (20 i n. l bs.).
REMOVAL
The front posi ti on l amps are i ntegral to the head-
l amp uni ts on vehi cl es manufactured for certai n mar-
kets where these l amps are requi red.
cabl e.
(2) Remove the headl amp uni t from the front gri l l e
openi ng rei nforcement. (Refer to 8 - ELECTRI CAL/
LAMPS/LI GHTI NG - EXTERI OR/HEADLAMP UNI T
- REMOVAL).
(3) Rotate the front posi ti on l amp socket near the
bottom of the headl amp uni t housi ng countercl ock-
wi se about 30 degrees (Fi g. 20).
headl amp uni t housi ng.
(5) Pul l the bul b strai ght out of the front posi ti on
l amp socket.
INSTALLATION
i n the front posi ti on l amp socket.
(2) Push the bul b strai ght i nto the front posi ti on
l amp socket unti l i t i s fi rml y seated.
i ng near the bottom of the headl amp uni t housi ng
(Fi g. 20).
headl amp uni t housi ng unti l i t i s fi rml y seated
bottom of the headl amp uni t housi ng cl ockwi se about
30 degrees.
(6) Rei nstal l the headl amp uni t onto the gri l l e
- I NSTALLATI ON).
(8) Confi rm proper headl amp uni t al i gnment.
EXTERI OR/HEADLAMP UNI T - ADJUSTMENTS).
Fig. 20 Front Position Lamp Bulb Remove/Install
1 - HEADLAMP HOUSING
2 - SOCKET
3 - BULB
FRONT LAMP UNIT (Continued)
HAZARD SWITCH
DESCRIPTION
The hazard swi tch i s i ntegral to the hazard swi tch
modul e, whi ch i s secured near the center of i nstrument
panel just above the radi o (Fi g. 21). Onl y the hazard
swi tch button i s vi si bl e through a dedi cated, round, bev-
el ed openi ng on the outer surface of the i nstrument
panel between the two center panel outl ets of the heater
and ai r condi ti oni ng system. A red, stenci l -l i ke I nterna-
ti onal Control and Di spl ay Symbol i con for Hazard
Warni ng i denti fi es the hazard swi tch button. On the
opposi te end of the bl ack, mol ded pl asti c hazard swi tch
modul e housi ng from the swi tch button i s an i ntegral
connector receptacl e and a stamped steel mounti ng
bracket wi th two l atch feature tabs that extend down-
ward, whi l e a short dowel -l i ke al i gnment pi n i s i ntegral
to each si de of the housi ng just bel ow the swi tch button.
The swi tch modul e i s connected to the vehi cl e el ectri cal
system through a dedi cated take out and connector of
the i nstrument panel wi re harness. Wi thi n the hazard
swi tch modul e housi ng i s the hazard swi tch ci rcui try
and an el ectroni c ci rcui t board wi th the i ntegral combi -
nati on fl asher ci rcui try. The el ectroni c combi nati on
fl asher ci rcui try performs both the hazard fl asher and
turn si gnal fl asher functi ons.
The hazard swi tch modul e cannot be adjusted or
repl aced.
OPERATION
The hazard swi tch button i s sl i ghtl y recessed i n the
i nstrument panel when the swi tch i s i n the Off posi ti on,
and l atches at a posi ti on that i s fl ush wi th the outer
surface of the i nstrument panel when i n the On posi -
ti on. The hazard swi tch modul e produces an audi bl e
cl i cki ng sound that emul ates the sound of a conven-
ti onal fl asher whenever the turn si gnal s or the hazard
warni ng system are acti vated. The hazard swi tch mod-
ul e recei ves battery current on a fused B(+) ci rcui t from
a fuse i n the Juncti on Bl ock (JB) at al l ti mes for oper-
ati on of the hazard warni ng, and on a fused i gni ti on
swi tch output (run) ci rcui t from another fuse i n the JB
whenever the i gni ti on swi tch i s i n the On posi ti on for
operati on of the turn si gnal s. The modul e recei ves a
path to ground through a spl i ce bl ock l ocated i n the
i nstrument panel wi re harness wi th an eyel et termi nal
connector that i s secured by a nut to a ground stud on
the dri ver si de i nstrument panel end bracket near the
JB. I nputs to and outputs from the hazard swi tch mod-
ul e i ncl ude:
Panel Lamps Dimmer Input - A non-servi ce-
abl e i ncandescent bul b sol dered onto the hazard
swi tch modul e ci rcui t board provi des i l l umi nati on of
the swi tch button when the exteri or l i ghti ng i s
turned On through an i nput recei ved on the fused
panel l amps di mmer swi tch si gnal ci rcui t. However,
thi s bul b fl ashes on and off at ful l i ntensi ty whenever
the hazard swi tch button i s i n the On posi ti on,
regardl ess of the status of the exteri or l i ghti ng.
Hazard Switch Input - The combi nati on
fl asher ci rcui try of the hazard swi tch modul e recei ves
an i nternal ground i nput from the hazard swi tch to
request hazard fl asher operati on.
Multi-Function Switch Input - The combi na-
ti on fl asher ci rcui try of the hazard swi tch modul e
recei ves separate ground i nputs from the turn si gnal
swi tch ci rcui try of the mul ti -functi on swi tch on ri ght
and l eft turn swi tch sense ci rcui ts to request ri ght or
l eft turn si gnal fl asher operati on.
Body Control Module Input - The Body Con-
trol Modul e (BCM) can request hazard fl asher opera-
ti on by provi di ng a ground path to the combi nati on
fl asher ci rcui try of the hazard swi tch modul e through
a hazard l amp control ci rcui t.
Turn Signal Output - The combi nati on fl asher
ci rcui try wi thi n the hazard swi tch modul e responds
to the fl asher request i nputs by energi zi ng and
de-energi zi ng two mi ni ature rel ays on the modul e
ci rcui t board. These rel ays control the swi tch output
through the ri ght and l eft turn si gnal ci rcui ts. One
rel ay control s the ri ght l amps, whi l e the other con-
trol s the l eft.
hazard swi tch modul e, i t cannot be tested wi th con-
hazard swi tch modul e i s bel i eved to be faul ty, repl ace
the swi tch wi th a known good uni t to confi rm system
operati on.
Fig. 21 Hazard Switch
1 - HAZARD SWITCH BUTTON
2 - SCREW (1)
3 - MOUNTING BRACKET TABS
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM
STEERING COLUMN, DRIVER AIRBAG, PASSENGER
AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT
SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE. DIS-
CONNECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE SUP-
PLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(2) Remove the radi o from the i nstrument panel .
(Refer to 8 - ELECTRI CAL/AUDI O/RADI O - REMOVAL).
(3) Remove the screw at the top of the i nstrument
panel radi o openi ng that secures the hazard swi tch
to the i nstrument panel tri m (Fi g. 22).
(4) Reach through and above the i nstrument panel
radi o openi ng to access the two l atch tabs of the
stamped metal hazard swi tch mounti ng bracket.
(5) Usi ng two fi ngerti ps, pul l rearward and down-
ward on the l atch tabs on the back of the hazard
swi tch unti l i t i s di sengaged from the i nstrument
panel tri m.
(6) Push the hazard swi tch button through the
button openi ng of the i nstrument panel far enough to
di sengage the al i gnment pi ns on each si de of the
swi tch housi ng from the saddl e formati ons of the two
stanchi ons on the back of the i nstrument panel tri m,
just bel ow and to ei ther si de of the button openi ng.
connector for the hazard swi tch from the swi tch con-
nector receptacl e.
(8) Remove the hazard swi tch through the i nstru-
ment panel radi o openi ng.
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the hazard swi tch through the i nstru-
connector for the hazard swi tch to the swi tch connec-
tor receptacl e.
radi o openi ng to posi ti on the hazard swi tch for
i nstal l ati on.
(4) Gui de the hazard swi tch button through the
button openi ng of the i nstrument panel , whi ch wi l l
engage the al i gnment pi ns on each si de of the swi tch
housi ng wi th the saddl e formati ons of the two stan-
chi ons on the back of the i nstrument panel tri m, just
bel ow and to ei ther si de of the button openi ng.
(5) Usi ng hand pressure, press upward on the
back of the hazard swi tch unti l the l atch tabs of the
mounti ng bracket on the back of the swi tch are both
engaged wi th the i nstrument panel tri m (Fi g. 22).
(6) I nstal l and ti ghten the screw at the top of the
i nstrument panel radi o openi ng that secures the haz-
ard swi tch to the i nstrument panel tri m. Ti ghten the
screw to 2 Nm (17 i n. l bs.).
(7) Rei nstal l the radi o i nto the i nstrument panel .
(Refer to 8 - ELECTRI CAL/AUDI O/RADI O -
I NSTALLATI ON).
Fig. 22 Hazard Switch Remove/Install
2 - HAZARD SWITCH
3 - ALIGNMENT PIN (2)
4 - STANCHION (2)
6 - SCREW (1)
7 - MOUNTING BRACKET LATCH TAB (2)
HAZARD SWITCH (Continued)
HEADLAMP BULB
REMOVAL
NORTH AMERICA
cabl e.
(2) Reach behi nd the headl amp uni t from the
engi ne compartment si de of the upper radi ator cross-
member to access the headl amp bul b l ock ri ng (Fi g.
23).
(3) Fi rml y grasp the l ock ri ng on the back of the
(4) Rotate the l ock ri ng on the back of the head-
degrees.
result.
(5) Pul l the l ock ri ng, socket, and bul b strai ght out
of the headl amp uni t housi ng and up from behi nd
the upper radi ator crossmember (Fi g. 24).
(6) Di sconnect the gri l l e openi ng rei nforcement
wi re harness connector for the headl amp bul b from
the connector receptacl e on the bul b socket.
(7) Remove the bul b and bul b socket from the l ock
ri ng as a uni t.
REST-OF-WORLD
cabl e.
(2) Remove the headl amp uni t from the gri l l e
- REMOVAL).
(3) Fi rml y grasp the tab of the headl amp boot seal
on the back of the headl amp uni t housi ng (Fi g. 25).
(4) Pul l the tab away from the back of the head-
l amp uni t housi ng to remove the boot seal from the
housi ng and the bul b base.
Fig. 23 Headlamp Bulb Lock Ring
1 - HEADLAMP UNIT HOUSING
2 - LOCK RING
3 - SOCKET & BULB
Fig. 24 Headlamp Bulb Remove/Install
1 - HEADLAMP BULB
2 - SOCKET
3 - LOCK RING
Fig. 25 Headlamp Bulb Boot Seal Remove
1 - LEVELING MOTOR (IF EQUIPPED)
2 - BOOT SEAL
3 - FRONT POSITION LAMP
4 - ADJUSTING SCREW
5 - TAB
6 - BULB BASE
(5) Pi nch the two hooked ends of the wi re head-
l amp bul b retai ner cl i p together and di sengage them
from the sl ots i n the fl ange of the refl ector (Fi g. 26).
(6) Pi vot the headl amp bul b retai ner cl i p up off of
the bul b fl ange and out of the way.
result.
(7) Pul l the bul b strai ght out of the headl amp uni t
refl ector (Fi g. 27).
INSTALLATION
NORTH AMERICA
result.
(1) Posi ti on the headl amp bul b and socket uni t
i nto the l ock ri ng (Fi g. 24).
(2) Reconnect the gri l l e openi ng rei nforcement
wi re harness connector for the headl amp bul b to the
connector receptacl e on the bul b socket.
(3) Posi ti on the l ock ri ng, socket, and bul b down
behi nd the upper radi ator crossmember and al i gn
them wi th the socket openi ng on the back of the
headl amp uni t housi ng unti l they are fi rml y seated.
(5) Posi ti on the l ock ri ng over the socket and
engage i t wi th the fl ange on the back of the head-
l amp uni t housi ng (Fi g. 23).
REST-OF-WORLD
result.
(1) Posi ti on the bul b i nto the headl amp uni t refl ec-
tor (Fi g. 27).
(2) Pi vot the headl amp bul b retai ner cl i p back over
the bul b fl ange.
Fig. 26 Headlamp Bulb Retainer Clip Engage/
Disengage
1 - RETAINER CLIP
2 - BULB BASE
4 - REFLECTOR
5 - BULB FLANGE
6 - RETAINER SLOTS
1 - BULB BASE
2 - RETAINER CLIP
4 - REFLECTOR
6 - BULB FLANGE
HEADLAMP BULB (Continued)
l amp bul b retai ner cl i p together and engage them
i nto the sl ots i n the fl ange of the refl ector (Fi g. 26).
(4) Posi ti on the center openi ng of the boot seal
over the base of the headl amp bul b and pul l i t down-
ward unti l the seal i s ful l y engaged over the bul b
base (Fi g. 25).
(5) Posi ti on the outer ci rcumference of the boot
seal over the fl ange on the back of the headl amp uni t
housi ng and pul l i t downward unti l the seal i s ful l y
engaged over the fl ange.
- I NSTALLATI ON).
HEADLAMP HIGH BEAM
RELAY
DESCRIPTION
The headl amp hi gh beam rel ay i s l ocated i n the
of the i nstrument panel i n the passenger compart-
ment of the vehi cl e. The headl amp hi gh beam rel ay
i s omi tted from vehi cl es manufactured for sal e i n
Canada, whi ch have a Dayti me Runni ng Lamp (DRL)
sol i d state rel ay i nstal l ed i n the JB that al so per-
forms the functi on of the headl amp hi gh beam rel ay.
The headl amp hi gh beam rel ay i s a conventi onal
I nternati onal Standards Organi zati on (I SO) mi cro
rel ay (Fi g. 28). Rel ays conformi ng to the I SO speci fi -
cati ons have common physi cal di mensi ons, current
capaci ti es, termi nal patterns, and termi nal functi ons.
The rel ay i s contai ned wi thi n a smal l , rectangul ar,
mol ded pl asti c housi ng and i s connected to al l of the
requi red i nputs and outputs by fi ve i ntegral mal e
spade-type termi nal s that extend from the bottom of
the rel ay base.
The headl amp hi gh beam rel ay cannot be adjusted
or repai red and, i f faul ty or damaged, the uni t must
be repl aced.
OPERATION
The headl amp hi gh beam rel ay i s an el ectrome-
chani cal swi tch that uses a l ow current i nput from
the Body Control Modul e (BCM) to control a hi gh
current output to the headl amp hi gh beam fi l aments.
The movabl e common feed contact poi nt i s hel d
agai nst the fi xed normal l y cl osed contact poi nt by
spri ng pressure. When the rel ay coi l i s energi zed, an
el ectromagneti c fi el d i s produced by the coi l wi nd-
i ngs. Thi s el ectromagneti c fi el d draws the movabl e
rel ay contact poi nt away from the fi xed normal l y
cl osed contact poi nt, and hol ds i t agai nst the fi xed
normal l y open contact poi nt. When the rel ay coi l i s
de-energi zed, spri ng pressure returns the movabl e
contact poi nt back agai nst the fi xed normal l y cl osed
contact poi nt. A resi stor i s connected i n paral l el wi th
the rel ay coi l i n the rel ay, and hel ps to di ssi pate vol t-
age spi kes and el ectromagneti c i nterference that can
be generated as the el ectromagneti c fi el d of the rel ay
coi l col l apses.
The headl amp hi gh beam rel ay termi nal s are con-
nected to the vehi cl e el ectri cal system through a con-
nector receptacl e i n the Juncti on Bl ock (JB). The
i nputs and outputs of the headl amp hi gh beam rel ay
i ncl ude:
from a fuse i n the Power Di stri buti on Center (PDC)
through a fused B(+) ci rcui t.
nal (85) recei ves battery current at al l ti mes from a
fuse i n the PDC through a fused B(+) ci rcui t.
mi nal (86) i s connected to a control output of the
Body Control Modul e (BCM) and to the momentary
opti cal horn (fl ash-to-pass) output of the mul ti -func-
ti on swi tch through a hi gh beam rel ay control ci rcui t.
The BCM and/or the mul ti -functi on swi tch control s
headl amp hi gh beam operati on by control l i ng a
ground path through thi s ci rcui t.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
termi nal (87) i s connected to the headl amp hi gh
beam fi l aments through the hi gh beam rel ay output
ci rcui t and provi des battery current to the headl amp
hi gh beams whenever the rel ay i s energi zed.
cati on.
The headl amp hi gh beam rel ay can be di agnosed
usi ng conventi onal di agnosti c tool s and methods.
DIAGNOSIS AND TESTING - HEADLAMP HIGH
BEAM RELAY
The headl amp hi gh beam rel ay (Fi g. 29) i s l ocated
i n the Juncti on Bl ock (JB) on the dri ver si de out-
board end of the i nstrument panel . Refer to the
PERSONAL INJURY.
(1) Remove the headl amp hi gh beam rel ay from
the JB. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR/HEADLAMP HI GH BEAM RELAY
- REMOVAL).
REMOVAL
PERSONAL INJURY.
cabl e.
(3) Remove the headl amp hi gh beam rel ay by
graspi ng i t fi rml y and pul l i ng i t strai ght out from the
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
HEADLAMP HIGH BEAM RELAY (Continued)
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the headl amp hi gh beam rel ay to the
proper receptacl e i n the Juncti on Bl ock (JB) (Fi g. 30).
(2) Al i gn the headl amp hi gh beam rel ay termi nal s
wi th the termi nal cavi ti es i n the JB receptacl e.
(3) Push fi rml y and evenl y on the top of the head-
l amp hi gh beam rel ay unti l the termi nal s are ful l y
seated i n the termi nal cavi ti es i n the JB receptacl e.
DESCRIPTION
The headl amp l evel i ng motor i s l ocated on the rear
i nboard si de of each headl amp uni t on model s
equi pped wi th the headl amp l evel i ng system, whi ch
i s avai l abl e onl y i n certai n markets where requi red
(Fi g. 31). The motor i s encased wi thi n a mol ded pl as-
ti c housi ng and i s secured by an i ntegral wedge-type
mounti ng boss on i ts forward surface to a fl anged
receptacl e on the back of the headl amp uni t housi ng.
A rubber seal around the ci rcumference of the
mounti ng boss i s compressed and seal s the motor to
the headl amp uni t when the boss i s properl y
i nstal l ed i n the fl anged receptacl e. The outsi de of the
motor housi ng features an i ntegral mol ded connector
receptacl e on i ts rearward surface, a hex-headed
adjusti ng screw extends from the top of the housi ng,
and a pl asti c pushrod wi th a bal l formati on on i ts
free end extends from the center of the mounti ng
boss at the front. Wi thi n the motor housi ng i s a
12-vol t Di rect Current (DC) servo motor, an el ec-
troni c control l er board that i ncl udes the motor l ogi c
ci rcui ts, and an i ntegral screw-dri ve transmi ssi on.
The headl amp l evel i ng motor i s connected to the
vehi cl e el ectri cal system through a dedi cated take
out and connector of the front fasci a wi re harness.
The headl amp l evel i ng motor cannot be repai red
and, i f faul ty or damaged, the uni t must be repl aced.
2 - HIGH BEAM RELAY
3 - DRL RELAY
Fig. 31 Headlamp Unit - With Leveling
2 - BOOT SEAL
3 - ADJUSTING SCREW
4 - LOCATOR TAB
5 - HOUSING
6 - FRONT POSITION LAMP SOCKET & BULB
7 - HEADLAMP BULB
8 - MOUNTING TAB (2)
OPERATION
The control l er board and l ogi c ci rcui try of the
headl amp l evel i ng motor wi l l energi ze the motor and
extend or retract the motor pushrod through the
i ntegral screw-dri ve transmi ssi on based upon the
vol tage si gnal i nput recei ved from the resi stor mul ti -
pl exed headl amp l evel i ng swi tch. The bal l formati on
on the end of the headl amp l evel i ng motor pushrod i s
snapped i nto a socket formati on on the back of the
movabl e refl ector wi thi n the headl amp uni t housi ng.
The headl amp l evel i ng motors and swi tch have a
path to ground at al l ti mes. The headl amp l evel i ng
components operate on battery current recei ved
through the fused park l amp rel ay output ci rcui t so
that the system wi l l onl y operate when the exteri or
l i ghti ng i s turned On.
headl amp l evel i ng motor, i t cannot be tested wi th
conventi onal automoti ve el ectri cal test equi pment. I f
the headl amp l evel i ng motor i s bel i eved to be faul ty,
repl ace the motor wi th a known good uni t to confi rm
system operati on.
REMOVAL
The headl amp l evel i ng motors are i ntegral to the
headl amp uni ts on vehi cl es manufactured for certai n
markets where headl amp l evel i ng i s requi red.
cabl e.
(2) Remove the headl amp bul b from the headl amp
uni t housi ng. (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/HEADLAMP BULB -
REMOVAL).
(3) Rotate the headl amp l evel i ng motor on the
back of the headl amp uni t housi ng countercl ockwi se
about 30 degrees (Fi g. 32).
(4) Fi rml y grasp the motor wi th one hand whi l e
stabi l i zi ng the headl amp uni t housi ng wi th the other
hand.
(5) Fi rml y, steadi l y, and forceful l y pul l the head-
l amp l evel i ng motor strai ght away from the back of
the headl amp uni t housi ng to unsnap the bal l forma-
ti on on the end of the motor pushrod from the socket
on the headl amp uni t refl ector (Fi g. 33).
(6) Remove the headl amp l evel i ng motor and push-
rod from the back of the headl amp uni t housi ng.
INSTALLATION
(1) Posi ti on the headl amp l evel i ng motor and
pushrod from to the mounti ng hol e on the back of the
(2) I nsert two fi ngers through the bul b mounti ng
hol e i n the center of the headl amp refl ector and pul l
the refl ector upwards toward the headl amp l evel i ng
motor.
(3) Al i gn the bal l formati on on the end of the l ev-
el i ng motor pushrod wi th the socket on the headl amp
uni t refl ector (Fi g. 33).
(4) Whi l e conti nui ng to pul l i ng the refl ector
toward the motor, fi rml y, steadi l y, and forceful l y push
the headl amp l evel i ng motor strai ght i nto the back of
the headl amp uni t housi ng to snap the bal l formati on
on the end of the motor pushrod i nto the socket on
the headl amp uni t refl ector.
(5) After the pushrod i s engaged to the refl ector,
remove your fi ngers from the bul b mounti ng hol e i n
Fig. 32 Headlamp Leveling Motor Remove/Install
1 - LEVELING MOTOR
3 - PUSHROD
Fig. 33 Leveling Motor Pushrod - Typical
1 - REFLECTOR PUSHROD SOCKET
2 - PUSHROD
3 - LEVELING MOTOR
HEADLAMP LEVELING MOTOR (Continued)
the center of the headl amp refl ector and thoroughl y
cl ean any fi ngerpri nts from the refl ector.
(6) Push the mounti ng fl ange of the headl amp l ev-
el i ng motor i nto the mounti ng hol e on the back of
headl amp uni t housi ng uni t the motor i s fi rml y
seated (Fi g. 32).
back of the headl amp uni t housi ng cl ockwi se about
30 degrees.
(8) Rei nstal l the headl amp bul b i nto the headl amp
I NSTALLATI ON).
HEADLAMP LEVELING
SWITCH
DESCRIPTION
The headl amp l evel i ng swi tch (Fi g. 34) i s used onl y
on vehi cl es manufactured for certai n markets where
the headl amp l evel i ng system i s requi red. The head-
l amp l evel i ng swi tch i s mounted i n the dri ver si de
i nboard tri m bezel on the i nstrument panel , where i t
i s secured by mol ded l atch features that are i ntegral
to the swi tch housi ng. Onl y the swi tch bezel and
thumbwheel are vi si bl e on the outer surface of the
i nstrument panel tri m bezel . The bl ack pl asti c swi tch
thumbwheel i s marked wi th whi te numbers 0, 1,
2, and 3, each of whi ch i ndi cates one of the four
swi tch detent posi ti ons. Each hi gher number repre-
sents a l ower ai mi ng posi ti on of the headl amp beam
rel ati ve to the road surface. The bl ack, mol ded pl as-
ti c swi tch housi ng has an i ntegral connector recepta-
cl e on the back, a si ngl e l atch feature on the top, and
two l atch features (one on each si de) on the bottom.
The swi tch i s connected to the vehi cl e el ectri cal sys-
tem through a dedi cated take out and connector of
the i nstrument panel wi re harness. Wi thi n the
swi tch housi ng i s the l evel i ng swi tch ci rcui try i ncl ud-
i ng the swi tch contacts and a seri es resi stor confi gu-
rati on.
The headl amp l evel i ng swi tch cannot be adjusted
be repl aced.
OPERATION
The headl amp l evel i ng swi tch recei ves battery cur-
rent on a fused park l amp rel ay output ci rcui t from a
fuse i n the Juncti on Bl ock (JB) whenever the park
l amp rel ay i s energi zed (park l amps are turned On).
The swi tch recei ves a path to ground through a spl i ce
bl ock l ocated i n the i nstrument panel wi re harness
wi th an eyel et termi nal connector that i s secured by
a nut to a ground stud on the dri ver si de i nstrument
panel end bracket near the JB. The onl y output from
the swi tch i s a vol tage si gnal that i t provi des to the
headl amp l evel i ng motors on a headl amp adjust si g-
nal ci rcui t. Each swi tch posi ti on sel ects a di fferent
tap on a seri es resi stor wi thi n the swi tch to provi de a
di fferent vol tage si gnal to the l evel i ng motors. The
hi gher the swi tch posi ti on number, the hi gher the
output vol tage l evel .
The headl amp l evel i ng swi tch can be tested usi ng
LEVELING SWITCH
PERSONAL INJURY.
Fig. 34 Headlamp Leveling Switch
1 - SWITCH
2 - UPPER LATCH FEATURE (1)
4 - LOWER LATCH FEATURE (2)
5 - THUMBWHEEL
connector for the headl amp l evel i ng swi tch from the
(2) Usi ng an ohmmeter, perform the resi stance
tests at the termi nal pi ns i n the headl amp l evel i ng
swi tch connector receptacl e (Fi g. 35) as shown i n the
Headl amp Level i ng Swi tch Tests tabl e.
HEADLAMP LEVELING SWITCH TESTS
SWITCH POSITION
RESISTANCE (OHMS)
BETWEEN PINS 1 & 3
0 0.5 0.5
1 301 1
2 595 1
3 739 1
(3) I f the swi tch fai l s any of the resi stance tests,
repl ace the faul ty headl amp l evel i ng swi tch as
requi red.
REMOVAL
The headl amp l evel i ng swi tch i s used onl y on vehi -
cl es manufactured for certai n markets where head-
l amp l evel i ng i s requi red.
PERSONAL INJURY.
cabl e.
(2) Remove the dri ver si de i nboard bezel from the
i nstrument panel . (Refer to 23 - BODY/I NSTRU-
MENT PANEL/I NSTRUMENT PANEL DRI VER
SI DE BEZEL - REMOVAL).
swi tch connector receptacl e (Fi g. 36).
(4) From the back of the tri m bezel , depress the
two l ower l atch features on the headl amp l evel i ng
swi tch housi ng and rock the bottom of the swi tch out
through the face of the bezel .
upper l atch feature on the headl amp l evel i ng swi tch
housi ng and push the swi tch out through the face of
the bezel .
INSTALLATION
Fig. 35 Headlamp Leveling Switch Connector
Receptacle
Fig. 36 Headlamp Leveling Switch Remove/Install
1 - HEADLAMP LEVELING SWITCH
2 - UPPER LATCH TAB
3 - RECEPTACLE
4 - DRIVER SIDE INBOARD BEZEL
5 - LOWER LATCH TAB (2)
HEADLAMP LEVELING SWITCH (Continued)
PERSONAL INJURY.
(1) From the face of the dri ver si de i nboard bezel ,
al i gn the headl amp l evel i ng swi tch housi ng to the
mounti ng hol e i n the bezel (Fi g. 36).
(2) Push the headl amp l evel i ng swi tch i nto the
mounti ng hol e unti l i t i s ful l y seated and the upper
l atch and two l ower l atch features on the swi tch
housi ng are engaged on the back of the bezel .
(3) Posi ti on the swi tch and bezel uni t to the
i nstrument panel .
connector for the headl amp l evel i ng swi tch to the
(5) Rei nstal l the dri ver si de i nboard bezel onto the
SI DE BEZEL - I NSTALLATI ON).
DESCRIPTION
The headl amp l ow beam rel ay i s l ocated i n the
Juncti on Bl ock (JB) bel ow the dri ver si de outboard
end of the i nstrument panel i n the passenger com-
partment of the vehi cl e. The headl amp l ow beam
rel ay i s a conventi onal I nternati onal Standards
Organi zati on (I SO) mi cro rel ay (Fi g. 37). Rel ays con-
formi ng to the I SO speci fi cati ons have common phys-
i cal di mensi ons, current capaci ti es, termi nal
patterns, and termi nal functi ons. The rel ay i s con-
tai ned wi thi n a smal l , rectangul ar, mol ded pl asti c
housi ng and i s connected to al l of the requi red i nputs
and outputs by fi ve i ntegral mal e spade-type termi -
nal s that extend from the bottom of the rel ay base.
The headl amp l ow beam rel ay cannot be adjusted
be repl aced.
OPERATION
The headl amp l ow beam rel ay i s an el ectromechan-
i cal swi tch that uses a l ow current i nput from the
Body Control Modul e (BCM) to control a hi gh current
output to the headl amp l ow beam fi l aments. The
movabl e common feed contact poi nt i s hel d agai nst
the fi xed normal l y cl osed contact poi nt by spri ng
pressure. When the rel ay coi l i s energi zed, an el ectro-
magneti c fi el d i s produced by the coi l wi ndi ngs. Thi s
el ectromagneti c fi el d draws the movabl e rel ay con-
tact poi nt away from the fi xed normal l y cl osed con-
tact poi nt, and hol ds i t agai nst the fi xed normal l y
open contact poi nt. When the rel ay coi l i s de-ener-
gi zed, spri ng pressure returns the movabl e contact
poi nt back agai nst the fi xed normal l y cl osed contact
poi nt. A resi stor i s connected i n paral l el wi th the
rel ay coi l i n the rel ay, and hel ps to di ssi pate vol tage
spi kes and el ectromagneti c i nterference that can be
generated as the el ectromagneti c fi el d of the rel ay
coi l col l apses.
The headl amp l ow beam rel ay termi nal s are con-
i nputs and outputs of the headl amp l ow beam rel ay
i ncl ude:
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
Body Control Modul e (BCM) through a l ow beam
rel ay control ci rcui t. The BCM control s headl amp l ow
beam operati on by control l i ng a ground path through
thi s ci rcui t.
termi nal (87) i s connected to the headl amp l ow beam
fi l aments through the l ow beam rel ay output ci rcui t
and provi des battery current to the headl amp l ow
beams whenever the rel ay i s energi zed.
cati on.
The headl amp l ow beam rel ay can be di agnosed
BEAM RELAY
The headl amp l ow beam rel ay (Fi g. 38) i s l ocated
i n the Juncti on Bl ock (JB) under the dri ver si de out-
PERSONAL INJURY.
(1) Remove the headl amp l ow beam rel ay from the
JB. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG -
EXTERI OR/HEADLAMP LOW BEAM RELAY -
REMOVAL).
REMOVAL
PERSONAL INJURY.
cabl e.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
HEADLAMP LOW BEAM RELAY (Continued)
(3) Remove the headl amp l ow beam rel ay by
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the headl amp l ow beam rel ay to the
(2) Al i gn the headl amp l ow beam rel ay termi nal s
l amp l ow beam rel ay unti l the termi nal s are ful l y
HEADLAMP UNIT
REMOVAL
cabl e.
(2) Remove the gri l l e panel from the gri l l e openi ng
rei nforcement. (Refer to 23 - BODY/EXTERI OR/
GRI LLE - REMOVAL).
(3) Remove the two screws that secure the mount-
i ng tabs on the i nboard si de of the headl amp uni t
housi ng to the gri l l e openi ng rei nforcement (Fi g. 40).
(4) Pul l the i nboard si de of the headl amp uni t
away from the gri l l e openi ng rei nforcement far
Rotate 180for RHD)
3 - LOW BEAM RELAY
7 - DOOR LOCK RELAY
8 - DEFOGGER RELAY
9 - SPARE
11 - HORN RELAY
12 - SPARE
13 - SPARE
Fig. 40 Headlamp Unit Remove/Install
1 - FENDER PANEL
2 - HEADLAMP UNIT
4 - MOUNTING PANEL
5 - LOCATOR TAB
enough to di sengage the l ocator tab on the outboard
si de of the uni t (Fi g. 41) or (Fi g. 42) from the engage-
ment sl ot i n the outboard edge of the rei nforcement.
(5) Pul l the headl amp uni t away from the gri l l e
openi ng rei nforcement far enough to di sconnect the
wi re harness connectors from the headl amp bul b
socket (North Ameri ca), the headl amp bul b base
(Rest-Of-Worl d), the front posi ti on l amp socket (i f
equi pped), and the headl amp l evel i ng motor (i f
equi pped).
openi ng rei nforcement.
INSTALLATION
(1) Posi ti on the headl amp uni t to the gri l l e open-
i ng rei nforcement.
(2) Reconnect the wi re harness connectors to the
headl amp bul b socket (North Ameri ca), the headl amp
bul b base (Rest-Of-Worl d), the front posi ti on l amp
socket (i f equi pped), and the headl amp l evel i ng motor
(i f equi pped) (Fi g. 41) or (Fi g. 42).
(3) Engage the l ocator tab on the outboard si de of
the headl amp uni t i nto the engagement sl ot i n the
outboard edge of the gri l l e openi ng rei nforcement.
(4) Al i gn the two mounti ng tabs on the i nboard
si de of the headl amp uni t housi ng to the mounti ng
hol es i n the gri l l e openi ng rei nforcement (Fi g. 40).
the mounti ng tabs on the i nboard si de of the head-
l amp uni t housi ng to the gri l l e openi ng rei nforce-
ment. Ti ghten the screws to 3 Nm (30 i n. l bs.).
(6) Rei nstal l the gri l l e panel onto the gri l l e open-
i ng rei nforcement. (Refer to 23 - BODY/EXTERI OR/
GRI LLE - I NSTALLATI ON).
ADJ USTMENTS
ADJUSTMENT - HEADLAMP UNIT
VEHICLE PREPARATION FOR HEADLAMP ALIGNMENT
(1) Veri fy headl amp di mmer (mul ti -functi on)
swi tch and hi gh beam i ndi cator operati on.
(2) I f the vehi cl e i s equi pped wi th headl amp l evel -
i ng, be certai n that the headl amp l evel i ng swi tch i s
i n the 0 posi ti on.
(5) Cl ean headl amp l enses.
(6) Veri fy that cargo area i s not heavi l y l oaded.
HEADLAMP ALIGNMENT SCREEN PREPARATION
Prepare an al i gnment screen as i l l ustrated.
Fig. 41 Headlamp Unit - North America
2 - ADJUSTING SCREW
3 - LOCK RING
4 - HOUSING
5 - LOCATOR TAB
6 - SOCKET & BULB
Fig. 42 Headlamp Unit - Rest-Of-World
2 - BOOT SEAL
3 - ADJUSTING SCREW
4 - LOCATOR TAB
5 - HOUSING
7 - HEADLAMP BULB
HEADLAMP UNIT (Continued)
the front of the headl amp l ens for North Ameri can
vehi cl es, or 10.0 meters (32.81 feet) away from the
front of the headl amp l ens for Rest-Of-Worl d vehi cl es
(Fi g. 43). I f necessary, tape a l i ne on the fl oor at the
appropri ate di stance away from and paral l el to the
wal l .
tance from the center of the headl amp l ens to the
fl oor. Transfer thi s measurement to the al i gnment
screen and tape a hori zontal l i ne on the wal l at thi s
mark. Thi s l i ne wi l l be used for up-and-down adjust-
ment reference.
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer these measurements to the al i gnment
screen and tape a verti cal l i ne thi s di stance to each
si de of the vehi cl e centerl i ne. These l i nes wi l l be used
for l eft/ri ght reference.
HEADLAMP ADJUSTMENT
A properl y al i gned headl amp wi l l project a pattern
on the al i gnment screen from just bel ow hori zontal to
75 mi l l i meters (3 i nches) bel ow the headl amp center-
l i ne for vehi cl es i n North Ameri ca, or from just bel ow
hori zontal to 125 mi l l i meters (5 i nches) bel ow the
headl amp hori zontal centerl i ne for vehi cl es i n Rest-
Of-Worl d.
(1) Vehi cl es for al l markets except Japan shoul d
have the headl amp l ow beams sel ected wi th the di m-
mer (mul ti -functi on) swi tch duri ng the adjustment
procedure. Vehi cl es for the Japanese market shoul d
have the headl amp hi gh beams sel ected.
(2) Cover the l ens of the headl amp that i s not
bei ng adjusted.
Fig. 43 Headlamp Alignment Screen - Typical
1 - CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS
2 - FLOOR TO CENTER OF HEADLAMP LENS
3 - 7.62 METERS (25 FEET) NORTH AMERICA/10.0 METERS
(32.81 FEET) REST-OF-WORLD
4 - FRONT OF HEADLAMP
(3) Turn the adjusti ng screw (Fi g. 44) unti l the top
edge of the beam i ntensi ty pattern i s posi ti oned from
just bel ow hori zontal to 75 mi l l i meters (3 i nches)
bel ow the headl amp hori zontal centerl i ne for vehi cl es
i n North Ameri ca, or from just bel ow hori zontal to
125 mi l l i meters (5 i nches) bel ow the headl amp hori -
zontal centerl i ne for vehi cl es i n Rest-Of-Worl d.
(4) Repeat the adjustment procedure for the oppo-
si te headl amp.
REMOVAL
NORTH AMERICA
cabl e.
(2) Reach through the openi ng i n the rear bumper
fasci a between the l i cense pl ate and the l amp to
access and fi rml y grasp the socket on the back of the
l i cense pl ate l amp uni t housi ng (Fi g. 45).
back of the l i cense pl ate l amp uni t housi ng.
(4) Pul l the bul b strai ght out of the l i cense pl ate
l amp uni t socket.
REST-OF-WORLD
cabl e.
(2) Unsnap and l i ft up the bottom of the l i cense
mounti ng pl ate far enough to access and remove the
two screws that secure the l i cense pl ate bracket to
the speci al l ug nuts on the spare ti re (Fi g. 46).
(3) Swi ng the l i cense pl ate bracket away from the
spare ti re far enough to access the l i cense pl ate l amp
bul b sockets.
(4) Fi rml y grasp the socket on the top of the
l i cense pl ate l amp uni t housi ng for the bul b that i s
bei ng removed (Fi g. 47).
(5) Rotate the socket on the top of the l i cense pl ate
degrees.
(6) Pul l the socket and bul b strai ght out of the top
of the l i cense pl ate l amp uni t housi ng.
Fig. 44 Headlamp Adjusting Screw
1 - HEADLAMP UNIT
2 - FENDER PANEL
3 - ADJUSTING SCREW ACCESS HOLE
4 - UPPER RADIATOR CROSSMEMBER
Fig. 45 License Plate Lamp Bulb Remove/Install -
North America
1 - REAR BUMPER FASCIA
2 - LICENSE PLATE LAMP
3 - SOCKET
4 - BULB
Fig. 46 License Plate Bracket - Rest-Of-World
1 - SPARE TIRE
2 - SPECIAL LUG NUT (2)
3 - LICENSE PLATE BRACKET
4 - SCREW (2)
l amp uni t socket.
INSTALLATION
NORTH AMERICA
i n the l i cense pl ate l amp uni t socket.
(2) Push the bul b strai ght i nto the l i cense pl ate
l amp uni t socket unti l i t i s fi rml y seated.
al i gn the socket and bul b wi th the socket openi ng on
the back of the l amp uni t housi ng (Fi g. 45).
l i cense pl ate l amp uni t housi ng unti l i t i s fi rml y
seated.
REST-OF-WORLD
i ng on the top of the l i cense pl ate l amp uni t housi ng
(Fi g. 47).
seated.
(6) Swi ng the l i cense pl ate bracket back agai nst
the spare ti re (Fi g. 46).
(7) Li ft up the bottom of the l i cense mounti ng
pl ate far enough to i nstal l and ti ghten the two
screws that secure the l i cense pl ate bracket to the
speci al l ug nuts on the spare ti re. Ti ghten the screws
to 28 Nm (21 ft. l bs.).
(8) Lower the bottom of the l i cense mounti ng pl ate
and, usi ng hand pressure, snap i t i nto pl ace on the
l i cense pl ate bracket.
REMOVAL
NORTH AMERICA
cabl e.
(2) Remove the two screws that secure the l i cense
pl ate l amp uni t to the rear bumper fasci a (Fi g. 48).
(3) Pul l the l i cense pl ate l amp uni t down and out
through the mounti ng hol e i n the rear bumper fasci a
connector for the l amp socket pi gtai l wi re.
(4) Remove the l i cense pl ate l amp uni t from the
rear bumper fasci a.
Rest-Of-World
1 - LAMP UNIT (2)
3 - SCREW (4)
4 - BULB & SOCKET (2)
Fig. 48 License Plate Lamp Unit Remove/Install
3 - SCREW (2)
LICENSE PLATE LAMP BULB (Continued)
REST-OF-WORLD
cabl e.
(2) Remove the bul b and socket uni t from the
l i cense pl ate l amp uni t housi ng that i s bei ng
removed. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR/LI CENSE PLATE LAMP BULB -
REMOVAL - REST-OF-WORLD).
pl ate l amp uni t to the back of the l i cense pl ate
bracket (Fi g. 49).
back of the l i cense pl ate bracket.
INSTALLATION
NORTH AMERICA
(1) Posi ti on the l i cense pl ate l amp uni t to the rear
bumper fasci a.
l i cense pl ate l amp uni t to the l amp socket pi gtai l
wi re.
(3) Posi ti on the l i cense pl ate l amp uni t i nto the
mounti ng hol e i n the rear bumper fasci a (Fi g. 48).
the l i cense pl ate l amp uni t housi ng to the rear
bumper fasci a. Ti ghten the screws to 2 Nm (20 i n.
l bs.).
REST-OF-WORLD
(1) Posi ti on the l i cense pl ate l amp uni t onto the
back of the l i cense pl ate bracket (Fi g. 49).
the l i cense pl ate l amp uni t to the back of the l i cense
pl ate bracket. Ti ghten the screws to 2 Nm (20 i n.
l bs.).
(3) Rei nstal l the bul b and socket uni t i nto the
repl aced. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NSTALLATI ON - REST-OF-WORLD).
DESCRIPTION
The mul ti -functi on swi tch i s l ocated on the steeri ng
col umn, just bel ow the steeri ng wheel (Fi g. 50). The
onl y vi si bl e components of the mul ti -functi on swi tch
are two l evers, or control stal ks that extend through
dedi cated openi ngs i n each si de of the steeri ng col -
umn shrouds. The remai nder of the swi tch, i ts
mounti ng provi si ons, and i ts el ectri cal connecti ons
are al l conceal ed beneath the steeri ng col umn
shrouds. The swi tch housi ng and control s are con-
structed of mol ded bl ack pl asti c. A saddl e-l i ke forma-
ti on i n the center of the mul ti -functi on swi tch
housi ng straddl es the steeri ng col umn tube just
bel ow the col umn l ock housi ng, and two posts i nte-
gral to the l ower surface of the swi tch housi ng
engage two hol es on the forward-faci ng si de of the
l ock housi ng. Two i ntegral l edge-l i ke l ocati ng tabs
near the top of the rearward faci ng swi tch housi ng
surface are supported and l ocated by two upri ght
stanchi ons that extend upward from the top of the
l ock housi ng. Al so on the rearward faci ng swi tch
housi ng surface near the center, an i ntegral l edge-
l i ke mounti ng tab rests on a si mi l ar l edge-l i ke tab
that extends from each si de of the steeri ng col umn
l ock housi ng. When the steeri ng col umn shrouds are
i nstal l ed on the col umn, the swi tch mounti ng tabs
are cl amped al ong wi th the mounti ng tabs of the
cl ockspri ng between the i ntegral mounti ng stan-
chi ons of the upper shroud and the l ock housi ng tabs,
and are secured to the steeri ng col umn l ock housi ng
by the same two screws that secure the two shroud
hal ves to each other and the col umn.
There are several versi ons of the mul ti -functi on
swi tch to support both opti onal equi pment and equi p-
ment that i s requi red onl y i n certai n markets. Each
mul ti -functi on swi tch control stal k has both whi te
nomencl ature and I nternati onal Control and Di spl ay
Symbol graphi cs appl i ed to i t, whi ch cl earl y i denti fy
i ts many functi ons. Each control stal k has a control
knob on i ts end wi th a fl attened face to al l ow i t to be
easi l y rotated. On vehi cl es equi pped wi th opti onal
front fog l amps, the knob on the end of l eft control
Rest-Of-World
1 - LAMP UNIT (2)
3 - SCREW (4)
LICENSE PLATE LAMP UNIT (Continued)
stal k can al so be pul l ed outward to sel ect those
l amps. Each control stal k al so features a knurl ed
control ri ng l ocated just bel ow the control knob. The
l eft control stal k i s dedi cated to provi di ng dri ver con-
trol s for the i nteri or and exteri or l i ghti ng systems,
whi l e the ri ght control stal k i s dedi cated to provi di ng
dri ver control s for the front and rear wi per systems.
Two i ntegral connector receptacl es on the forward
faci ng surface of the mul ti -functi on swi tch housi ng
connect the swi tch two the vehi cl e el ectri cal system
through two take outs and connectors of the i nstru-
ment panel wi re harness. The l eft connector recepta-
cl e contai ns ni ne termi nal pi ns for the l i ghti ng
control ci rcui ts of the swi tch, whi l e the ri ght connec-
tor receptacl e contai ns si x termi nal pi ns for the
wi per control ci rcui ts of the swi tch. The mul ti -func-
ti on swi tch cannot be adjusted or repai red and, i f
faul ty or damaged, i t must be repl aced.
LEFT CONTROL STALK The l eft (l i ghti ng) control
stal k of the mul ti -functi on swi tch supports the fol -
l owi ng functi ons and features:
Front Fog Lamps - For vehi cl es so equi pped,
the i nternal ci rcui try and hardware of the mul ti -
functi on swi tch l eft (l i ghti ng) control stal k provi de
detent swi tchi ng for the opti onal front fog l amps.
Headlamps - The i nternal ci rcui try and hard-
ware of the mul ti -functi on swi tch l eft (l i ghti ng) con-
trol stal k provi de detent swi tchi ng for the
headl amps.
Headlamp Beam Selection - The i nternal ci r-
cui try and hardware of the mul ti -functi on swi tch l eft
(l i ghti ng) control stal k provi de detent swi tchi ng for
sel ecti on of the headl amp hi gh or l ow beams.
Headlamp Optical Horn - The i nternal ci r-
(l i ghti ng) control stal k i ncl udes momentary swi tchi ng
of the headl amp hi gh beam ci rcui ts to provi de an
opti cal horn feature (someti mes referred to as fl ash-
to-pass), whi ch al l ows the vehi cl e operator to momen-
tari l y fl ash the headl amp hi gh beams as an opti cal
si gnal l i ng devi ce.
Interior Lamps Defeat - The i nternal ci rcui try
and hardware of the mul ti -functi on swi tch l eft (l i ght-
i ng) control stal k provi de detent swi tchi ng to defeat
the i l l umi nati on of al l i nteri or courtesy l amps when a
door, the rear fl i p-up gl ass, or the tai l gate are
opened.
Interior Lamps On - The i nternal ci rcui try and
hardware of the mul ti -functi on swi tch l eft (l i ghti ng)
control stal k provi de detent swi tchi ng to si mul ta-
neousl y i l l umi nate al l i nteri or courtesy l amps.
Panel Lamps Dimming - The i nternal ci r-
(l i ghti ng) control stal k provi de si mul taneous adjust-
abl e control of the i l l umi nati on i ntensi ty of al l i nstru-
ment panel l i ghti ng at one of si x avai l abl e
i l l umi nati on i ntensi ty l evel s.
Parade Mode - The i nternal ci rcui try and hard-
Fig. 50 Multi-Function Switch
1 - MULTI-FUNCTION SWITCH
2 - RIGHT (WIPER) CONTROL STALK
3 - LEFT (LIGHTING) CONTROL STALK
4 - TURN SIGNAL CANCEL ACTUATOR
5 - RIGHT (WIPER) CONTROL KNOB
6 - RIGHT (WIPER) CONTROL RING
7 - LEFT (LIGHTING) CONTROL RING
8 - LEFT (LIGHTING) CONTROL KNOB
MULTI-FUNCTION SWITCH (Continued)
trol stal k provi de detent swi tchi ng for a parade mode
that maxi mi zes the i l l umi nati on i ntensi ty of al l
i nstrument panel l i ghti ng for vi si bi l i ty when dri vi ng
i n dayl i ght wi th the exteri or l amps turned on.
Park Lamps - The i nternal ci rcui try and hard-
trol stal k provi de detent swi tchi ng for the park
l amps.
Rear Fog Lamps - For vehi cl es so equi pped,
detent swi tchi ng for the opti onal rear fog l amps.
Rear fog l amps are opti onal onl y for vehi cl es manu-
factured for certai n markets, where they are
requi red.
Turn Signal Control - The i nternal ci rcui try
i ng) control stal k provi de both momentary non-detent
swi tchi ng and detent swi tchi ng wi th automati c can-
cel l ati on for both the l eft and ri ght turn si gnal
l amps.
RI GHT CONTROL STALK The ri ght (wi per) con-
trol stal k of the mul ti -functi on swi tch supports the
fol l owi ng functi ons and features:
Continuous Front Wipe Modes - The i nternal
ci rcui try and hardware of the mul ti -functi on swi tch
ri ght (wi per) control stal k provi de two conti nuous
front wi pe swi tch posi ti ons, l ow speed or hi gh speed.
Continuous Rear Wipe Mode - The i nternal
ri ght (wi per) control stal k provi de one conti nuous
rear wi pe swi tch posi ti on.
Front Washer Mode - The i nternal ci rcui try
and hardware of the mul ti -functi on swi tch ri ght
(wi per) control stal k swi tch provi de front washer sys-
tem operati on.
Front Wipe-After-Wash Mode - The i nternal
ri ght (wi per) control stal k provi de a wi pe-after-wash
mode.
Front Wiper Mist Mode - The i nternal ci r-
cui try and hardware of the mul ti -functi on swi tch
ri ght (wi per) control stal k provi de a front wi per sys-
tem mi st mode.
Intermittent Front Wipe Mode - The i nternal
ri ght (wi per) control stal k provi de an i ntermi ttent
front wi pe mode wi th fi ve del ay i nterval posi ti ons.
Intermittent Rear Wipe Mode - The i nternal
ri ght (wi per) control stal k provi de one fi xed i nterval
i ntermi ttent rear wi pe mode swi tch posi ti on.
Rear Washer Mode - The i nternal ci rcui try and
hardware of the mul ti -functi on swi tch ri ght (wi per)
control stal k provi de rear washer system operati on.
OPERATION
The mul ti -functi on swi tch uses a combi nati on of
resi stor mul ti pl exed and conventi onal l y swi tched out-
puts to control the many functi ons and features i t
provi des. The swi tch recei ves battery current on a
fused i gni ti on swi tch output (run-acc) ci rcui t from a
fuse i n the Juncti on Bl ock (JB) whenever the i gni ti on
swi tch i s i n the On or Accessory posi ti ons. The swi tch
recei ves a path to ground at al l ti mes through a
spl i ce bl ock l ocated i n the i nstrument panel wi re har-
ness wi th an eyel et termi nal connector that i s
secured by a nut to a ground stud on the dri ver si de
i nstrument panel end bracket near the Juncti on
Bl ock (JB). Fol l owi ng are descri pti ons of how each of
the two mul ti -functi on swi tch control stal ks operate
to control the functi ons and features they provi de.
stal k of the mul ti -functi on swi tch operates as fol l ows:
the control knob on the end of the mul ti -functi on
swi tch l eft (l i ghti ng) control stal k i s pul l ed outward
to acti vate the opti onal front fog l amps. The control
knob i s mechani cal l y keyed so that i t cannot be
pul l ed outward unl ess i t i s fi rst rotated to turn on
the exteri or l i ghti ng. The mul ti -functi on swi tch pro-
vi des a resi stor mul ti pl exed output to the Body Con-
trol Modul e (BCM) on a fog l amp swi tch sense
ci rcui t, and the BCM responds by energi zi ng or de-
energi zi ng the front fog l amp rel ay i n the Juncti on
Bl ock (JB) as requi red.
Headlamps - The control knob on the end of
the mul ti -functi on swi tch l eft (l i ghti ng) control stal k
i s rotated forward (countercl ockwi se) to i ts second
detent posi ti on to acti vate the headl amps. The mul ti -
functi on swi tch provi des a resi stor mul ti pl exed out-
put to the Body Control Modul e (BCM) on a
headl amp swi tch sense ci rcui t, and the BCM
responds by energi zi ng or de-energi zi ng the sel ected
l ow or hi gh beam rel ay (Dayti me Runni ng Lamp
rel ay i n Canadi an vehi cl es) i n the Juncti on Bl ock
(JB) as requi red.
Headlamp BeamSelection - The l eft (l i ghti ng)
control stal k of the mul ti -functi on swi tch i s pul l ed
towards the steeri ng wheel past a detent to actuate
the i ntegral beam sel ect swi tch ci rcui try. Each ti me
the control stal k i s acti vated i n thi s manner, the
opposi te headl amp beam from what i s currentl y
sel ected wi l l be energi zed. The mul ti -functi on swi tch
provi des a ground output to the Body Control Modul e
(BCM) on a hi gh beam swi tch sense ci rcui t, and the
BCM responds by energi zi ng or de-energi zi ng the
sel ected l ow or hi gh beam rel ay (Dayti me Runni ng
Lamp rel ay i n Canadi an vehi cl es) i n the Juncti on
Headlamp Optical Horn - The l eft (l i ghti ng)
towards the steeri ng wheel to just before a detent, to
momentari l y acti vate the headl amp opti cal horn fea-
ture. The hi gh beams wi l l remai n i l l umi nated unti l
the control stal k i s rel eased. The mul ti -functi on
swi tch provi des a ground output on a hi gh beam
rel ay control ci rcui t to energi ze the headl amp hi gh
beam rel ay (Dayti me Runni ng Lamp rel ay i n Cana-
di an vehi cl es) i n the Juncti on Bl ock (JB) as requi red.
Interior Lamps Defeat - The control ri ng on
i s rotated to a ful l rearward (cl ockwi se) detent to
defeat the i l l umi nati on of al l i nteri or courtesy l amps.
The mul ti -functi on swi tch provi des a resi stor mul ti -
pl exed output to the Body Control Modul e (BCM) on
a panel l amps di mmer swi tch mux ci rcui t, and the
BCM responds by de-energi zi ng i ts i nternal courtesy
l amp dri ver ci rcui t.
Interior Lamps On - The control ri ng on the
mul ti -functi on swi tch l eft (l i ghti ng) control stal k i s
rotated to a ful l forward (countercl ockwi se) detent to
i l l umi nate al l i nteri or courtesy l amps. The mul ti -
put to the Body Control Modul e (BCM) on a panel
l amps di mmer swi tch mux ci rcui t, and the BCM
responds by energi zi ng i ts i nternal courtesy l amp
dri ver ci rcui t.
Panel Lamps Dimming - The control ri ng on
i s rotated to one of si x mi nor i ntermedi ate detents to
si mul taneousl y sel ect the desi red i l l umi nati on i nten-
si ty of al l adjustabl e i nstrument panel and i nstru-
ment cl uster l i ghti ng. The control ri ng i s rotated
rearward (cl ockwi se) to di m, or forward (counter-
cl ockwi se) to bri ghten. The mul ti -functi on swi tch pro-
vi des a resi stor mul ti pl exed output to the Body
Control Modul e (BCM) on a panel l amps di mmer
swi tch mux ci rcui t, and the BCM responds by send-
i ng an el ectroni c panel l amps di mmi ng l evel message
(PCI ) data bus. The EMI C el ectroni c ci rcui try then
provi des the proper PWM output to the cl uster i l l u-
mi nati on l amps and the VFD on the EMI C ci rcui t
board, then provi des a matchi ng PWM output on the
hard wi red fused panel l amps di mmer swi tch si gnal
ci rcui t.
Parade Mode - The control ri ng on the mul ti -
functi on swi tch l eft (l i ghti ng) control stal k i s rotated
to an i ntermedi ate detent that i s one detent rear-
ward (cl ockwi se) from the ful l forward (countercl ock-
wi se) detent to sel ect the Parade mode. The mul ti -
functi on swi tch provi des a resi stor mul ti pl exed
output to the Body Control Modul e (BCM) on a panel
responds by sendi ng an el ectroni c panel l amps di m-
mi ng l evel message to the El ectroMechani cal I nstru-
ment Cl uster (EMI C) over the Programmabl e
Communi cati ons I nterface (PCI ) data bus. The EMI C
el ectroni c ci rcui try then provi des the proper PWM
output to the cl uster i l l umi nati on l amps and the
VFD on the EMI C ci rcui t board, then provi des a
matchi ng PWM output on the hard wi red fused panel
l amps di mmer swi tch si gnal ci rcui t to i l l umi nate al l
l amps at ful l (dayl i ght) i ntensi ty wi th the exteri or
l amps turned On.
Park Lamps - The control knob on the end of
i s rotated forward (countercl ockwi se) to i ts fi rst
detent from the Off posi ti on to acti vate the park
l amps. The mul ti -functi on swi tch provi des a resi stor
mul ti pl exed output to the Body Control Modul e
(BCM) on a headl amp swi tch sense ci rcui t, and the
park l amp rel ay i n the Juncti on Bl ock (JB) as
requi red.
swi tch l eft (l i ghti ng) control stal k i s rotated forward
(countercl ockwi se) to i ts thi rd detent posi ti on to acti -
vate the rear fog l amps. The mul ti -functi on swi tch
provi des a resi stor mul ti pl exed output to the Body
Control Modul e (BCM) on a headl amp swi tch sense
energi zi ng the rear fog l amp rel ay i n the Juncti on
Bl ock (JB) as requi red. Rear fog l amps are opti onal
onl y for vehi cl es manufactured for certai n markets,
where they are requi red.
Turn Signal Control - The l eft (l i ghti ng) con-
trol stal k of the mul ti -functi on swi tch i s moved
upward to acti vate the ri ght turn si gnal ci rcui try,
and, downward to acti vate the l eft turn si gnal ci r-
cui try. The turn si gnal swi tch has a detent posi ti on
i n each di recti on that provi des turn si gnal s wi th
automati c cancel l ati on, and an i ntermedi ate, momen-
tary posi ti on i n each di recti on that provi des turn si g-
nal s onl y unti l the l eft mul ti -functi on swi tch control
stal k i s rel eased. When the control stal k i s moved to
a turn si gnal swi tch detent posi ti on, the cancel
actuator extends toward the center of the steeri ng
col umn. A turn si gnal cancel cam that i s i ntegral to
the cl ockspri ng rotates wi th the steeri ng wheel and
the cam l obes contact the cancel actuator when i t i s
extended from the l eft mul ti -functi on swi tch. When
the steeri ng wheel i s rotated duri ng a turni ng
maneuver, one of the two turn si gnal cancel cam
l obes wi l l contact the turn si gnal cancel actuator. The
cancel actuator l atches agai nst the cancel cam rota-
ti on i n the di recti on opposi te that whi ch i s si gnal ed.
I n other words, i f the l eft turn si gnal detent i s
sel ected, the l obes of the cancel cam wi l l ratchet past
the cancel actuator when the steeri ng wheel i s
rotated to the l eft, but wi l l unl atch the cancel actua-
tor as the steeri ng wheel rotates to the ri ght and
returns to center, whi ch wi l l cancel the turn si gnal
event and rel ease the control stal k from the detent so
i t returns to the neutral Off posi ti on. When a turn
si gnal i s acti vated, the mul ti -functi on swi tch provi des
a ground output on a ri ght or l eft turn swi tch sense
ci rcui t to the combi nati on fl asher ci rcui try wi thi n the
hazard swi tch, and the combi nati on fl asher fl ashes
the turn si gnal l amps.
trol stal k of the mul ti -functi on swi tch operates as fol -
l ows:
Continuous Front Wipe Modes - The control
knob on the end of the mul ti -functi on swi tch ri ght
(wi per) control stal k i s rotated to an i ntermedi ate
detent that i s one detent rearward (countercl ockwi se)
from the ful l forward (cl ockwi se) detent to sel ect the
l ow speed conti nuous front wi per mode, or to i ts ful l
forward (cl ockwi se) detent to sel ect the hi gh speed
conti nuous front wi per mode. The mul ti -functi on
swi tch provi des a resi stor mul ti pl exed output to the
Body Control Modul e (BCM) on a front wi per swi tch
mux ci rcui t, and the BCM responds by energi zi ng the
wi per on/off rel ay i n the Power Di stri buti on Center
(PDC) for the front l ow speed conti nuous wi pe mode,
or the wi per on/off rel ay and the wi per hi gh/l ow rel ay
i n the PDC for the front hi gh speed conti nuous wi pe
mode as requi red.
Continuous Rear Wipe Mode - The control
ri ng on the mul ti -functi on swi tch ri ght (wi per) con-
trol stal k i s rotated to the most forward (cl ockwi se)
detent to sel ect the conti nuous rear wi per mode. The
mul ti -functi on swi tch provi des a battery current out-
put to the rear wi per motor on a rear wi per on dri ver
ci rcui t to si gnal the rear wi per motor to operate i n
the conti nuous wi pe mode.
Front Washer Mode - The ri ght (wi per) control
stal k of the mul ti -functi on swi tch i s pul l ed towards
the steeri ng wheel to momentari l y acti vate the
washer pump i n the front washer mode. The washer
pump wi l l conti nue to operate i n the front washer
mode unti l the control stal k i s rel eased. The mul ti -
functi on swi tch provi des a ground output on a
washer pump sense ci rcui t, and battery current on a
washer pump dri ver ci rcui t to energi ze the washer
pump i n the front washer mode.
Front Wiper Mist Mode - The ri ght (wi per)
control stal k of the mul ti -functi on swi tch i s pushed
towards the fl oor to momentari l y acti vate the front
wi per motor i n the mi st mode. The front wi per motor
wi l l conti nue to operate i n the mi st mode unti l the
control stal k i s rel eased. The mul ti -functi on swi tch
Control Modul e (BCM) on a front wi per swi tch mux
ci rcui t, and the BCM responds by energi zi ng the
(PDC) to operate the front wi per motor momentari l y
at l ow speed to provi de the front wi per mi st mode.
Intermittent Front Wipe Mode - The control
(wi per) control stal k i s rotated to one of fi ve mi nor
i ntermedi ate detents to sel ect the desi red i ntermi t-
tent front wi pe del ay i nterval . The control knob i s
rotated rearward (countercl ockwi se) to i ncrease the
del ay, or forward (cl ockwi se) to decrease the del ay.
a front wi per swi tch mux ci rcui t, and the BCM
responds by energi zi ng the wi per on/off rel ay i n the
Power Di stri buti on Center (PDC) to operate the front
wi per motor at the sel ected del ay i nterval s.
Intermittent Rear Wipe Mode - The control
trol stal k i s rotated to the center detent to sel ect the
i ntermi ttent rear wi per mode. The mul ti -functi on
swi tch provi des a battery current output to the rear
wi per motor on a rear wi per i ntermi ttent dri ver ci r-
cui t to si gnal the rear wi per motor to operate i n the
i ntermi ttent wi pe mode.
Rear Washer Mode - The control ri ng on the
mul ti -functi on swi tch ri ght (wi per) control stal k i s
rotated to ei ther the ful l forward (cl ockwi se) or ful l
rearward (countercl ockwi se) momentary posi ti ons to
acti vate the washer pump i n the rear washer mode.
The washer pump wi l l conti nue to operate i n the rear
washer mode unti l the control ri ng i s rel eased. The
mul ti -functi on swi tch provi des a ground output on a
washer pump dri ver ci rcui t, and battery current on a
washer pump sense ci rcui t to energi ze the washer
pump i n the rear washer mode.
DIAGNOSIS AND TESTING - MULTI-FUNCTION
SWITCH
PERSONAL INJURY.
cabl e.
(2) Remove the mul ti -functi on swi tch from the
steeri ng col umn. (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/MULTI -FUNCTI ON
SWI TCH - REMOVAL).
and resi stance tests at the termi nal s (Fi g. 51) i n the
mul ti -functi on swi tch connector receptacl es as shown
i n the Mul ti -Functi on Swi tch Tests tabl e.
Fig. 51 Multi-Function Switch Connector Receptacle Pin-Out
2 - C-1 (LIGHTING) CONNECTOR RECEPTACLE
3 - C-2 (WIPER) CONNECTOR RECEPTACLE
MULTI-FUNCTION SWITCH TESTS
EXTERIOR LIGHTING FUNCTIONS
SWITCH POSITION CONNECTOR C-1 PINS RESISTANCE (OHMS) 10%
Off 4 & 5 3781
Park Lamps On 4 & 5 911
Headlamp Low Beams On 4 & 5 349
Rear Fog Lamps On 4 & 5 75
Headlamp High Beams On 8 & 9 0 - 1
Front Fog Lamps On 2 & 4 0 - 1
Optical Horn (Flash-to-Pass) On 7 & 8 0 - 1
Turn Signal Neutral 6 & 8, 8 & 10 Infinite (Open)
Turn Signal Left 6 & 8 0 - 1
Turn Signal Right 8 & 10 0 - 1
INTERIOR LIGHTING FUNCTIONS
Off (Courtesy Disable) 1 & 4 63
Dimming 1 1 & 4 200
Dimming 2 1 & 4 557
Dimming 3 1 & 4 914
Dimming 4 1 & 4 1271
Dimming 5 1 & 4 1628
Dimming 6 1 & 4 1985
Parade Mode On 1 & 4 3565
Courtesy On 1 & 4 7885
FRONT WIPER FUNCTIONS
SWITCH POSITION
CONNECTOR C-1 & C-2
PINS
RESISTANCE (OHMS) 10%
Front Wiper Off C-1 Pin 4 & C-2 Pin 4 4587
Delay 1 C-1 Pin 4 & C-2 Pin 4 1267
Delay 2 C-1 Pin 4 & C-2 Pin 4 792
Delay 3 C-1 Pin 4 & C-2 Pin 4 531
Delay 4 C-1 Pin 4 & C-2 Pin 4 369
Delay 5 C-1 Pin 4 & C-2 Pin 4 262
Front Wiper Low C-1 Pin 4 & C-2 Pin 4 125
Front Wiper High C-1 Pin 4 & C-2 Pin 4 38
Front Wiper Mist C-1 Pin 4 & C-2 Pin 4 125
Front Washer On C-2 Pins 5 & 7 0 - 1
REAR WIPER FUNCTIONS
Rear Wiper Off 1 & 5, 2 & 5 Infinite (Open)
Rear Wiper Intermittent 2 & 5 0 - 1
Rear Wiper On 1 & 5 0 - 1
Rear Washer On 2 & 5, 3 & 5 0 - 1
(4) I f the mul ti -functi on swi tch fai l s any of the
conti nui ty or resi stance tests, repl ace the faul ty
swi tch uni t as requi red.
REMOVAL
PERSONAL INJURY.
cabl e.
shroud (Fi g. 52).
other.
(6) Di sconnect the two i nstrument panel wi re har-
ness connectors for the mul ti -functi on swi tch from
the two connector receptacl es on the back of the
swi tch housi ng.
steeri ng col umn l ock housi ng by careful l y rocki ng the
swi tch and pul l i ng the swi tch housi ng upward far
enough to di sengage i ts al i gnment posts and l ocator
tabs from the l ock housi ng.
INSTALLATION
PERSONAL INJURY.
CAUTION: Before attempting to install the multi-
function switch, be certain that the left control stalk
is in the neutral turn signal position and the turn
signal cancel actuator is in the retracted (neutral)
position.
(1) Posi ti on the mul ti -functi on swi tch to the steer-
i ng col umn.
(2) Reconnect the two i nstrument panel wi re har-
ness connectors for the mul ti -functi on swi tch to the
two connector receptacl es on the back of the swi tch
housi ng (Fi g. 52).
Fig. 52 Multi-Function Switch Remove/Install
1 - UPPER SHROUD
3 - CLOCKSPRING
4 - LOWER SHROUD
5 - SCREW (2)
6 - STEERING COLUMN
7 - WIRE HARNESS CONNECTOR (2)
(3) Posi ti on the mul ti -functi on swi tch onto the
steeri ng col umn l ock housi ng. Be certai n that the
swi tch al i gnment posts and l ocator tabs are ful l y
seated on the l ock housi ng.
(4) Posi ti on the upper and l ower shrouds onto the
steeri ng col umn.
i n. l bs.).
steeri ng col umn, move the ti l t steeri ng col umn back
to the ful l y rai sed posi ti on and move the ti l t rel ease
l ever i nto the l ocked (up) posi ti on.
PARK LAMP RELAY
DESCRIPTION
The park l amp rel ay i s l ocated i n the Juncti on
Bl ock (JB) bel ow the dri ver si de outboard end of the
the vehi cl e. The park l amp rel ay i s a conventi onal
the rel ay base.
The park l amp rel ay cannot be adjusted or
repl aced.
OPERATION
The park l amp rel ay i s an el ectromechani cal
put to the park l amps. The movabl e common feed
The park l amp rel ay termi nal s are connected to
the vehi cl e el ectri cal system through a connector
outputs of the headl amp l ow beam rel ay i ncl ude:
termi nal (30) i s connected to the park l amps through
the park l amp rel ay output ci rcui t and provi des
ground to the park l amps when the rel ay i s de-ener-
gi zed, and battery current to the park l amps when-
nal (85) i s connected to a control output of the Body
Control Modul e (BCM) through a park l amp rel ay
control ci rcui t. The BCM control s park l amp opera-
ti on by control l i ng a ground path through thi s ci r-
cui t.
a fuse i n the PDC through a fused B(+) ci rcui t.
cl osed termi nal (87A) i s connected to ground at al l
ti mes through a ground ci rcui t that recei ves ground
through a spl i ce bl ock l ocated i n the i nstrument
panel wi re harness wi th an eyel et termi nal connector
that i s secured by a nut to a ground stud on the
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
dri ver si de i nstrument panel end bracket near the
The park l amp rel ay can be di agnosed usi ng con-
RELAY
The park l amp rel ay (Fi g. 54) i s l ocated i n the
and grounds.
PERSONAL INJURY.
(1) Remove the park l amp rel ay from the JB.
EXTERI OR/PARK LAMP RELAY - REMOVAL).
REMOVAL
PERSONAL INJURY.
cabl e.
(3) Remove the park l amp rel ay by graspi ng i t
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
PARK LAMP RELAY (Continued)
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the park l amp rel ay to the proper
(2) Al i gn the park l amp rel ay termi nal s wi th the
termi nal cavi ti es i n the JB receptacl e.
(3) Push fi rml y and evenl y on the top of the park
l amp rel ay unti l the termi nal s are ful l y seated i n the
REAR FOG LAMP RELAY
DESCRIPTION
The rear fog l amp rel ay i s l ocated i n the Juncti on
the vehi cl e. The rear fog l amp rel ay i s a conventi onal
the rel ay base.
The rear fog l amp rel ay cannot be adjusted or
repl aced.
Rotate 180for RHD)
3 - LOW BEAM RELAY
7 - DOOR LOCK RELAY
8 - DEFOGGER RELAY
9 - SPARE
11 - HORN RELAY
12 - SPARE
13 - SPARE
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
OPERATION
The rear fog l amp rel ay i s an el ectromechani cal
put to the rear fog l amps. The movabl e common feed
The rear fog l amp rel ay termi nal s are connected to
outputs of the rear fog l amp rel ay i ncl ude:
mi um Body Control Modul e (BCM) through a rear
fog l amp rel ay control ci rcui t. The BCM control s rear
fog l amp operati on by control l i ng a ground path
termi nal (87) i s connected to the rear fog l amps
through a rear fog l amp rel ay output ci rcui t and pro-
vi des battery current to the rear fog l amps whenever
the rel ay i s energi zed.
cati on.
The rear fog l amp rel ay can be di agnosed usi ng
DIAGNOSIS AND TESTING - REAR FOG LAMP
RELAY
The rear fog l amp rel ay (Fi g. 57) i s l ocated i n the
and grounds.
PERSONAL INJURY.
(1) Remove the rear fog l amp rel ay from the JB.
EXTERI OR/REAR FOG LAMP RELAY - REMOVAL).
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
REAR FOG LAMP RELAY (Continued)
REMOVAL
PERSONAL INJURY.
cabl e.
(3) Remove the rear fog l amp rel ay by graspi ng i t
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the rear fog l amp rel ay to the proper
(2) Al i gn the rear fog l amp rel ay termi nal s wi th
(3) Push fi rml y and evenl y on the top of the rear
REAR LAMP BULB
REMOVAL
The rear l amp uni t may contai n up to four bul bs,
dependi ng upon the market for whi ch the vehi cl e was
manufactured. The servi ce procedures for each bul b
i s the same, onl y the bul b si zes and types may di ffer.
Rotate 180for RHD)
3 - LOW BEAM RELAY
7 - DOOR LOCK RELAY
8 - DEFOGGER RELAY
9 - SPARE
11 - HORN RELAY
12 - SPARE
13 - SPARE
Be certai n any removed bul b i s repl aced wi th the
same bul b si ze and type that was removed.
cabl e.
(2) Remove the rear l amp uni t from the end of the
quarter panel . (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/REAR LAMP UNI T -
REMOVAL).
(3) Fi rml y grasp the socket on the socket pl ate at
the back of the rear l amp uni t housi ng for the bul b
that i s bei ng removed (Fi g. 59).
(4) Rotate the socket on the socket pl ate at the
back of the rear l amp uni t housi ng countercl ockwi se
about 30 degrees.
back of the rear l amp uni t housi ng.
(6) Pul l the bul b strai ght out of the rear l amp uni t
socket.
INSTALLATION
i n the rear l amp uni t socket.
(2) Push the bul b strai ght i nto the rear l amp uni t
(3) Al i gn the socket and bul b wi th the openi ng i n
the socket pl ate on the back of the rear l amp uni t
(4) Push the socket and bul b strai ght i nto the rear
l amp uni t housi ng unti l the socket i s fi rml y seated
agai nst the socket pl ate.
back of the rear l amp uni t housi ng cl ockwi se about
30 degrees.
(6) Rei nstal l the rear l amp uni t onto the end of the
I NSTALLATI ON).
REAR LAMP UNIT
REMOVAL
cabl e.
(2) Open the tai l gate to access and remove the two
screws that secure the i nboard si de of the rear l amp
uni t to the si de jamb of the tai l gate openi ng (Fi g. 60).
(3) Pul l the outboard si de of the rear l amp uni t
rearward (away from the end of the quarter panel )
far enough to unsnap the two bal l studs on the out-
board si de of the l amp housi ng from the pl asti c nuts
i n the quarter panel .
(4) Pul l the rear l amp uni t away from the quarter
panel far enough to access and di sconnect the wi re
harness connector for the l amp uni t from the connec-
tor receptacl e on the l amp socket pl ate.
(5) Remove the rear l amp uni t from the quarter
panel .
Fig. 59 Rear Lamp Bulb Remove/Install
1 - REAR LAMP HOUSING
2 - BULB HOLDER
3 - BULB
4 - SOCKET PLATE
Fig. 60 Rear Lamp Unit Remove/Install
1 - PLASTIC NUT (2)
3 - PLASTIC NUT (2)
4 - REAR LAMP UNIT
5 - SCREW (2)
REAR LAMP BULB (Continued)
(6) Remove the pl asti c nuts from the quarter panel
and di scard.
INSTALLATION
(1) I nstal l new pl asti c nuts i nto the quarter panel
(Fi g. 60).
(2) Posi ti on the rear l amp uni t to the quarter
panel .
rear l amp uni t to the connector receptacl e on the
l amp socket pl ate.
(4) Al i gn the two bal l studs on the outboard si de of
the rear l amp uni t housi ng wi th the pl asti c nuts i n
the quarter panel .
(5) Usi ng hand pressure, push the outboard si de of
the rear l amp uni t forward (towards the end of the
quarter panel ) far enough to snap the two bal l studs
on the outboard si de of the l amp housi ng i nto the
pl asti c nuts i n the quarter panel .
(6) Al i gn the mounti ng hol es on the i nboard si de of
the si de jamb of the tai l gate openi ng.
the i nboard si de of the rear l amp uni t housi ng to the
pl asti c nuts i n the si de jamb of the tai l gate openi ng.
REPEATER LAMP BULB
REMOVAL
Si de repeater l amps are used onl y on vehi cl es man-
ufactured for certai n markets where these l amps are
requi red.
cabl e.
(2) Remove the repeater l amp uni t from the front
fender panel . (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/REPEATER LAMP UNI T -
REMOVAL).
(3) Rotate the repeater l amp socket i n the l amp
l ens countercl ockwi se about 30 degrees (Fi g. 61).
repeater l amp l ens.
(5) Pul l the bul b strai ght out of the repeater l amp
socket.
INSTALLATION
requi red.
i n the repeater l amp socket.
(2) Push the bul b strai ght i nto the repeater l amp
i ng i n the repeater l amp l ens (Fi g. 61).
repeater l amp l ens unti l i t i s fi rml y seated
l ens cl ockwi se about 30 degrees.
(6) Rei nstal l the repeater l amp uni t onto the front
I NSTALLATI ON).
REPEATER LAMP UNIT
REMOVAL
requi red.
cabl e.
(2) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , careful l y pry at the cl earance notch
i n the l ower edge of the repeater l amp l ens to di sen-
gage the snap features of the l ens from the mounti ng
hol e i n the front fender panel (Fi g. 62).
(3) Pul l the repeater l amp uni t out from the front
fender panel far enough to access and di sconnect the
Fig. 61 Repeater Lamp Bulb Remove/Install
1 - FRONT FENDER
2 - SOCKET
3 - BULB
4 - LENS
REAR LAMP UNIT (Continued)
repeater l amp wi re harness connector from the con-
nector receptacl e on the back of the repeater l amp
uni t socket.
fender panel .
INSTALLATION
requi red.
(1) Posi ti on the repeater l amp uni t to the front
fender panel (Fi g. 62).
(2) Reconnect the repeater l amp wi re harness con-
nector to the connector receptacl e on the back of the
repeater l amp uni t socket.
(3) Posi ti on the repeater l amp uni t i nto the mount-
i ng hol e i n the front fender panel . Be certai n that the
cl earance notch on the edge of the repeater l amp l ens
i s ori ented toward the bottom.
(4) Usi ng hand pressure, press on the repeater
l amp uni t fi rml y and evenl y unti l the snap features
of the l ens are ful l y engaged i n the mounti ng hol e of
the front fender panel .
REMOVAL
cabl e.
(2) Remove the four screws that secure the trai l er
tow connector to the bracket on the trai l er hi tch
recei ver (Fi g. 63).
(3) Pul l the trai l er tow connector rearward from
the bracket on the trai l er hi tch recei ver far enough to
access and di sconnect the rear body wi re harness
connector from the receptacl e on the back of the
trai l er tow connector.
(4) Remove the trai l er tow connector from the
trai l er hi tch recei ver.
INSTALLATION
(1) Posi ti on the trai l er tow connector to the trai l er
hi tch recei ver (Fi g. 63).
(2) Reconnect the rear body wi re harness connec-
tor to the receptacl e on the back of the trai l er tow
connector.
(3) Posi ti on the trai l er tow connector i nto the
the trai l er tow connector to the bracket on the trai l er
hi tch recei ver. Ti ghten the screws to 4 Nm (35 i n.
l bs.).
TRAILER TOW RELAY
DESCRIPTION
The trai l er tow rel ays are l ocated i n a connector
bank above the ri ght rear wheel house and behi nd the
quarter tri m panel on vehi cl es equi pped wi th the
opti onal factory-i nstal l ed trai l er towi ng package.
Four i ndi vi dual rel ays are used, one each for fused
i gni ti on swi tch output (run), brake l amps, ri ght turn
si gnal , and l eft turn si gnal outputs to a trai l er
through the rear body wi ri ng and connectors. The
trai l er tow rel ays are conventi onal I nternati onal
Standards Organi zati on (I SO) mi cro rel ays (Fi g. 64).
Fig. 62 Repeater Lamp Unit Remove/Install
1 - REPEATER LAMP UNIT
2 - FRONT FENDER PANEL
3 - INNER FENDER
4 - FRONT FASCIA WIRE HARNESS
Fig. 63 Trailer Tow Connector Remove/Install
1 - HITCH RECEIVER
2 - 7-WAY TRAILER TOW CONNECTOR
3 - SCREW (4)
4 - BRACKET
REPEATER LAMP UNIT (Continued)
Rel ays conformi ng to the I SO speci fi cati ons have
common physi cal di mensi ons, current capaci ti es, ter-
mi nal patterns, and termi nal functi ons. The rel ay i s
contai ned wi thi n a smal l , rectangul ar, mol ded pl asti c
The trai l er tow rel ays cannot be adjusted or
repai red and, i f faul ty or damaged, the i noperati ve
rel ay must be repl aced.
OPERATION
The trai l er tow rel ays are el ectromechani cal
swi tches. The rel ays each use an i nput from the ci r-
cui t that they i sol ate from the trai l er wi ri ng to con-
trol a hi gh current output to the trai l er. The movabl e
common feed contact poi nt i s hel d agai nst the fi xed
normal l y cl osed contact poi nt by spri ng pressure.
When the rel ay coi l i s energi zed, an el ectromagneti c
fi el d i s produced by the coi l wi ndi ngs. Thi s el ectro-
magneti c fi el d draws the movabl e rel ay contact poi nt
away from the fi xed normal l y cl osed contact poi nt,
and hol ds i t agai nst the fi xed normal l y open contact
The termi nal s of each trai l er tow rel ay are con-
nector bank i n the rear l i ghti ng wi re harness above
the ri ght rear wheel house. Refer to the appropri ate
and grounds. The trai l er tow rel ays can be di agnosed
RELAY
The trai l er tow rel ays (Fi g. 65) are l ocated i n a
connector bank above the ri ght rear wheel house.
PERSONAL INJURY.
(1) Remove the trai l er tow rel ay from the connec-
tor bank. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR/TRAI LER TOW RELAY -
REMOVAL).
and 30. I f OK, test the i nput and output ci rcui ts of
the rel ay. Refer to the appropri ate wi ri ng i nforma-
ti on.
Fig. 64 Trailer Tow Relays
1 - RELAY CONNECTOR BANK
2 - REAR BODY WIRE HARNESS
3 - LEFT TURN RELAY
4 - RIGHT TURN RELAY
5 - BRAKE LAMP RELAY
6 - FUSED IGNITION SWITCH OUTPUT (RUN) RELAY
TRAILER TOW RELAY (Continued)
REMOVAL
The trai l er tow rel ay bank contai ns four rel ays.
The servi ce procedures for each rel ay are the same.
Be certai n any removed rel ay i s repl aced wi th the
same rel ay si ze and type that was removed.
PERSONAL INJURY.
cabl e.
(2) Remove the tri m from the ri ght si de quarter
i nner panel . (Refer to 23 - BODY/I NTERI OR/QUAR-
TER TRI M PANEL - REMOVAL).
(3) Reach through the access hol e i n the quarter
i nner panel behi nd the ri ght rear wheel house to
l ocate and retri eve the trai l er tow rel ay connector
bank, whi ch i s envel oped i n foam rubber and pl aced
on the top of the ri ght rear wheel house between the
quarter i nner and outer panel s (Fi g. 66).
(4) Pul l the trai l er tow rel ay connector bank i nto
the cargo area far enough to access the uni t for ser-
vi ce.
(5) Careful l y remove the trai l er tow rel ay connec-
tor bank from the foam wrap.
(6) Remove the trai l er tow rel ay by graspi ng i t
fi rml y and pul l i ng i t strai ght out from the connector
bank (Fi g. 67).
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
Fig. 66 Trailer Tow Relay Wrap
1 - FOAM WRAP
Fig. 67 Trailer Tow Relay Remove/Install
3 - LEFT TURN RELAY
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the trai l er tow rel ay to the proper con-
nector i n the connector bank (Fi g. 67).
(2) Al i gn the trai l er tow rel ay termi nal s wi th the
termi nal cavi ti es i n the connector.
(3) Push fi rml y and evenl y on the top of the trai l er
tow rel ay unti l the termi nal s are ful l y seated i n the
(4) Careful l y restore the foam wrap around the
trai l er tow rel ay connector bank (Fi g. 66).
pl ace the trai l er tow rel ay connector bank on the top
of the ri ght rear wheel house between the quarter
i nner and outer panel s.
(6) Rei nstal l the tri m onto the ri ght si de quarter
TER TRI M PANEL - I NSTALLATI ON).
TRAILER TOW WIRING
DESCRIPTION
Vehi cl es equi pped wi th an opti onal factory-i n-
stal l ed (not deal er-i nstal l ed or port-i nstal l ed) trai l er
towi ng package have a rear body wi re harness that
i ncl udes an i ntegral trai l er tow wi ri ng take out that
connects to a heavy duty, seal ed, 7-pi n trai l er tow
connector l ocated on a bracket on the trai l er hi tch
recei ver (Fi g. 68). Thi s harness i ncl udes a second
take out wi th a trai l er tow rel ay connector bank and
four trai l er tow rel ays that i sol ate the ri ght turn si g-
nal , l eft turn si gnal , and brake l amp ci rcui ts of the
vehi cl e from the el ectri cal system of the trai l er. The
fourth rel ay i n the connector bank provi des a fused
i gni ti on swi tch output (run) source of battery current
to the trai l er tow connector through a trai l er tow
rel ay output ci rcui t. The package al so i ncl udes an
adapter harness (stored beneath the l eft rear seat
cushi on of the vehi cl e when i t i s shi pped from the
factory) that adapts the 7-pi n trai l er tow connector to
a standard, l i ght-duty, 4-pi n trai l er tow connector.
Fig. 68 Trailer Tow Wiring
1 - RETAINER CLIP (4)
2 - REAR BODY HARNESS (TRAILER TOW TAKE OUT)
LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
LIGHTING - INTERIOR . . . . . . . . . . . . . . . . . . 68
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
ASH RECEIVER LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
ASH RECEIVER LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72
CARGO LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
CARGO LAMP SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
CARGO LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
COMPASS MINI-TRIP ILLUMINATION BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 75
COURTESY LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76
COURTESY LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
DOOR AJAR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 77
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
FLIP-UP GLASS AJAR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 77
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
HEATER-A/C CONTROL ILLUMINATION BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 78
READING LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
READING LAMP SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
READING LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81
TAILGATE AJAR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 82
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ILLUMINATION BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
VANITY LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
DESCRIPTION
The i nteri or l i ghti ng system (Fi g. 1) for thi s model
i ncl udes the fol l owi ng i ncandescent i nteri or l amps:
Ash Receiver Lamp - An avai l abl e ash recei ver
l amp i s l ocated above the ash recei ver housi ng
behi nd the i nstrument panel center bezel , and i s con-
trol l ed by the panel l amps di mmer ci rcui t.
Cargo Lamp - An avai l abl e cargo l amp wi th an
i ntegral l ens-actuated courtesy di sabl e swi tch i s
l ocated i n the headl i ner near the rear roof header,
and i s control l ed by the courtesy l amp ci rcui t.
Courtesy Lamps - Avai l abl e courtesy l amps are
l ocated bel ow both the ri ght and l eft si de of the
i nstrument panel , and are control l ed by the courtesy
l amp ci rcui t.
Compass Mini-Trip Control Illumination
Lamps - The opti onal Compass Mi ni -Tri p Computer
(CMTC) has three repl aceabl e control i l l umi nati on
bul b/bul b hol der uni ts on i ts ci rcui t board that are
control l ed by the panel l amps di mmer ci rcui t.
Dome Lamp - A standard front dome l amp that
does not i ncl ude an on-off swi tch i s l ocated i n the
headl i ner near the wi ndshi el d header, and i s con-
trol l ed by the courtesy l amp ci rcui t.
Hazard Switch Illumination/Indicator
Lamp - The hazard swi tch control button has a non-
repl aceabl e i l l umi nati on/i ndi cator bul b sol dered onto
i ts ci rcui t board that i s control l ed by both the hazard
swi tch ci rcui try and the panel l amps di mmer ci rcui t.
EXTERI OR/HAZARD SWI TCH - DESCRI PTI ON).
Heater-Air Conditioner Control Illumina-
tion Lamps - The heater-ai r condi ti oner control has
KJ LAMPS/LIGHTING - INTERIOR 8L - 65
two repl aceabl e control i l l umi nati on bul b/bul b hol der
uni ts on i ts ci rcui t board that are control l ed by the
panel l amps di mmer ci rcui t.
Instrument Cluster Illumination Lamps -
The El ectroMechani cal I nstrument Cl uster (EMI C)
has ni ne repl aceabl e general i l l umi nati on bul b/bul b
hol der uni ts on i ts ci rcui t board that are control l ed
by the panel l amps di mmer ci rcui t. (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER -
DESCRI PTI ON).
Reading Lamps - Avai l abl e front seat dri ver
si de and passenger si de readi ng l amps l ocated i n the
headl i ner near the wi ndshi el d header are control l ed
by both the courtesy l amp ci rcui t and i ndependent
l ens-actuated swi tches.
Transmission Range Indicator Illumination
Lamp - Vehi cl es equi pped wi th an automati c trans-
Fig. 1 Courtesy Lamps
1 - COURTESY LAMP (2)
2 - DOME OR READING LAMP
3 - VANITY LAMP (2)
4 - CARGO LAMP
8L - 66 LAMPS/LIGHTING - INTERIOR KJ
LAMPS/LIGHTING - INTERIOR (Continued)
mi ssi on have an i l l umi nated transmi ssi on range i ndi -
cator i ntegral to the consol e mounted gearshi ft
mechani sm, and control l ed by the panel l amps di m-
mer ci rcui t.
Vanity Lamps - Avai l abl e si ngl e i ntensi ty van-
i ty l amps are l ocated on each si de of a covered mi rror
on both the ri ght and l eft sun vi sors, and are con-
trol l ed by an i ntegral vani ty mi rror cover-actuated
swi tch on the courtesy l amp ci rcui t.
Other components of the i nteri or l i ghti ng system
- DESCRI PTI ON).
Door Ajar Switches - A door ajar swi tch i s
i ntegral to the door l atch mechani sm of each front
and rear door.
Flip-Up Glass Ajar Switch - A fl i p-up gl ass
ajar swi tch i s i ntegral to the fl i p-up gl ass l atch mech-
ani sm on the top of the tai l gate i nner panel .
tems. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG
- EXTERI OR/MULTI -FUNCTI ON SWI TCH -
DESCRI PTI ON).
TailgateAjar Switch - A tai l gate ajar swi tch i s
i ntegral to the l atch mechani sm of the tai l gate.
Hard wi red ci rcui try connects the i nteri or l i ghti ng
vehi cl e el ectri cal system and to the i nteri or l i ghti ng
OPERATION
The i nteri or l i ghti ng systems can be di vi ded i nto
two general cl assi fi cati ons based upon the ci rcui t
that control s thei r operati on: The courtesy l amp ci r-
cui t, or the panel l amps di mmer ci rcui t. Fol l owi ng
are paragraphs that bri efl y descri be the operati on of
each of the major i nteri or l i ghti ng systems. The hard
wi red ci rcui ts and components of the i nteri or l i ghti ng
systems may be di agnosed and tested usi ng conven-
ti onal di agnosti c tool s and procedures. However, con-
venti onal di agnosti c methods may not prove
concl usi ve i n the di agnosi s of the Body Control Mod-
ul e (BCM), the El ectroMechani cal I nstrument Cl us-
ter (EMI C), or the Programmabl e Communi cati ons
I nterface (PCI ) data bus network. The most rel i abl e,
effi ci ent, and accurate means to di agnose the BCM,
the EMI C, and the PCI data bus network i nputs and
outputs rel ated to the vari ous i nteri or l i ghti ng sys-
tems requi res the use of a DRBI I I scan tool . Refer
COURTESY LAMP CI RCUI T Dependi ng upon the
sel ected vehi cl e opti ons the courtesy l amp ci rcui t
may i ncl ude the courtesy l amps l ocated bel ow the
i nstrument panel , the dome or map/readi ng l amps
l ocated i n the headl i ner near the wi ndshi el d, the
cargo l amp l ocated i n the headl i ner near the rear
roof header, and the vani ty l amps l ocated i n the sun
vi sors. The l amps i n the courtesy l amp ci rcui t are
provi ded wi th battery current at al l ti mes from a
fused B(+) fuse i n the Juncti on Bl ock (JB) through a
fused B(+) ci rcui t. The Body Control Modul e (BCM)
control s the ground path for these l amps usi ng an
i nternal dri ver through the courtesy l amp dri ver ci r-
cui t based upon hard wi red i nputs from the door ajar
swi tches, the fl i p-up gl ass ajar swi tch, and the tai l -
gate ajar swi tch. After al l of the ajar swi tch i nputs to
the BCM transi ti on to open, the BCM wi l l keep the
l amps i l l umi nated for about 27 seconds, then fade
the l amps to off (theater di mmi ng) over about three
seconds.
The BCM al so provi des courtesy l amp operati on
based upon a resi stor mul ti pl exed i nput from the
i nteri or l i ghti ng control ri ng on the l eft (l i ghti ng)
control stal k of the mul ti -functi on swi tch through the
headl amp swi tch mux ci rcui t, and i n response to cer-
tai n i nputs from the opti onal Remote Keyl ess Entry
(RKE) system. A resi stor mul ti pl exed courtesy l amp
defeat i nput from the control ri ng on the l eft (l i ght-
i ng) control stal k of the mul ti -functi on swi tch wi l l
cause the BCM to overri de normal courtesy l amp
operati on based upon i nputs from al l of the ajar
swi tches. A hard wi red i nput from the courtesy l amp
defeat swi tch i n the opti onal cargo l amp through a
rear courtesy l amp control ci rcui t wi l l cause the BCM
to overri de normal courtesy l amp operati on based
upon i nputs from onl y the fl i p-up gl ass and tai l gate
ajar swi tches.
For those l amps on the courtesy l amp ci rcui t wi th
i ndependent swi tchi ng, such as the opti onal readi ng
l amps and vani ty l amps, the BCM provi des a ground
path to the swi tches usi ng another i nternal dri ver
through the courtesy l amp l oad shed ci rcui t. The
for al l courtesy l amps, whi ch wi l l automati cal l y turn
Off posi ti on.
PANEL LAMPS DI MMER CI RCUI T The panel
l amps di mmer ci rcui t i ncl udes the El ectroMechani cal
I nstrument Cl uster (EMI C), heater-ai r condi ti oner
control , hazard swi tch and, dependi ng upon the
sel ected vehi cl e opti ons, ash recei ver, and automati c
transmi ssi on range i ndi cator i l l umi nati on l amps. Al l
l amps i n the panel l amps di mmer ci rcui t are pro-
vi ded a path to ground at al l ti mes through a hard
wi red ground ci rcui t. These l amps i l l umi nate based
upon i nputs to the Body Control Modul e (BCM) from
the exteri or l i ghti ng control knob and the i nteri or
l i ghti ng control ri ng on the l eft (l i ghti ng) control
stal k of the mul ti -functi on swi tch. The control knob
on the l eft control stal k of the mul ti -functi on swi tch
sel ects the exteri or l i ghts, whi l e the control ri ng
sel ects the panel l amps i ntensi ty (di mmi ng) l evel .
When the exteri or l i ghti ng i s turned On, the BCM
energi zes the park l amp rel ay and provi des an el ec-
troni c di mmi ng l evel message to the El ectroMechani -
cal I nstrument Cl uster (EMI C), the radi o, and the
Compass Mi ni -Tri p Computer (CMTC) over the Pro-
grammabl e Communi cati ons I nterface (PCI ) data
bus. The energi zed park l amp rel ay provi des a hard
wi red battery current si gnal i nput to the EMI C on
the park l amp rel ay output ci rcui t. The EMI C
responds to these i nputs by suppl yi ng a 12-vol t Pul se
Wi dth Modul ated (PWM) output to al l of the i ncan-
descent l amps i n the panel l amps di mmer ci rcui t
over the fused panel l amps di mmer swi tch si gnal ci r-
cui t. Thi s shared PWM output synchroni zes the
sel ected i l l umi nati on i ntensi ty l evel of al l of the
i ncandescent l amps i n the panel l amps di mmer ci r-
cui t.
The EMI C and the radi o each use the el ectroni c
di mmi ng l evel message from the BCM to control and
synchroni ze the i l l umi nati on i ntensi ty of thei r own
Vacuum Fl uorescent Di spl ay (VFD), whi l e the CMTC
uses the di mmi ng l evel message to control the i l l umi -
nati on i ntensi ty of both i ts VFD and i ts i ncandescent
l i ghti ng. I n addi ti on, when the control ri ng on the
l eft (l i ghti ng) control stal k of the mul ti -functi on
swi tch i s moved to the Parade Mode detent posi ti on,
al l of the VFDs are i l l umi nated at thei r ful l i ntensi ty
l evel s for i ncreased vi si bi l i ty when the vehi cl e i s
dri ven duri ng dayl i ght hours wi th the exteri or l i ghts
turned On.
- INTERIOR
i nteri or l i ghti ng system may be di agnosed and tested
usi ng conventi onal di agnosti c tool s and procedures.
However, conventi onal di agnosti c methods may not
prove concl usi ve i n the di agnosi s of the Body Control
Modul e (BCM), the El ectroMechani cal I nstrument
Cl uster (EMI C), or the Programmabl e Communi ca-
the BCM, the EMI C, and the PCI data bus network
i nputs and outputs rel ated to the vari ous i nteri or
l i ghti ng systems requi res the use of a DRBI I I scan
When di agnosi ng the i nteri or l i ghti ng ci rcui ts,
PERSONAL INJURY.
COURTESY LAMP CIRCUIT
A SINGLE LAMP IN THE
COURTESY LAMP
CIRCUIT DOES NOT
ILLUMINATE
1. Faulty or missing bulb. 1. Test and replace the courtesy lamp bulb
as required.
2. Faulty lamp switch. 2. Test and replace a faulty map/reading
lamp switch, cargo lamp switch, or sunvisor
(vanity lamp switch) as required.
3. Faulty ground circuit. 3. Test and repair the open courtesy lamp
driver circuit as required.
4. Faulty ground circuit
(independently switched lamps only).
4. Test and repair the open courtesy lamp
load shed circuit as required.
5. Faulty feed circuit. 5. Test and repair the open fused B(+)
ALL LAMPS IN THE
COURTESY LAMP
CIRCUIT DO NOT
ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace the fused B(+) fuse
(IOD) in the Junction Block (JB) as
required.
2. Faulty ground circuit. 2. Test and repair the open courtesy lamp
driver circuit as required.
3. Faulty feed circuit. 3. Test and repair the open fused B(+)
4. Faulty cargo lamp (courtesy
defeat) switch.
4. Test and replace the cargo lamp switch
as required.
5. Faulty rear courtesy lamp control
circuit.
5. Test and repair the shorted courtesy
lamp control circuit as required.
6. Faulty multi-function switch. 6. Test and replace the multi-function switch
as required.
7. Faulty Body Control Module
(BCM), BCM input, or BCM output.
7. Use a DRBIII scan tool to test the BCM,
its inputs, and its outputs. Refer to the
appropriate diagnostic information.
A SINGLE LAMP IN THE
COURTESY LAMP
CIRCUIT DOES NOT
EXTINGUISH
1. Faulty lamp switch. 1. Test and replace a faulty map/reading
lamp switch, cargo lamp switch, or sunvisor
(vanity lamp switch) as required.
2. Faulty ground circuit. 2. Test and repair the shorted courtesy
lamp driver circuit as required.
ALL LAMPS IN THE
COURTESY LAMP
CIRCUIT DO NOT
EXTINGUISH
1. Faulty ajar switch. 1. Test and replace a faulty door, tailgate,
or liftglass ajar switch as required.
2. Faulty ajar switch sense circuit. 2. Test and repair the shorted ajar switch
sense circuit as required.
3. Faulty ground circuit. 3. Test and repair the shorted courtesy
lamp driver circuit as required.
PANEL LAMPS DIMMER CIRCUIT
A SINGLE LAMP DOES
NOT ILLUMINATE
1. Faulty or missing bulb. 1. Test and replace lamp bulb as required.
2. Faulty ground circuit. 2. Test and repair lamp ground circuit as
required.
3. Faulty feed circuit. 3. Test and repair open fused panel lamps
dimmer switch signal circuit as required.
A SINGLE LAMP DOES
NOT EXTINGUISH
1. Faulty feed circuit. 1. Test and repair shorted fused panel
lamps dimmer switch signal circuit as
required.
ALL LAMPS DO NOT
ILLUMINATE
1. Faulty fused park lamp relay
output circuit.
1. Test and repair open fused park lamp
2. Faulty or missing park
lamp relay.
2. Test and replace park lamp relay as
required.
3. Faulty fused panel lamps dimmer
switch signal circuit.
3. Test and repair open fused panel lamps
dimmer switch signal circuit as required.
5. Faulty ElectroMechanical
Instrument Cluster (EMIC), EMIC
input, or EMIC output.
5. Use a DRBIII scan tool to test the
EMIC, its inputs, and its outputs. Refer to
the appropriate diagnostic information.
6. Faulty multi-function switch. 6. Test and replace the multi-function switch
as required.
ALL LAMPS EXCEPT
CLUSTER ILLUMINATION
DO NOT EXTINGUISH
1. Faulty feed circuit. 1. Test and repair shorted fused panel
lamps dimmer switch signal circuit as
required.
INTERIOR
BULB SPECIFICATIONS
LAMP BULB
Ash Receiver 161
Cargo 214-2
Cluster Illumination 103
Compass Mini-Trip
Illumination
MOPAR 4437661
Courtesy 906
Heater-A/C Control
Illumination
74
Map/Reading 192
Transmission Range
Indicator Illumination
S14V
Vanity Mirror MOPAR 6501966
ASH RECEIVER LAMP BULB
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Remove the ash recei ver l amp uni t from the
top of the ash recei ver housi ng. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - I NTERI OR/ASH
RECEI VER LAMP UNI T - REMOVAL).
(3) Careful l y di sengage the ash recei ver l amp hood
from the i ntegral snap features on each si de of the
l amp uni t socket and remove the hood (Fi g. 2).
(4) Pul l the ash recei ver l amp bul b strai ght out of
the l amp uni t socket.
INSTALLATION
PERSONAL INJURY.
(1) Al i gn the base of the ash recei ver l amp bul b
wi th the receptacl e i n the l amp uni t socket.
(2) Push the ash recei ver l amp bul b strai ght i nto
the l amp uni t socket unti l i t i s fi rml y seated (Fi g. 2).
(3) Careful l y sl i de the ash recei ver l amp hood onto
the l amp uni t socket unti l i t i s ful l y engaged wi th
the i ntegral snap features on each si de of the socket.
(4) Rei nstal l the ash recei ver l amp uni t onto the
top of the ash recei ver housi ng. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - I NTERI OR/ASH
RECEI VER LAMP UNI T - I NSTALLATI ON).
Fig. 2 Ash Receiver Lamp Bulb Remove/Install
1 - SOCKET
2 - BULB
3 - HOOD
ASH RECEIVER LAMP UNIT
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Remove the center bezel from the i nstrument
I NSTRUMENT PANEL CENTER BEZEL - REMOV-
AL).
(3) Whi l e pul l i ng the ash recei ver l amp uni t away
from the top of the ash recei ver housi ng, from i nsi de
the housi ng careful l y rel ease the four i ntegral l atches
that secure the l amp uni t to the mounti ng hol e i n the
top of the housi ng.
(4) Remove the ash recei ver l amp uni t from the
top of the ash recei ver housi ng (Fi g. 3).
INSTALLATION
PERSONAL INJURY.
(1) Al i gn the four i ntegral l atches of the ash
recei ver l amp uni t to the mounti ng hol e on the top of
the ash recei ver housi ng (Fi g. 3).
(2) Usi ng hand pressure, press fi rml y and evenl y
on the ash recei ver l amp uni t unti l the four i ntegral
l atches snap i nto pl ace i n the ash recei ver housi ng
mounti ng hol e.
(3) Rei nstal l the center bezel onto the i nstrument
I NSTRUMENT PANEL CENTER BEZEL - I NSTAL-
LATI ON).
CARGO LAMP BULB
REMOVAL
cabl e.
(2) Usi ng a smal l thi n-bl aded screwdri ver, gentl y
pry outward on ei ther si de near the top of the cargo
l amp l ens unti l the l ens pi vot unsnaps from the pi vot
pi n wi thi n the l amp uni t housi ng (Fi g. 4).
(3) Move the cargo l amp l ens upward far enough
to di sengage the swi tch tab at the bottom of the l ens
from between the swi tch pl unger and the l amp uni t
housi ng.
(4) Remove the cargo l amp l ens from the l amp
uni t housi ng.
(5) Fi rml y grasp the cargo l amp bul b and pul l each
end outward unti l i t i s di sengaged from i ts respecti ve
bul b hol der wi thi n the l amp uni t housi ng (Fi g. 5).
(6) Remove the cargo l amp bul b from the l amp
uni t housi ng.
Fig. 3 Ash Receiver Lamp Unit Remove/Install
1 - CENTER BEZEL
2 - ASH RECEIVER HOUSING
3 - ASH RECEIVER LAMP UNIT
INSTALLATION
(1) Posi ti on the cargo l amp bul b i nto the l amp uni t
housi ng.
(2) Al i gn the ends of the cargo l amp bul b wi th
each of the bul b hol ders wi thi n the l amp uni t hous-
i ng (Fi g. 5).
on both ends of the cargo l amp bul b unti l they snap
i nto thei r respecti ve bul b hol ders wi thi n the l amp
uni t housi ng.
(4) Posi ti on the cargo l amp l ens to the l amp uni t
housi ng.
(5) I nsert the swi tch tab at the bottom of the cargo
l amp l ens between the swi tch pl unger and the l amp
uni t housi ng.
(6) Al i gn the pi vots on each si de near the top of
the cargo l amp l ens wi th the pi vot pi ns wi thi n the
l amp uni t housi ng.
on the cargo l amp l ens over both pi vots unti l they
snap i nto pl ace over the pi vot pi ns wi thi n the l amp
uni t housi ng.
CARGO LAMP SWITCH
REMOVAL
cabl e.
(2) Remove the cargo l amp uni t from the headl i ner
near the rear roof header. (Refer to 8 - ELECTRI -
CAL/LAMPS/LI GHTI NG - I NTERI OR/CARGO
LAMP UNI T - REMOVAL).
(3) From the back of the cargo l amp uni t housi ng,
fi rml y grasp the swi tch body (Fi g. 6).
Fig. 4 Cargo Lamp Lens Remove
1 - HEADLINER
2 - CARGO LAMP
3 - LENS
4 - SCREWDRIVER
Fig. 5 Cargo Lamp Bulb Remove/Install
1 - HEADLINER
2 - CARGO LAMP
3 - LENS PIVOT PIN
4 - BULB
5 - SWITCH
Fig. 6 Cargo Lamp Switch Remove/Install
1 - CARGO LAMP UNIT HOUSING
2 - SWITCH
CARGO LAMP BULB (Continued)
(4) Usi ng hand pressure, pul l the cargo l amp
swi tch toward the outsi de of the l amp uni t housi ng
unti l i t unsnaps from the housi ng.
(5) Conti nue sl i di ng the cargo l amp swi tch away
from the termi nal pi ns and out of the l amp uni t
housi ng.
INSTALLATION
(1) Al i gn the termi nal receptacl es i n the cargo
l amp swi tch wi th the termi nal pi ns of the l amp uni t
housi ng (Fi g. 6).
(2) Usi ng hand pressure, push the cargo l amp
swi tch toward the termi nal s of the l amp uni t housi ng
unti l i t snaps i nto the housi ng.
(3) Rei nstal l the cargo l amp uni t onto the head-
l i ner near the rear roof header. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - I NTERI OR/CARGO
CARGO LAMP UNIT
REMOVAL
cabl e.
fl at-bl aded tool , gentl y pry between the fl ange
around the edge of the cargo l amp uni t housi ng and
the headl i ner to rel ease the metal snap cl i p on each
si de of the housi ng from the receptacl es i n the rear
roof header (Fi g. 7).
(3) Pul l the cargo l amp uni t away from the head-
l i ner far enough to access and di sconnect the rear
body wi re harness connector for the l amp from the
connector receptacl e on the l amp uni t housi ng.
(4) Remove the cargo l amp uni t from the mounti ng
hol e i n the headl i ner.
INSTALLATION
(1) Posi ti on the cargo l amp uni t to the mounti ng
tor for the cargo l amp to the connector receptacl e on
the l amp uni t housi ng.
(3) Wi th the fi nger depressi on i n the cargo l amp
l ens ori ented towards the rear of the vehi cl e, posi ti on
the cargo l amp uni t housi ng i nto the headl i ner
mounti ng hol e and al i gn the metal snap cl i p on each
si de of the housi ng wi th thei r receptacl es i n the rear
roof header (Fi g. 7).
(4) Usi ng hand pressure, press upward fi rml y and
evenl y on both ends of the cargo l amp uni t unti l both
snap cl i ps are ful l y engaged i n thei r receptacl es.
COMPASS MINI-TRIP
ILLUMINATION BULB
REMOVAL
The Compass Mi ni -Tri p Computer (CMTC) i n the
overhead consol e i ncl udes ei ther two or three i ncan-
descent i l l umi nati on bul b and bul b hol der uni ts.
Three bul bs are used onl y on model s that al so fea-
ture the opti onal Uni versal Garage Door Opener
(UGDO).
PERSONAL INJURY.
Fig. 7 Cargo Lamp Unit Remove/Install
1 - CARGO LAMP UNIT
2 - HEADLINER
3 - TRIM STICK
CARGO LAMP SWITCH (Continued)
cabl e.
(2) Remove the overhead consol e from the head-
l i ner. (Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE - REMOVAL).
(3) From the back of the uni t, use a smal l thi n-
bl aded screwdri ver to rotate the compass mi ni -tri p
i l l umi nati on bul b hol der countercl ockwi se about 30
degrees on the ci rcui t board (Fi g. 8).
(4) Pul l the compass mi ni -tri p i l l umi nati on bul b
hol der and bul b uni t strai ght out of the ci rcui t board
bul b mounti ng hol e.
INSTALLATION
The Compass Mi ni -Tri p Computer (CMTC) i n the
overhead consol e i ncl udes ei ther two or three i ncan-
descent i l l umi nati on bul b and bul b hol der uni ts.
Three bul bs are used onl y on model s that al so fea-
ture the opti onal Uni versal Garage Door Opener
(UGDO).
PERSONAL INJURY.
(1) Al i gn the compass mi ni -tri p i l l umi nati on bul b
hol der and bul b uni t wi th the ci rcui t board bul b
mounti ng hol e.
(2) I nsert the compass mi ni -tri p i l l umi nati on bul b
hol der and bul b uni t strai ght i nto the ci rcui t board
bul b mounti ng hol e unti l i t i s fi rml y seated (Fi g. 8).
(3) Usi ng a smal l thi n-bl aded screwdri ver, rotate
the compass mi ni -tri p i l l umi nati on bul b hol der cl ock-
wi se about 30 degrees on the ci rcui t board.
(4) Rei nstal l the overhead consol e onto the head-
l i ner. (Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE - I NSTALLATI ON).
COURTESY LAMP BULB
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Support the courtesy l amp uni t housi ng wi th
one hand whi l e fi rml y graspi ng the fl ange on the
outer ci rcumference of the l ens wi th the other hand,
then pul l the l ens strai ght down to unsnap i t from
the housi ng (Fi g. 9).
(3) Pul l the courtesy l amp bul b strai ght out of the
l amp uni t socket.
Fig. 8 Compass Mini-Trip Illumination Bulb
Remove/Install
1 - OVERHEAD CONSOLE
2 - BULB & HOLDER (3)
3 - COMPASS MINI-TRIP COMPUTER
COMPASS MINI-TRIP ILLUMINATION BULB (Continued)
INSTALLATION
PERSONAL INJURY.
(1) Al i gn the base of the courtesy l amp bul b wi th
the receptacl e i n the l amp uni t socket.
(2) Push the courtesy l amp bul b strai ght i nto the
l amp uni t socket unti l i t i s fi rml y seated (Fi g. 9).
(3) Al i gn the courtesy l amp l ens wi th the l amp
uni t housi ng.
(4) Support the courtesy l amp uni t housi ng wi th
one hand whi l e fi rml y and evenl y pushi ng the l ens
i nto the housi ng wi th the other hand, unti l the l ens
snaps i nto pl ace.
COURTESY LAMP UNIT
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Remove the screw that secures the i ntegral
mounti ng tab of the courtesy l amp uni t to the l ower
i nstrument panel (Fi g. 10).
(3) Pul l the courtesy l amp uni t down from the
l ower i nstrument panel far enough to access and di s-
connect the i nstrument panel wi re harness connector
Fig. 9 Courtesy Lamp Lens Remove/Install
1 - COURTESY LAMP
2 - LOWER INSTRUMENT PANEL
3 - BULB
4 - LENS
Fig. 10 Courtesy Lamp Unit Remove/Install
1 - COURTESY LAMP UNIT
2 - SCREW (1)
3 - LOWER INSTRUMENT PANEL
COURTESY LAMP BULB (Continued)
for the courtesy l amp from the connector receptacl e
on the back of the l amp uni t housi ng.
(4) Remove the courtesy l amp uni t from under the
i nstrument panel .
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the courtesy l amp uni t under the
i nstrument panel .
connector for the courtesy l amp to the connector
receptacl e on the back of the l amp uni t housi ng.
(3) Posi ti on the courtesy l amp uni t to the l ower
i ntegral mounti ng tab of the courtesy l amp uni t to
the l ower i nstrument panel .
DOOR AJ AR SWITCH
DESCRIPTION
Thi s vehi cl e has four door ajar swi tches, one for
each door. Each swi tch i s conceal ed wi thi n and i nte-
gral to i ts respecti ve door l atch uni t. The swi tches
are momentary l eaf contact-type uni ts that are actu-
ated by the door l atch mechani sms. A short pi gtai l
wi re and connector on each door l atch connects the
door ajar swi tch to the vehi cl e el ectri cal system
through i ts respecti ve door wi re harness. The door
ajar swi tches cannot be adjusted or repai red and, i f
faul ty or damaged, the door l atch uni t must be
repl aced. (Refer to 23 - BODY/DOOR - FRONT/
LATCH - REMOVAL) or (Refer to 23 - BODY/DOOR -
REAR/LATCH - REMOVAL).
OPERATION
The door ajar swi tches are actuated by the door
l atch mechani sms. When a door i s cl osed and prop-
erl y l atched, i ts door ajar swi tch i s an open ci rcui t.
When a door i s open or onl y parti al l y l atched, the
door ajar swi tch i s a cl osed ci rcui t. The door ajar
swi tches are hard wi red between a body ground and
the Body Control Modul e (BCM). The dri ver si de
front door ajar swi tch i s connected to the BCM
through a dri ver door ajar swi tch sense ci rcui t, whi l e
the remai ni ng three door ajar swi tches are connected
to the BCM through a passenger door ajar swi tch
sense ci rcui t i n a paral l el -seri es arrangement. The
BCM reads the door ajar swi tch status through an
i nternal pul l -up, then uses these i nputs to control
many el ectroni c functi ons and features of the vehi cl e.
The door ajar swi tches can be di agnosed usi ng con-
venti onal di agnosti c tool s and methods; however, for
proper di agnosi s of the BCM, and both the hard
wi red and el ectroni c BCM outputs affected by the
door ajar swi tch i nputs, a DRBI I I scan tool i s
mati on.
FLIP-UP GLASS AJ AR SWITCH
DESCRIPTION
A fl i p-up gl ass ajar swi tch i s standard equi pment
i n thi s vehi cl e. Thi s swi tch i s conceal ed wi thi n and
i ntegral to the fl i p-up gl ass l atch uni t. The swi tch i s
a momentary l eaf contact-type uni t that i s actuated
by the fl i p-up gl ass l atch mechani sm. A dedi cated
connector receptacl e on the fl i p-up gl ass l atch uni t
connects the fl i p-up gl ass ajar swi tch to the vehi cl e
el ectri cal system through the tai l gate wi re harness.
The fl i p-up gl ass ajar swi tch cannot be adjusted or
repai red and, i f faul ty or damaged, the fl i p-up gl ass
l atch uni t must be repl aced. (Refer to 23 - BODY/
SWI NG GATE/FLI P-UP GLASS LATCH - REMOV-
AL).
OPERATION
The fl i p-up gl ass ajar swi tch i s actuated by the
fl i p-up gl ass l atch mechani sm. When the fl i p-up gl ass
i s cl osed and properl y l atched, the fl i p-up gl ass ajar
swi tch i s an open ci rcui t. When the fl i p-up gl ass i s
open or onl y parti al l y l atched, the fl i p-up gl ass ajar
swi tch i s a cl osed ci rcui t. The fl i p-up gl ass ajar
swi tch i s hard wi red between a body ground, the
Body Control Modul e (BCM), and the rear wi per
motor. The output of the swi tch i s connected to the
BCM and rear wi per motor through a fl i p-up gl ass
ajar swi tch sense ci rcui t. The BCM reads the fl i p-up
gl ass ajar swi tch status through an i nternal pul l -up,
then uses thi s i nput to control many el ectroni c func-
COURTESY LAMP UNIT (Continued)
ti ons and features of the vehi cl e. The rear wi per
motor uses thi s i nput to restri ct rear wi per operati on
when the fl i p-up gl ass i s ajar. The fl i p-up gl ass ajar
swi tch can be di agnosed usi ng conventi onal di agnos-
ti c tool s and methods; however, for proper di agnosi s
of the BCM, and both the hard wi red and el ectroni c
BCM outputs affected by the fl i p-up gl ass ajar swi tch
i nput, a DRBI I I scan tool i s requi red. Refer to the
HEATER-A/C CONTROL
ILLUMINATION BULB
REMOVAL
PERSONAL INJURY.
cabl e.
I NSTRUMENT PANEL CENTER BEZEL - REMOV-
AL).
(3) From the back of the center bezel , use a smal l
thi n-bl aded screwdri ver to rotate the heater-A/C con-
trol i l l umi nati on bul b hol der countercl ockwi se about
30 degrees on the ci rcui t board (Fi g. 11).
(4) Pul l the heater-A/C i l l umi nati on bul b hol der
and bul b uni t strai ght out of the ci rcui t board bul b
mounti ng hol e.
INSTALLATION
PERSONAL INJURY.
(1) Al i gn the heater-A/C control i l l umi nati on bul b
hol der and bul b uni t wi th the ci rcui t board bul b
mounti ng hol e.
(2) I nsert the heater-A/C control i l l umi nati on bul b
hol der and bul b uni t strai ght i nto the ci rcui t board
bul b mounti ng hol e unti l i t i s fi rml y seated (Fi g. 11).
(3) Usi ng a smal l thi n-bl aded screwdri ver, rotate
the heater-A/C control i l l umi nati on bul b hol der cl ock-
wi se about 30 degrees on the ci rcui t board.
I NSTRUMENT PANEL CENTER BEZEL - I NSTAL-
LATI ON).
Fig. 11 Heater-A/C Control Illumination Bulb
Remove/Install
1 - CENTER BEZEL
2 - BULB HOLDER & BULB (2)
3 - HEATER-A/C CONTROL
FLIP-UP GLASS AJ AR SWITCH (Continued)
READING LAMP BULB
REMOVAL
PERSONAL INJURY.
cabl e.
(2) I f the vehi cl e i s not equi pped wi th the opti onal
Compass Mi ni -Tri p Computer (CMTC), remove the
readi ng l amp uni t from the headl i ner mounti ng hol e.
I NTERI OR/READI NG LAMP UNI T - REMOVAL). I f
the vehi cl e i s equi pped wi th the opti onal CMTC,
remove the overhead consol e from the headl i ner.
(Refer to 8 - ELECTRI CAL/OVERHEAD CONSOLE -
REMOVAL).
(3) From the back of the uni t whi l e pul l i ng the
readi ng l amp socket away from the outsi de of the
l amp uni t bul b housi ng, use a smal l thi n-bl aded
screwdri ver to rel ease the i ntegral l atch tabs of the
socket from the i nsi de of the bul b housi ng (Fi g. 12).
(4) Pul l the readi ng l amp socket and bul b uni t
strai ght out from the l amp uni t bul b housi ng.
(5) Pul l the ash readi ng l amp bul b strai ght out of
the l amp uni t socket.
INSTALLATION
PERSONAL INJURY.
(1) Al i gn the base of the readi ng l amp bul b wi th
the receptacl e i n the l amp uni t socket.
(2) Push the readi ng l amp bul b strai ght i nto the
(3) Al i gn the readi ng l amp socket and bul b uni t
wi th the mounti ng hol e i n the bul b housi ng (Fi g. 12).
(4) Push the readi ng l amp socket and bul b uni t
strai ght i nto the bul b housi ng unti l i t i s fi rml y
seated and the i ntegral socket l atches are engaged
wi thi n the bul b housi ng.
(5) I f the vehi cl e i s not equi pped wi th the opti onal
Compass Mi ni -Tri p Computer (CMTC), rei nstal l the
readi ng l amp uni t i nto the headl i ner mounti ng hol e.
I NTERI OR/READI NG LAMP - I NSTALLATI ON). I f
the vehi cl e i s equi pped wi th the opti onal CMTC,
rei nstal l the overhead consol e onto the headl i ner.
(Refer to 8 - ELECTRI CAL/OVERHEAD CONSOLE -
I NSTALLATI ON).
Fig. 12 Reading Lamp Bulb Remove/Install
1 - BEZEL
2 - BULB HOUSING
3 - SWITCH (2)
4 - BULB (2)
5 - SOCKET (2)
READING LAMP SWITCH
REMOVAL
The readi ng l amp swi tches are servi ced as a uni t
wi th the readi ng l amp sockets, wi re harness, and
connector.
PERSONAL INJURY.
cabl e.
(2) Remove both readi ng l amp sockets and thei r
bul bs from the l amp uni t housi ng. (Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - I NTERI OR/
READI NG LAMP BULB - REMOVAL).
(3) From the back of the readi ng l amp uni t hous-
i ng, careful l y depress the bl ocki ng tab that engages
the termi nal end of the readi ng l amp wi re harness
connector, then sl i de the connector over the tab and
off of the mount near the center of the l amp uni t
housi ng.
(4) From the back of the readi ng l amp uni t hous-
i ng, fi rml y press each swi tch body toward the l arge
end of the keyed hol e i nto whi ch i t i s secured unti l i t
unsnaps from the housi ng (Fi g. 13).
(5) Remove the connector, wi re harness, both sock-
ets, and both swi tches from the back of the readi ng
INSTALLATION
The readi ng l amp swi tches are servi ced as a uni t
wi th the readi ng l amp sockets, wi re harness, and
connector.
PERSONAL INJURY.
(1) Posi ti on the connector, wi re harness, both sock-
ets, and both swi tches onto the back of the readi ng
(2) I nsert the pl unger of each swi tch i nto the l arge
end of the keyed hol e i n the readi ng l amp uni t hous-
i ng.
(3) Fi rml y press each swi tch body toward the
smal l end of the keyed hol e i nto whi ch i t i s secured
unti l i t snaps i nto the housi ng (Fi g. 13).
(4) Engage the wi re end of the readi ng l amp wi re
harness connector onto the connector mount near the
center of the l amp uni t housi ng, then sl i de the con-
nector over the mount unti l the bl ocki ng tab snaps
up i nto pl ace.
(5) Rei nstal l both readi ng l amp bul bs and thei r
sockets i nto the l amp uni t housi ng. (Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - I NTERI OR/
READI NG LAMP BULB - I NSTALLATI ON).
Fig. 13 Reading Lamp Switch Remove/Install
1 - READING LAMP BULB
2 - SWITCH
READING LAMP UNIT
REMOVAL
I f the vehi cl e i s equi pped wi th an opti onal Com-
pass Mi ni -Tri p Computer (CMTC), the readi ng l amps
are housed i n the overhead consol e. (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - REMOV-
AL).
PERSONAL INJURY.
cabl e.
fl at-bl aded tool , gentl y pry between the fl ange
around the edge of the readi ng l amp uni t housi ng
and the headl i ner to rel ease the metal snap cl i p on
each si de of the housi ng from the receptacl es i n the
mounti ng bracket above the headl i ner (Fi g. 14).
(3) Pul l the readi ng l amp uni t away from the
headl i ner far enough to access and di sconnect the
body wi re harness connector for the l amp from the
connector on the l amp uni t housi ng.
(4) I f the vehi cl e i s equi pped wi th an opti onal
power sunroof, di sconnect the body wi re harness con-
nector for the sunroof swi tch from the connector
receptacl e on the back of the swi tch.
(5) Remove the readi ng l amp uni t from the mount-
i ng hol e i n the headl i ner.
INSTALLATION
I f the vehi cl e i s equi pped wi th an opti onal Com-
pass Mi ni -Tri p Computer (CMTC), the readi ng l amps
are housed i n the overhead consol e. (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - I NSTALLA-
TI ON).
PERSONAL INJURY.
(1) Posi ti on the readi ng l amp uni t to the mounti ng
(2) I f the vehi cl e i s equi pped wi th an opti onal
power sunroof, reconnect the body wi re harness con-
nector for the sunroof swi tch to the connector recep-
tacl e on the back of the swi tch.
(3) Reconnect the body wi re harness connector for
the readi ng l amp to the connector on the l amp uni t
housi ng.
(4) Wi th the curved corners of the readi ng l amp
l enses ori ented towards the rear of the vehi cl e, posi -
ti on the readi ng l amp uni t housi ng i nto the headl i ner
mounti ng hol e and al i gn the metal snap cl i p on each
si de of the housi ng wi th thei r receptacl es i n the
(5) Usi ng hand pressure, press upward fi rml y and
evenl y on both ends of the readi ng l amp uni t unti l
both snap cl i ps are ful l y engaged i n thei r receptacl es.
Fig. 14 Reading Lamp Unit Remove/Install
1 - TRIM STICK
2 - SUNROOF SWITCH
3 - READING LAMP UNIT
4 - HEADLINER
5 - LENS (2)
TAILGATE AJ AR SWITCH
DESCRIPTION
A tai l gate ajar swi tch i s standard equi pment i n
thi s vehi cl e. Thi s swi tch i s conceal ed wi thi n and i nte-
gral to the tai l gate l atch uni t. The swi tch i s a
momentary l eaf contact-type uni t that i s actuated by
the tai l gate l atch mechani sm. A pi gtai l wi re harness
and connector on the tai l gate l atch uni t connects the
tai l gate ajar swi tch to the vehi cl e el ectri cal system
through the tai l gate wi re harness. The tai l gate ajar
swi tch cannot be adjusted or repai red and, i f faul ty
or damaged, the tai l gate l atch uni t must be repl aced.
(Refer to 23 - BODY/SWI NG GATE/LATCH -
REMOVAL).
OPERATION
The tai l gate swi tch i s actuated by the tai l gate
l atch mechani sm. When the tai l gate i s cl osed and
properl y l atched, the tai l gate ajar swi tch i s an open
ci rcui t. When the tai l gate i s open or onl y parti al l y
l atched, the tai l gate ajar swi tch i s a cl osed ci rcui t.
The tai l gate ajar swi tch i s hard wi red between a
body ground and the Body Control Modul e (BCM).
The output of the swi tch i s connected to the BCM
through a tai l gate ajar swi tch sense ci rcui t. The
BCM reads the tai l gate ajar swi tch status through
an i nternal pul l -up, then uses thi s i nput to control
many el ectroni c functi ons and features of the vehi cl e.
The tai l gate ajar swi tch can be di agnosed usi ng con-
venti onal di agnosti c tool s and methods; however, for
proper di agnosi s of the BCM, and both the hard
wi red and el ectroni c BCM outputs affected by the
tai l gate ajar swi tch i nput, a DRBI I I scan tool i s
mati on.
TRANSMISSION RANGE
INDICATOR ILLUMINATION
BULB
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Remove the center consol e from the fl oor panel
transmi ssi on tunnel . (Refer to 23 - BODY/I NTERI -
OR/FLOOR CONSOLE - REMOVAL).
(3) From the l eft si de of the vehi cl e, reach between
transmi ssi on range i ndi cator and the fl oor panel
transmi ssi on tunnel to grasp the i l l umi nati on l amp
socket (Fi g. 15).
Fig. 15 Transmission Range Indicator Illumination
Bulb Remove/Install
1 - AUTOMATIC TRANSMISSION SHIFT MECHANISM
2 - ILLUMINATION LAMP SOCKET
(4) Rotate the transmi ssi on range i ndi cator i l l umi -
nati on l amp socket countercl ockwi se about 30
degrees on the bottom of the range i ndi cator.
(5) Pul l the transmi ssi on range i ndi cator i l l umi na-
ti on l amp socket and bul b uni t strai ght out of the
bul b mounti ng hol e i n the bottom of the i ndi cator.
(6) Pul l the transmi ssi on range i ndi cator i l l umi na-
ti on l amp bul b strai ght out of the socket.
INSTALLATION
PERSONAL INJURY.
(1) Al i gn the base of the transmi ssi on range i ndi -
cator i l l umi nati on l amp bul b wi th the receptacl e i n
the l amp socket.
(2) Push the transmi ssi on range i ndi cator i l l umi -
nati on l amp bul b strai ght i nto the l amp socket unti l
i t i s fi rml y seated.
(3) Al i gn the transmi ssi on range i ndi cator i l l umi -
nati on l amp socket and bul b uni t wi th the mounti ng
hol e on the bottom of the i ndi cator (Fi g. 15).
(4) Push the transmi ssi on range i ndi cator i l l umi -
nati on l amp socket and bul b uni t strai ght i nto the
bottom of the i ndi cator unti l i t i s fi rml y seated.
(5) Rotate the transmi ssi on range i ndi cator i l l umi -
nati on l amp socket cl ockwi se about 30 degrees on the
bottom of the i ndi cator.
(6) Rei nstal l the center consol e onto the fl oor panel
transmi ssi on tunnel . (Refer to 23 - BODY/I NTERI -
OR/FLOOR CONSOLE - I NSTALLATI ON).
VANITY LAMP BULB
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Usi ng a smal l thi n-bl aded tool , gentl y pry out-
ward on ei ther si de near the top or bottom of the
vani ty l amp l ens unti l the l ens unsnaps from the
Fig. 16 Vanity Lamp Lens Remove
1 - LENS (2)
2 - MIRROR
3 - SUN VISOR
TRANSMISSION RANGE INDICATOR ILLUMINATION BULB (Continued)
(3) Usi ng smal l needl e-nose pl i ers, careful l y pul l
the vani ty l amp bul b strai ght out from the l amp
socket (Fi g. 17).
INSTALLATION
PERSONAL INJURY.
(1) Usi ng smal l needl e-nose pl i ers, careful l y grasp
the vani ty l amp bul b and al i gn the base of the bul b
wi th the receptacl e i n the l amp socket (Fi g. 17).
(2) Careful l y push the vani ty l amp bul b base
strai ght i nto the l amp socket unti l i t i s ful l y seated.
(3) I nsert one tab on the top or the bottom of the
vani ty l amp l ens i nto the proper sl ot i n the l amp uni t
housi ng.
(4) Careful l y fl ex the vani ty l amp l ens far enough
to engage the l oose tab i nto i ts sl ot i n the l amp uni t
housi ng.
Fig. 17 Vanity Lamp Bulb Remove/Install
1 - HOUSING
2 - MIRROR
3 - SOCKET
4 - NEEDLE-NOSE PLIERS
5 - BULB
VANITY LAMP BULB (Continued)
LAMPS
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LIGHTING - EXTERIOR . . . . . . . . . . . . . . . . . . 7
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BACKUP LAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BRAKE LAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
CENTER HIGH MOUNTED STOP LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
COMBINATION FLASHER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DAYTIME RUNNING LAMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT FOG LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING - FRONT FOG
LAMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
FRONT FOG LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
ADJUSTMENTS
ADJUSTMENT - FRONT FOG LAMP UNIT . . . 25
FRONT LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
FRONT LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
HAZARD SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
HEADLAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
HEADLAMP HIGH BEAM RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HIGH BEAM RELAY . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
HEADLAMP LEVELING SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
LEVELING SWITCH . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
BEAM RELAY . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
HEADLAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
ADJUSTMENTS
ADJUSTMENT - HEADLAMP UNIT . . . . . . . . 42
KJ LAMPS 8Ls - 1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53
PARK LAMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56
REAR FOG LAMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DIAGNOSIS AND TESTING - REAR FOG
LAMP RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 57
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
REAR LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
REAR LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
REPEATER LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
REPEATER LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
TRAILER TOW RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 62
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63
TRAILER TOW WIRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 64
LAMP BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DIAGNOSIS AND TESTING - LAMP BAR . . . . . 65
STANDARD PROCEDURE - LAMP BAR
AIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
REMOVAL
REMOVAL - LAMP BAR . . . . . . . . . . . . . . . . . 65
REMOVAL - LAMP . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION
INSTALLATION - LAMP BAR . . . . . . . . . . . . . 66
INSTALLATION - LAMP . . . . . . . . . . . . . . . . . 66
LAMP BAR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 67
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
DESCRIPTION
The exteri or l i ghti ng system for thi s model
i ncl udes the fol l owi ng exteri or l amps (Fi g. 1):
Backup Lamps - The backup (or reverse) l amps
are i ntegral to the rear l amp uni ts mounted to the
back of the quarter panel on each si de of the tai l gate
Brake Lamps - The brake (or stop) l amps
i ncl ude a l amp that i s i ntegral to the rear l amp uni ts
si de of the tai l gate, and the Center Hi gh Mounted
Stop Lamp (CHMSL) that i s centered on the rear
edge of the roof panel above the fl i p-up gl ass openi ng
Daytime Running Lamps - Vehi cl es manufac-
tured for sal e i n Canada i l l umi nate the hi gh beam
fi l ament i n each headl amp bul b serves as the Day-
ti me Runni ng Lamps (DRL).
Front Fog Lamps - Opti onal front fog l amps
i ncl ude a si ngl e round front fog l amp uni t wi th an
adjustabl e refl ector and a removabl e bul b that i s
secured behi nd a dedi cated openi ng on each forward-
faci ng end of the front bumper fasci a.
Hazard Warning Lamps - The hazard warni ng
l amps i ncl ude al l of the ri ght and l eft turn si gnal
l amps.
Headlamps - A si ngl e round headl amp housi ng
wi th a fi xed l ens, an adjustabl e refl ector, and a si ngl e
removabl e hal ogen bul b i s secured to the gri l l e open-
i ng panel on each si de of the gri l l e openi ng at the
front of the vehi cl e. I n certai n markets where
requi red, a headl amp l evel i ng actuator motor i s
i ncl uded on each headl amp.
Park Lamps - The park l amps i ncl ude the front
park l amps and front si de marker l amps that are
i ntegral to the front l amp uni ts mounted at each end
of the bumper fasci a at the front of the vehi cl e, as
wel l as the rear park l amps and rear si de marker
l amps that are i ntegral to the rear l amp uni ts
8Ls - 2 LAMPS KJ
Fig. 1 Exterior Lamps
KJ LAMPS 8Ls - 3
si de of the tai l gate at the rear of the vehi cl e. The
park l amps i ncl ude a l i cense pl ate l amp or l amps,
dependi ng upon the requi rements of the market for
whi ch the vehi cl e i s manufactured. Vehi cl es wi th a
l i cense pl ate tub l ocated near the l eft end of the rear
bumper fasci a have a si ngl e l amp, whi l e vehi cl es
wi th a l i cense pl ate modul e l ocated on the spare ti re
carri er have two l i cense pl ate l amps. I n certai n mar-
kets where requi red, a front posi ti on l amp that i s
i ntegral to each headl amp uni t i s i l l umi nated i nstead
of the front park l amps and front si de marker l amps
i n the park l amps ci rcui t; and, a rectangul ar, red
refl ector i s l ocated on the rear bumper fasci a just
i nboard and bel ow each rear l amp uni t.
Rear Fog Lamps - Rear fog l amps are avai l -
abl e onl y i n certai n markets where they are requi red
equi pment. The rear fog l amps are i ntegral to the
rear l amp uni ts mounted to the back of the quarter
panel on each si de of the tai l gate at the rear of the
vehi cl e.
Turn Signal Lamps - The turn si gnal l amps
i ncl ude the front turn si gnal and front si de marker
l amps that are i ntegral to the front l amp uni ts
mounted at each end of the bumper fasci a at the
front of the vehi cl e, as wel l as rear turn si gnal l amps
that are i ntegral to the rear l amp uni ts mounted to
the back of the quarter panel on each si de of the tai l -
gate at the rear of the vehi cl e. I n certai n markets
where requi red, a repeater l amp uni t mounted to
each front fender just behi nd the front wheel openi ng
i s i l l umi nated i nstead of the front si de marker l amp
i n each turn si gnal l amp ci rcui t.
Other components of the exteri or l i ghti ng system
ti on fl asher i s i ntegral to the hazard warni ng swi tch
i n the center of the i nstrument panel .
Backup Lamp Switch - Vehi cl es equi pped wi th
a manual transmi ssi on have a pl unger-type backup
l amp swi tch l ocated on the transmi ssi on housi ng. A
Transmi ssi on Range Sensor (TRS) i ntegral to the
sol enoi d pack on the val ve body of the opti onal el ec-
troni c automati c transmi ssi on performs the backup
l amp swi tch functi on on model s that are so equi pped.
Brake Lamp Switch - A pl unger-type brake
l amp swi tch i s l ocated on the steeri ng col umn sup-
port bracket under the i nstrument panel and actu-
ated by the brake pedal arm.
- DESCRI PTI ON).
Daytime Running Lamp Relay - Vehi cl es
manufactured for sal e i n Canada use a sol i d state
Dayti me Runni ng Lamps (DRL) rel ay i nstal l ed i n the
Juncti on Bl ock (JB) i nstead of the conventi onal hi gh
beam rel ay.
Front Fog Lamp Relay - Vehi cl es equi pped
wi th the opti onal front fog l amps have a front fog
l amp rel ay l ocated i n the Juncti on Bl ock (JB).
Hazard Switch - The hazard swi tch i s l ocated
near the center of the i nstrument panel and i ncl udes
the i ntegral el ectroni c combi nati on fl asher ci rcui try
for the hazard warni ng system and the turn si gnal
system.
Headlamp Leveling Motor - A headl amp l ev-
el i ng actuator motor i s l ocated on the back of each
headl amp housi ng of vehi cl es manufactured for cer-
tai n markets where thi s equi pment i s requi red.
Headlamp Leveling Switch - A thumbwheel
actuated headl amp l evel i ng swi tch i s mounted i n the
dri ver si de i nboard i nstrument panel tri m bezel of
vehi cl es manufactured for certai n markets where thi s
equi pment i s requi red.
High Beam Relay - A hi gh beam rel ay i s
l ocated i n the Juncti on Bl ock (JB) of al l vehi cl es
except those that are manufactured for sal e i n Can-
ada. Canadi an vehi cl es have a sol i d state Dayti me
Runni ng Lamps (DRL) rel ay i n the JB i nstead of the
hi gh beam rel ay.
Low Beam Relay - A l ow beam rel ay i s l ocated
i n the Juncti on Bl ock (JB) of al l vehi cl es.
tems.
Park Lamp Relay - A park l amp rel ay i s
l ocated i n the Juncti on Bl ock (JB) of al l vehi cl es.
Rear Fog Lamp Relay - Vehi cl es manufac-
tured for certai n markets where rear fog l amps are
requi red equi pment have a rear fog l amp rel ay
l ocated i n the Juncti on Bl ock (JB).
1 - HEADLAMP UNIT (2)
2 - REPEATER LAMP UNIT (2)
3 - FRONT POSITION LAMP (2)
4 - FRONT LAMP UNIT (2)
5 - FRONT FOG LAMP (2)
6 - CENTER HIGH MOUNTED STOP LAMP UNIT
7 - REAR LAMP UNIT
8Ls - 4 LAMPS KJ
Trailer Tow Adapter - Vehi cl es equi pped wi th
a factory-i nstal l ed trai l er towi ng package have an
adapter provi ded that adapts the factory-i nstal l ed
heavy duty 7-way trai l er tow connector to a conven-
ti onal 4-way l i ght duty connector.
Trailer Tow Connector - Vehi cl es equi pped
wi th a factory-i nstal l ed trai l er towi ng package have a
heavy duty 7-way trai l er tow connector i nstal l ed i n a
Trailer Tow Relays - Vehi cl es equi pped wi th a
factory-i nstal l ed trai l er towi ng package have a con-
nector bank contai ni ng four rel ays l ocated behi nd the
ri ght quarter tri m panel and over the ri ght rear
wheel housi ng. The four rel ays are used to suppl y
fused i gni ti on swi tch output (run), brake l amps, ri ght
turn si gnal , and l eft turn si gnal outputs to a trai l er
through the trai l er tow wi ri ng and connectors.
Hard wi red ci rcui try connects the exteri or l i ghti ng
vehi cl e el ectri cal system and to the exteri or l i ghti ng
OPERATION
operati on of each of the major exteri or l i ghti ng sys-
tems. The hard wi red ci rcui ts and components of the
ti c i nformati on.
BACKUP LAMPS
The backup (or reverse) l amps have a path to
ground at al l ti mes through thei r connecti on to the
backup l amps recei ve battery current from a fused
i gni ti on swi tch output (run) fuse i n the Juncti on
Bl ock (JB) on the back-up l amp feed ci rcui t onl y
when the backup l amp swi tch (manual transmi ssi on),
or backup l amp swi tch ci rcui t of the Transmi ssi on
Range Sensor (TRS - el ectroni c automati c transmi s-
si on) i s cl osed by the gearshi ft mechani sm wi thi n the
transmi ssi on.
BRAKE LAMPS
The brake (or stop) l amps have a path to ground at
al l ti mes through thei r connecti on to the rear l i ght-
i ng wi re harness from a take out of the rear body
wi re harness wi th an eyel et termi nal connector that
i s secured by a screw to the base of the ri ght D-pi l l ar
behi nd the quarter tri m panel . The Center Hi gh
Mounted Stop Lamp (CHMSL) has a path to ground
at al l ti mes through i ts connecti on to the rear body
wi re harness from a take out of the rear body wi re
secured by a ground screw to the dri ver si de D-pi l l ar
(l eft si de D-pi l l ar for l eft-hand dri ve, ri ght si de D-pi l -
l ar for ri ght-hand dri ve) behi nd the quarter tri m
panel . The brake l amps and CHMSL recei ve battery
current from a fused B(+) fuse i n the Juncti on Bl ock
(JB) on the brake l amp swi tch output ci rcui t onl y
when the brake l amp swi tch ci rcui t of the brake
l amp swi tch i s cl osed by the brake pedal arm.
Vehi cl es manufactured for sal e i n Canada i l l umi -
nate the hi gh beam fi l ament at a reduced i ntensi ty
when the engi ne i s runni ng and the exteri or l amps
are turned off. Thi s feature i s enabl ed by the Body
Control Modul e (BCM) and a sol i d state Dayti me
Runni ng Lamps (DRL) rel ay, whi ch i s i nstal l ed i n the
Juncti on Bl ock (JB) and the hi gh beam rel ay i s omi t-
ted. When the BCM moni tors an engi ne speed si gnal
of greater than 450 RPM and the status of the exte-
ri or l i ghti ng swi tch i nput from the mul ti -functi on
swi tch i s Off, the BCM duty cycl es the DRL rel ay to
produce i l l umi nati on of the headl amp hi gh beam fi l -
aments at a reduced i ntensi ty. The BCM al so pro-
vi des normal headl amp hi gh beam operati on through
the DRL rel ay on vehi cl es so equi pped. When the
DRL rel ay i s energi zed, i t provi des battery current
from a fused B(+) fuse i n the JB to the headl amp
hi gh beam fi l ament through the DRL rel ay output
ci rcui t.
KJ LAMPS 8Ls - 5
FRONT FOG LAMPS
Vehi cl es equi pped wi th opti onal front fog l amps
have a premi um Body Control Modul e (BCM), a front
fog l amp rel ay i nstal l ed i n the Juncti on Bl ock (JB),
and a front fog l amp swi tch i ntegral to the l eft (l i ght-
i ng) control stal k of the mul ti -functi on swi tch. The
front fog l amps have a path to ground at al l ti mes
through thei r connecti on to the front fasci a wi re har-
ness from two take outs of the headl amp and dash
wi re harness wi th eyel et termi nal connectors that
are secured by ground screws to the l eft i nner fender
shi el d i n the engi ne compartment. The BCM control s
front fog l amp operati on by moni tori ng the exteri or
l i ghti ng swi tch i nput from the mul ti -functi on swi tch,
then energi zi ng or de-energi zi ng the front fog l amp
rel ay control coi l ; and, by sendi ng the appropri ate
el ectroni c message to the i nstrument cl uster over the
bus to turn the front fog l amp i ndi cator on or off.
When the front fog l amp rel ay i s energi zed, i t pro-
vi des battery current from a fused B(+) fuse i n the
JB to the front fog l amps through the front fog l amp
rel ay output ci rcui t. The BCM provi des a battery
saver (l oad sheddi ng) feature for the front fog l amps,
swi tch i n the Off posi ti on. I n certai n markets where
requi red, the front fog l amps are al so turned off by
the BCM whenever the headl amp hi gh beams are
sel ected. Each front fog l amp i ncl udes an i ntegral
adjustment screw to be used for stati c ai mi ng the fog
l amp beams.
Wi th the hazard swi tch i n the On posi ti on, the
hazard warni ng system i s acti vated causi ng the haz-
ard swi tch button i l l umi nati on l amp, the ri ght and
l eft turn si gnal i ndi cators, and the ri ght and l eft turn
si gnal l amps to fl ash on and off. When the hazard
warni ng system i s acti vated, the ci rcui try wi thi n the
hazard swi tch and el ectroni c combi nati on fl asher
uni t wi l l repeatedl y energi ze and de-energi ze two
i nternal rel ays that swi tch battery current from a
fused B(+) fuse i n the Juncti on Bl ock (JB) to the
ri ght si de and l eft si de turn si gnal i ndi cators, and
turn si gnal l amps through the ri ght and l eft turn si g-
nal ci rcui ts. The fl ashi ng of the hazard swi tch button
i l l umi nati on l amp i s performed i nternal l y by the haz-
ard swi tch and combi nati on fl asher uni t ci rcui t
board. The hazard warni ng l amps can al so be ener-
gi zed by the Body Control Modul e (BCM) through a
hazard l amp control ci rcui t i nput to the hazard
swi tch and combi nati on fl asher uni t.
HEADLAMPS
The headl amp system i ncl udes the Body Control
Modul e (BCM), a l ow beam rel ay i nstal l ed i n the
Juncti on Bl ock (JB), a hi gh beam rel ay i nstal l ed i n
the JB (except Canada), a sol i d state Dayti me Run-
ni ng Lamps (DRL) rel ay i nstal l ed i n the JB (Canada
onl y), and the exteri or l i ghti ng (headl amp and di m-
mer) swi tches i ntegral to the l eft (l i ghti ng) control
stal k of the mul ti -functi on swi tch. The headl amp
bul bs have a path to ground at al l ti mes through
thei r connecti on to the gri l l e openi ng rei nforcement
wi re harness from two take outs of the headl amp and
fender shi el d i n the engi ne compartment. The BCM
control s the headl amp operati on by moni tori ng the
exteri or l i ghti ng swi tch i nputs from the mul ti -func-
ti on swi tch, then energi zi ng or de-energi zi ng the con-
trol coi l s of the l ow beam rel ay, the hi gh beam rel ay,
or the sol i d state ci rcui try of the DRL rel ay; and, by
ni cati ons I nterface (PCI ) data bus to turn the hi gh
beam i ndi cator on or off. When each respecti ve rel ay
i s energi zed, i t provi des battery current from a fused
B(+) fuse i n the Power Di stri buti on Center (PDC)
through a rel ay (l ow beam, hi gh beam, or DRL) out-
put ci rcui t and four separate fuses i n the JB through
i ndi vi dual fused ri ght and l eft, l ow and hi gh beam
output ci rcui ts to the appropri ate headl amp bul b fi l -
aments. The BCM provi des a battery saver (l oad
sheddi ng) feature for the headl amps, whi ch wi l l turn
Off posi ti on; and, a headl amp del ay feature wi th a
DRBI I I scan tool programmabl e del ay i nterval .
Each headl amp i ncl udes an i ntegral adjustment
screw to be used for stati c ai mi ng of the headl amp
beams.
HEADLAMP LEVELING
I n certai n markets where requi red, a headl amp
l evel i ng system i s provi ded on the vehi cl e. The head-
l amp l evel i ng system i ncl udes uni que headl amp uni ts
equi pped wi th a headl amp l evel i ng actuator motor,
and a rotary thumbwheel actuated headl amp l evel i ng
swi tch on the i nstrument panel . The headl amp l evel -
i ng system al l ows the headl amp beams to be
adjusted to one of four verti cal posi ti ons to compen-
sate for changes i n i ncl i nati on caused by the l oadi ng
of the vehi cl e suspensi on. The actuator motors are
mechani cal l y connected through an i ntegral pushrod
to an adjustabl e headl amp refl ector. The headl amp
l evel i ng swi tch i s a resi stor mul ti pl exed uni t that
provi des one of four vol tage outputs to the headl amp
l evel i ng motors. The headl amp l evel i ng motors wi l l
8Ls - 6 LAMPS KJ
move the headl amps to the sel ected posi ti on based
upon the vol tage i nput recei ved from the swi tch. The
headl amp l evel i ng motors and swi tch have a path to
ground at al l ti mes. The headl amp l evel i ng compo-
nents operate on battery current recei ved through
the fused park l amp rel ay output ci rcui t so that the
system wi l l onl y operate when the exteri or l i ghti ng i s
turned on.
PARK LAMPS
The park l amps system i ncl udes the Body Control
Modul e (BCM), a park l amp rel ay i nstal l ed i n the
Juncti on Bl ock (JB), and the exteri or l i ghti ng swi tch
i ntegral to the l eft (l i ghti ng) control stal k of the
mul ti -functi on swi tch. The front park l amp and si de
marker or, i f equi pped, the front posi ti on l amp bul bs
each have a path to ground at al l ti mes through thei r
connecti ons to the gri l l e openi ng rei nforcement wi re
harness from two take outs of the headl amp and
fender shi el d i n the engi ne compartment. The rear
park l amp bul bs and l i cense pl ate l amp have a path
to ground at al l ti mes through thei r connecti on to the
BCM control s the park l amp operati on by moni tori ng
the exteri or l i ghti ng swi tch i nputs from the mul ti -
functi on swi tch, then energi zi ng or de-energi zi ng the
control coi l of the park l amp rel ay. When the park
l amp rel ay i s energi zed, i t provi des battery current
from a fused B(+) fuse i n the Power Di stri buti on
Center (PDC) through a park l amp rel ay output ci r-
cui t and a separate fuse i n the JB through a fused
park l amp rel ay output ci rcui t to the appropri ate
l amp bul b fi l aments. The BCM provi des a battery
saver (l oad sheddi ng) feature for the park l amps,
swi tch i n the Off posi ti on.
REAR FOG LAMPS
Rear fog l amps are i nstal l ed on vehi cl es manufac-
tured for certai n markets where they are requi red.
The rear fog l amp system i ncl udes a premi um Body
Control Modul e (BCM), a rear fog l amp rel ay
i nstal l ed i n the Juncti on Bl ock (JB), and a rear fog
l amp swi tch i ntegral to the l eft (l i ghti ng) control
stal k of the mul ti -functi on swi tch. The rear fog l amps
have a path to ground at al l ti mes through thei r con-
necti on to the rear l i ghti ng wi re harness from a take
out of the rear body wi re harness wi th an eyel et ter-
the base of the ri ght D-pi l l ar behi nd the quarter tri m
panel . The BCM control s rear fog l amp operati on by
moni tori ng the exteri or l i ghti ng swi tch i nput from
the mul ti -functi on swi tch, then energi zi ng or de-ener-
gi zi ng the rear fog l amp rel ay control coi l ; and, by
ni cati ons I nterface (PCI ) data bus to turn the rear
fog l amp i ndi cator on or off. When the rear fog l amp
rel ay i s energi zed, i t provi des battery current from a
fused B(+) fuse i n the JB to the rear fog l amps
through the rear fog l amp rel ay output ci rcui t. The
for the rear fog l amps, whi ch wi l l turn these l amps
off i f they are l eft on for more than about ei ght mi n-
utes wi th the i gni ti on swi tch i n the Off posi ti on.
TURN SIGNAL LAMPS
When the l eft control stal k of the mul ti -functi on
swi tch i s moved up (ri ght turn) or down (l eft turn),
the turn si gnal system i s acti vated causi ng the
sel ected ri ght or l eft turn si gnal i ndi cator, and ri ght
or l eft turn si gnal l amps to fl ash on and off. When
the turn si gnal system i s acti vated, the ci rcui try
wi thi n the turn si gnal swi tch and the hazard swi tch/
el ectroni c combi nati on fl asher uni t wi l l repeatedl y
energi ze and de-energi ze one of two i nternal rel ays
that swi tch battery current from a fused i gni ti on
swi tch output (run) fuse i n the Juncti on Bl ock (JB) to
the ri ght si de or l eft si de turn si gnal i ndi cators and
turn si gnal l amps through the ri ght or l eft turn si g-
nal ci rcui ts. The El ectroMechani cal I nstrument Cl us-
ter (EMI C) chi me tone generator wi l l generate an
audi bl e turn si gnal cancel warni ng each ti me the
vehi cl e i s dri ven for a di stance of about 3.2 ki l ome-
ters (about two mi l es) wi th a turn si gnal i ndi cator
fl ashi ng. The EMI C uses Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus di stance messages
from the Powertrai n Control Modul e (PCM) and a
hard wi red i nput from the turn si gnal swi tch ci r-
cui try of the mul ti -functi on swi tch to determi ne when
to sound the turn si gnal cancel warni ng.
- EXTERIOR
KJ LAMPS 8Ls - 7
ti c i nformati on.
When di agnosi ng the exteri or l i ghti ng ci rcui ts,
PERSONAL INJURY.
BACKUP LAMPS
BACKUP LAMP DOES
NOT ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace backup lamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace backup lamp bulb as
required.
required.
4. Faulty ground circuit. 4. Test and repair backup lamp ground
5. Faulty feed circuit. 5. Test and repair open back-up lamp feed
BACKUP LAMP DOES
NOT EXTINGUISH
required.
2. Faulty feed circuit. 2. Test and repair shorted back-up lamp
feed circuit as required.
8Ls - 8 LAMPS KJ
BRAKE LAMPS
BRAKE LAMP DOES NOT
ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace brake lamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace brake lamp bulb as
required.
required.
4. Faulty ground circuit. 4. Test and repair brake lamp ground circuit
as required.
5. Faulty feed circuit. 5. Test and repair open brake lamp switch
BRAKE LAMP DOES NOT
EXTINGUISH
required.
2. Faulty feed circuit. 2. Test and repair shorted brake lamp
switch output circuit as required.
Before performi ng the fol l owi ng tests, determi ne
whether the headl amp l ow and hi gh beams operate.
I f the headl amp hi gh and l ow beams are al so i noper-
ati ve, di agnose and repai r that probl em before
attempti ng to repai r the Dayti me Runni ng Lamps.
DAYTIME RUNNING
LAMPS WILL NOT
ILLUMINATE
1. High beam relay installed. 1. Remove high beam relay as required.
2. Faulty or missing DRL relay. 2. Replace DRL relay with a known good
unit and check operation. Replace DRL
relay as required.
3. Incorrect BCM programming. 3. Use a DRBIII scan tool to check and
program correct country code into BCM as
required.
inputs or outputs. Refer to the appropriate
KJ LAMPS 8Ls - 9
FRONT FOG LAMPS
FRONT FOG LAMP DOES
NOT ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace front fog lamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace front fog lamp bulb as
required.
3. Faulty or missing relay. 3. Test and replace front fog lamp relay as
required.
required.
5. Faulty ground circuit. 5. Test and repair front fog lamp ground
6. Faulty feed circuit. 6. Test and repair open front fog lamp relay
FRONT FOG LAMP DOES
NOT EXTINGUISH
1. Faulty relay. 1. Test and replace front fog lamp relay as
required.
required.
3. Faulty feed circuit. 3. Test and repair shorted front fog lamp
whether the l eft and ri ght turn si gnal s operate sati s-
factori l y. I f the turn si gnal s are i noperati ve or oper-
ate i mproperl y, di agnose and repai r that probl em
before attempti ng to repai r the Hazard Warni ng
Lamps.
HAZARD WARNING
LAMPS DO NOT FLASH
1. Faulty or missing fuse. 1. Test and replace hazard warning fuse as
required.
2. Faulty ground circuit. 2. Test and repair hazard switch ground
3. Faulty feed circuit. 3. Test and repair open hazard switch fused
B(+) circuit as required.
4. Faulty switch/flasher. 4. Replace hazard switch/combination
combination flasher unit if required.
8Ls - 10 LAMPS KJ
HEADLAMPS
HEADLAMP DOES NOT
ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace headlamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace headlamp bulb as
required.
3. Faulty or missing relay. 3. Test and replace low beam or high beam
relay as required. (Note: Vehicles with a
DRL relay do not use a high beam relay.
The DRL relay cannot be tested. Replace
DRL relay with a known good unit and
check operation. Replace DRL relay as
required.)
required.
5. Faulty ground circuit. 5. Test and repair open headlamp ground
6. Faulty feed circuit. 6. Test and repair open headlamp low
beam, high beam, or DRL relay output
HEADLAMP DOES NOT
EXTINGUISH
required.)
required.
3. Faulty feed circuit. 3. Test and repair shorted headlamp low
beam, high beam, or DRL relay output
KJ LAMPS 8Ls - 11
HEADLAMPS WILL NOT
SWITCH FROM HIGH TO
LOW BEAMS, OR FROM
LOW TO HIGH BEAMS
required.)
required.
HEADLAMP LEVELING
whether the park l amps operate sati sfactori l y. I f the
park l amps are i noperati ve, di agnose and repai r that
probl em before attempti ng to repai r the Headl amp
Level i ng System.
ONE LEVELING MOTOR
IS INOPERATIVE
1. Faulty ground circuit. 1. Test and repair open leveling motor
2. Faulty feed circuit. 2. Test and repair open leveling motor feed
3. Faulty signal circuit. 3. Test and repair open headlamp adjust
4. Faulty motor. 4. Test and replace headlamp leveling
motor as required.
BOTH LEVELING
MOTORS ARE
INOPERATIVE
1. Faulty switch ground circuit. 1. Test and repair open leveling switch
2. Faulty motor ground circuit. 2. Test and repair open leveling motor
3. Faulty switch feed circuit. 3. Test and repair open leveling switch feed
4. Faulty motor feed circuit. 4. Test and repair open leveling motor feed
5. Faulty signal circuit. 5. Test and repair open or shorted leveling
motor signal circuit as required.
6. Faulty switch. 6. Test and replace leveling switch as
required.
7. Faulty motors. 7. Test and replace leveling motors as
required.
8Ls - 12 LAMPS KJ
PARK LAMPS
PARK LAMP DOES NOT
ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace park lamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace park lamp bulb as
required.
3. Faulty or missing relay. 3. Test and replace park lamp relay as
required.
required.
5. Faulty ground circuit. 5. Test and repair open park lamp ground
6. Faulty feed circuit. 6. Test and repair open park lamp relay
PARK LAMP DOES NOT
EXTINGUISH
1. Faulty relay. 1. Test and replace park lamp relay as
required.
required.
3. Faulty feed circuit. 3. Test and repair shorted park lamp relay
REAR FOG LAMPS
REAR FOG LAMP DOES
NOT ILLUMINATE
1. Faulty or missing fuse. 1. Test and replace rear fog lamp fuse as
required.
2. Faulty or missing bulb. 2. Test and replace rear fog lamp bulb as
required.
3. Faulty or missing relay. 3. Test and replace rear fog lamp relay as
required.
required.
5. Faulty ground circuit. 5. Test and repair open rear fog lamp
6. Faulty feed circuit. 6. Test and repair open rear fog lamp relay
KJ LAMPS 8Ls - 13
REAR FOG LAMP DOES
NOT EXTINGUISH
1. Faulty relay. 1. Test and replace rear fog lamp relay as
required.
required.
3. Faulty feed circuit. 3. Test and repair shorted rear fog lamp
TURN SIGNAL LAMPS
ONE TURN SIGNAL LAMP
DOES NOT ILLUMINATE
1. Faulty or missing bulb. 1. Test and replace turn signal bulb as
required.
required.
3. Faulty feed circuit. 3. Test and repair open right or left turn
ALL RIGHT SIDE AND/OR
ALL LEFT SIDE TURN
SIGNAL LAMPS DO NOT
FLASH
1. Faulty sense circuit. 1. Test and repair open right or left turn
switch sense circuit as required.
required.
4. Faulty signal circuit. 4. Test and repair open right or left turn
ALL RIGHT SIDE OR ALL
LEFT SIDE TURN
SIGNALS FLASH TOO
RAPIDLY (MORE THAN
100 FLASHES PER
MINUTE)
1. Faulty or missing bulb. 1. Test and replace faulty bulb as required.
required.
3. Faulty signal circuit 3. Test and repair open right or left turn
8Ls - 14 LAMPS KJ
EXTERIOR
BULB SPECIFICATIONS
LAMP BULB
Backup 3157 P27/7W
Brake 3157 P27/7W
Center High Mounted
Stop
921/W16W
Front Fog 9145
Front Park 3157 P27/7W
Front Position W5W
Front Side Marker 168
Front Turn 3157 P27/7W
Headlamp (North
America)
9007QL
Headlamp (Rest-Of-
World)
H-4 W0W6
License Plate (North
America)
168
License Plate (Rest-Of-
World)
W5W
Rear Fog 3157 P27/7W
Rear Park/Tail 3157 P27/7W
Rear Turn 3157 P27/7W
Side Repeater W5W
BACKUP LAMP SWITCH
DESCRIPTION
Vehi cl es equi pped wi th a manual transmi ssi on
have a normal l y open, spri ng-l oaded pl unger type
back-up l amp swi tch (Fi g. 2). The backup l amp
swi tch i s l ocated i n a threaded hol e on the si de of the
manual transmi ssi on housi ng, beneath the fl oor
panel of the vehi cl e. The backup l amp swi tch has a
threaded body and a hex formati on near the pl unger
end of the swi tch, and an i ntegral connector recepta-
cl e at the opposi te end of the swi tch. When i nstal l ed,
onl y the connector receptacl e and the hex formati on
are vi si bl e on the outsi de of the transmi ssi on hous-
i ng. Vehi cl es wi th an opti onal el ectroni c automati c
transmi ssi on have a Transmi ssi on Range Sensor
(TRS) that i s used to perform several functi ons,
i ncl udi ng that of the backup l amp swi tch. The TRS i s
i nformati on. The backup l amp swi tch cannot be
enti re swi tch uni t must be repl aced.
OPERATION
The backup l amp swi tch control s the fl ow of bat-
tery current to the backup l amp bul bs at the back of
the vehi cl e through an output on the back-up l amp
feed ci rcui t. The swi tch pl unger i s mechani cal l y actu-
ated by the gearshi ft mechani sm wi thi n the trans-
mi ssi on, whi ch wi l l depress the swi tch pl unger and
cl ose the swi tch contacts whenever the reverse gear
has been sel ected. The swi tch recei ves battery cur-
rent through a fuse i n the Juncti on Bl ock (JB) on a
fused i gni ti on swi tch output (run) ci rcui t whenever
the i gni ti on swi tch i s i n the On posi ti on. A take out
of the engi ne wi re harness connects the backup l amp
swi tch to the vehi cl e el ectri cal system. The backup
l amp swi tch and ci rcui ts can be tested usi ng conven-
ti onal di agnosti c tool s and methods.
SWITCH
cabl e.
(3) Locate and di sconnect the engi ne wi re harness
connector for the backup l amp swi tch from the
(4) Check for conti nui ty between the two termi nal
pi ns i n the backup l amp swi tch connector receptacl e.
(a) Wi th the gear sel ector l ever i n the Reverse
posi ti on, there shoul d be conti nui ty.
(b) Wi th the gear sel ector l ever i n any posi ti on
other than Reverse, there shoul d be no conti nui ty.
Fig. 2 Backup Lamp Switch - Typical
1 - MANUAL TRANSMISSION
2 - BACKUP LAMP SWITCH
3 - ENGINE WIRE HARNESS
KJ LAMPS 8Ls - 15
BRAKE LAMP SWITCH
DESCRIPTION
The brake l amp swi tch i s a three ci rcui t, spri ng-
l oaded pl unger actuated swi tch that i s secured to the
steeri ng col umn support bracket under the dri ver
si de of the i nstrument panel (Fi g. 3). The brake l amp
swi tch i s contai ned wi thi n a rectangul ar mol ded pl as-
ti c housi ng wi th an i ntegral connector receptacl e fea-
turi ng si x termi nal pi ns and a red pl asti c Connector
Posi ti on Assurance (CPA) l ock. The swi tch i s con-
nected to the vehi cl e el ectri cal system through a ded-
i cated take out and connector of the i nstrument
panel wi re harness. The swi tch pl unger extends
through a mounti ng col l ar on one end of the swi tch
housi ng. The pl unger has a one ti me tel escopi ng sel f-
adjustment feature that i s achi eved after the swi tch
i s i nstal l ed by movi ng an adjustment rel ease l ever on
the opposi te end of the swi tch housi ng cl ockwi se,
unti l i t l ocks i n a posi ti on that i s paral l el to the con-
nector receptacl e. The brake l amp swi tch sel f-adjust-
ment i s a one ti me feature. Once the feature has
been used, the swi tch cannot be readjusted. A DO
NOT RE-I NSTALL warni ng i s mol ded i nto the
swi tch housi ng bel ow the connector receptacl e.
An i nstal l ed brake l amp swi tch cannot be read-
justed or repai red. I f the swi tch i s damaged, faul ty,
or removed from i ts mounti ng posi ti on for any rea-
son, i t must be repl aced wi th a new uni t.
OPERATION
The brake l amp swi tch control s three di fferent ci r-
cui ts, one normal l y open and two normal l y cl osed.
These ci rcui ts are descri bed as fol l ows:
Brake Lamp Switch Circuit - A normal l y
open brake l amp swi tch ci rcui t recei ves battery cur-
rent on a fused B(+) ci rcui t from a fuse i n the Junc-
ti on Bl ock (JB), and suppl i es battery current to the
brake l amps and the Control l er Anti l ock Brake
(CAB) on a brake l amp swi tch output ci rcui t when
the brake pedal i s depressed (brake l amp swi tch
pl unger rel eased).
Brake Lamp Switch Signal Circuit - A nor-
mal l y cl osed brake l amp swi tch si gnal ci rcui t recei ves
a path to ground through a spl i ce bl ock l ocated i n the
near the Juncti on Bl ock (JB). Thi s ci rcui t suppl i es a
ground i nput to the Powertrai n Control Modul e
(PCM) on a brake l amp swi tch sense ci rcui t when the
depressed).
Speed Control Circuit - A normal l y cl osed
speed control ci rcui t recei ves battery current from
the Powertrai n Control Modul e on a speed control
suppl y ci rcui t, and suppl i es battery current to the
speed control servo sol enoi ds (dump, vacuum, and
vent) on a speed control brake swi tch output ci rcui t
when the speed control system i s turned on and the
depressed).
Conceal ed wi thi n the brake l amp swi tch housi ng
the components of the sel f-adjusti ng brake swi tch
pl unger consi st of a two-pi ece tel escopi ng pl unger, a
spl i t pl unger l ocki ng col l ar, and a rel ease wedge. The
rel ease l ever has an i ntegral shaft wi th a wedge that
spreads the pl unger l ocki ng col l ar to an open or
rel eased posi ti on. After the swi tch i s i nstal l ed and
the brake pedal i s rel eased, the pl unger tel escopes to
the correct adjustment posi ti on. When the rel ease
l ever i s moved to the rel ease posi ti on, the wedge i s
di sengaged from the l ocki ng col l ar causi ng the col l ar
to appl y a cl ampi ng pressure to the two pl unger
hal ves fi xi ng the pl unger l ength.
The brake l amp swi tch can be di agnosed usi ng con-
Fig. 3 Brake Lamp Switch
3 - PLUNGER
4 - COLLAR
5 - LEVER
8Ls - 16 LAMPS KJ
SWITCH
PERSONAL INJURY.
tests at the termi nal pi ns i n the brake l amp swi tch
connector receptacl e (Fi g. 4) as shown i n the Brake
Lamp Swi tch Tests tabl e.
BRAKE LAMP SWITCH TESTS
PLUNGER POSITION CONTINUITY BETWEEN
Released (Extended) Pins 1 & 2
Compressed (Retracted) Pins 3 & 4, 5 & 6
(3) I f the swi tch fai l s any of the conti nui ty tests,
repl ace the faul ty brake l amp swi tch as requi red.
REMOVAL
PERSONAL INJURY.
cabl e.
connector receptacl e (Fi g. 5).
(3) Grasp the brake l amp swi tch housi ng fi rml y
and rotate the swi tch countercl ockwi se about 30
degrees to al i gn the tabs on the l ocki ng col l ar wi th
port bracket.
(4) Pul l the swi tch strai ght back from the mount-
i ng hol e to remove i t from the steeri ng col umn sup-
port bracket.
(5) Di scard the removed brake l amp swi tch.
Fig. 4 Brake Lamp Switch Terminal Identification
1 - TERMINAL PINS
2 - PLUNGER TEST POSITIONS
Fig. 5 Brake Lamp Switch Remove/Install
1 - STEERING COLUMN SUPPORT
3 - LEVER
5 - BRAKE PEDAL ARM
KJ LAMPS 8Ls - 17
INSTALLATION
PERSONAL INJURY.
(1) Whi l e hol di ng the brake pedal depressed, al i gn
the tabs on the brake l amp swi tch l ocki ng col l ar wi th
port bracket (Fi g. 5).
(2) Sti l l hol di ng the brake pedal depressed, i nsert
the tabs on the brake l amp swi tch housi ng through
port bracket unti l the swi tch i s fi rml y seated agai nst
the bracket.
(3) Sti l l hol di ng the brake pedal depressed, rotate
the swi tch cl ockwi se about 30 degrees to l ock the
tabs on the brake l amp swi tch l ocki ng col l ar to the
keyed mounti ng hol e i n the steeri ng col umn support
bracket.
(4) Rel ease the brake pedal .
CAUTION: Do not pull up on the brake pedal before
the switch plunger adjustment has been completed.
(5) Rotate the pl unger adjustment rel ease l ever
cl ockwi se unti l i t l ocks i nto pl ace paral l el to the
brake l amp swi tch connector receptacl e. Thi s acti on
wi l l set the swi tch pl unger l ength to a fi nal adjust-
ment posi ti on and cannot be undone. I f not per-
formed properl y the fi rst ti me, a new brake l amp
swi tch must be i nstal l ed.
connector for the brake l amp swi tch to the swi tch
CENTER HIGH MOUNTED
STOP LAMP BULB
REMOVAL
cabl e.
(CHMSL) uni t from the roof panel . (Refer to 8 -
CENTER HI GH MOUNTED STOP LAMP UNI T -
REMOVAL).
CHMSL uni t housi ng.
uni t housi ng countercl ockwi se about 30 degrees (Fi g.
6).
back of CHMSL uni t housi ng.
(6) Pul l the bul b strai ght out of the CHMSL uni t
socket.
Fig. 6 Center High Mounted Stop Lamp Bulb
Remove/Install
1 - CHMSL UNIT
2 - BULB
3 - SOCKET
8Ls - 18 LAMPS KJ
INSTALLATION
i n the Center Hi gh Mounted Stop Lamp (CHMSL)
uni t socket.
(2) Push the bul b strai ght i nto the CHMSL uni t
i ng on the back of CHMSL uni t housi ng.
CHMSL uni t housi ng unti l i t i s fi rml y seated (Fi g. 6).
(6) Rei nstal l the CHMSL uni t onto the roof panel .
EXTERI OR/CENTER HI GH MOUNTED STOP
CENTER HIGH MOUNTED
STOP LAMP UNIT
REMOVAL
cabl e.
(2) Remove the two screws that secure the Center
Hi gh Mounted Stop Lamp (CHMSL) uni t to the rear
of the roof panel (Fi g. 7).
(3) Pul l the CHMSL uni t away from the roof panel
connector for the CHMSL uni t from the l amp socket
pi gtai l wi re.
(4) Remove the CHMSL uni t from the roof panel .
INSTALLATION
(1) Posi ti on the Center Hi gh Mounted Stop Lamp
(CHMSL) uni t to the roof panel .
CHMSL uni t to the l amp socket pi gtai l wi re (Fi g. 7).
(3) Posi ti on the CHMSL uni t i nto the roof panel
openi ng.
the CHMSL uni t to the rear of the roof panel .
COMBINATION FLASHER
DESCRIPTION
The combi nati on fl asher for thi s model i s i ntegral
to the hazard swi tch l ocated i n the center of the
i nstrument panel , just above the radi o. The combi na-
ti on fl asher i s a smart rel ay that functi ons as both
the turn si gnal system and the hazard warni ng sys-
tem fl asher. The combi nati on fl asher contai ns acti ve
el ectroni c I ntegrated Ci rcui try (I C) el ements. Thi s
fl asher i s desi gned to handl e the current fl ow
requi rements of the factory-i nstal l ed l i ghti ng. I f sup-
pl emental l i ghti ng i s added to the turn si gnal l amp
ci rcui ts, such as when towi ng a trai l er wi th l i ghts,
the combi nati on fl asher wi l l automati cal l y try to
compensate to keep the fl ash rate the same.
The combi nati on fl asher cannot be repai red or
adjusted and, i f faul ty or damaged, the hazard swi tch
OPERATION
The combi nati on fl asher has the fol l owi ng i nputs and
outputs: fused B(+), fused i gni ti on swi tch output, ri ght
turn si gnal sense, l eft turn si gnal sense, and one out-
put each for the ri ght and l eft turn si gnal ci rcui ts. The
combi nati on fl asher al so recei ves an i nternal i nput
through the cl osed contacts of the hazard swi tch and,
on vehi cl es equi pped wi th the opti onal Vehi cl e Theft
Securi ty System (VTSS), the fl asher recei ves an i nput
from the Body Control Modul e (BCM) i n order to fl ash
the turn si gnal l amps as an opti cal al ert feature of that
Fig. 7 Center High Mounted Stop Lamp Remove/
Install
1 - ROOF PANEL
3 - BULB SOCKET
4 - CHMSL
5 - SCREW (2)
6 - PLASTIC NUT (2)
KJ LAMPS 8Ls - 19
CENTER HIGH MOUNTED STOP LAMP BULB (Continued)
system. Constant battery vol tage i s suppl i ed to the
fl asher so that i t can perform the hazard warni ng func-
ti on, and i gni ti on swi tched battery vol tage i s suppl i ed
for the turn si gnal functi on. The I ntegrated Ci rcui t (I C)
wi thi n the combi nati on fl asher contai ns the l ogi c that
control s the fl asher operati on and the fl ash rate. The
I C recei ves separate sense ground i nputs from the
mul ti -functi on swi tch for the ri ght and l eft turn si g-
nal s, and from the hazard swi tch contacts or the BCM
for the hazard warni ng si gnal s. A speci al desi gn feature
of the combi nati on fl asher al l ows i t to sense that a
turn si gnal ci rcui t or bul b i s not operati ng, and provi de
the dri ver an i ndi cati on of the condi ti on by fl ashi ng the
remai ni ng bul bs i n the affected ci rcui t at a hi gher rate
(120 fl ashes-per-mi nute or hi gher). Conventi onal fl ash-
ers ei ther conti nue fl ashi ng at thei r typi cal rate (heavy-
duty type), or di sconti nue fl ashi ng the affected ci rcui t
enti rel y (standard-duty type).
Because of the acti ve el ectroni c el ements wi thi n
the combi nati on fl asher, i t cannot be tested wi th con-
combi nati on fl asher i s bel i eved to be faul ty, test the
turn si gnal and hazard warni ng system. Then
repl ace the hazard swi tch wi th a known good uni t to
confi rm system operati on.
DAYTIME RUNNING LAMP
RELAY
DESCRIPTION
The Dayti me Runni ng Lamp (DRL) rel ay (Fi g. 8) i s
a sol i d state rel ay that i s used onl y on vehi cl es man-
ufactured for sal e i n Canada. The DRL rel ay features
a di e cast al umi num housi ng wi th i ntegral cool i ng
fi ns that act as a heat si nk for the sol i d state DRL
ci rcui try. Four mal e spade termi nal s extend from the
base of the rel ay through a potti ng materi al that
encl oses and protects the DRL ci rcui try. Al though the
DRL rel ay has four termi nal s that are l ai d out i n a
footpri nt that i s si mi l ar to that of a conventi onal
I nternati onal Standards Organi zati on (I SO) rel ay, a
standard I SO rel ay shoul d never be i nstal l ed i n pl ace
of the DRL rel ay. The DRL rel ay i s i nstal l ed i n the
of the i nstrument panel . Vehi cl es equi pped wi th thi s
rel ay do not have a headl amp hi gh beam rel ay
i nstal l ed i n the JB.
The DRL rel ay cannot be adjusted or repai red and,
i f faul ty or damaged, the uni t must be repl aced.
OPERATION
The Dayti me Runni ng Lamp (DRL) rel ay i s a sol i d
state rel ay that control s the fl ow of battery current
to the hi gh beam fi l aments of both headl amp bul bs
based upon a duty cycl ed control i nput recei ved from
the Body Control Modul e (BCM) of vehi cl es equi pped
wi th the DRL feature. By cycl i ng the DRL rel ay out-
put, the BCM control s the i l l umi nati on i ntensi ty of
the hi gh beam fi l aments. The DRL rel ay termi nal s
are connected to the vehi cl e el ectri cal system through
a connector receptacl e i n the Juncti on Bl ock (JB).
The i nputs and outputs of the DRL rel ay i ncl ude:
Battery Current Input - The DRL rel ay
recei ves battery current on a fused B(+) ci rcui t from
a fuse i n the Power Di stri buti on Center (PDC).
Ground Input - The DRL rel ay recei ves a path
to ground through a spl i ce bl ock l ocated i n the
near the Juncti on Bl ock (JB).
Control Input - The DRL rel ay control i nput i s
recei ved from the BCM and/or the momentary opti cal
horn (fl ash-to-pass) output of the mul ti -functi on
swi tch through a hi gh beam rel ay control ci rcui t.
Control Output - The DRL rel ay suppl i es bat-
tery current output to the headl amp hi gh beam fi l a-
ments through the hi gh beam rel ay output ci rcui t.
DRL rel ay, i t cannot be tested wi th conventi onal
automoti ve el ectri cal test equi pment. I f the DRL
rel ay i s bel i eved to be faul ty, repl ace the rel ay wi th a
known good uni t to confi rm system operati on.
Fig. 8 Daytime Running Lamp Relay
1 - DRL RELAY
2 - HEAT SINK
3 - POTTING MATERIAL
4 - TERMINAL (4)
8Ls - 20 LAMPS KJ
COMBINATION FLASHER (Continued)
REMOVAL
PERSONAL INJURY.
cabl e.
(3) Remove the Dayti me Runni ng Lamp (DRL)
rel ay by graspi ng i t fi rml y and pul l i ng i t strai ght out
from the receptacl e i n the Juncti on Bl ock (JB) (Fi g.
9).
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the Dayti me Runni ng Lamp (DRL)
rel ay to the proper receptacl e i n the Juncti on Bl ock
(JB) (Fi g. 9).
(2) Al i gn the DRL rel ay termi nal s wi th the termi -
nal cavi ti es i n the JB receptacl e.
(3) Push fi rml y and evenl y on the top of the DRL
rel ay unti l the termi nal s are ful l y seated i n the ter-
mi nal cavi ti es i n the JB receptacl e.
FRONT FOG LAMP BULB
REMOVAL
cabl e.
the socket on the back of the front fog l amp uni t
housi ng.
degrees.
result.
2 - HIGH BEAM RELAY
3 - DRL RELAY
KJ LAMPS 8Ls - 21
DAYTIME RUNNING LAMP RELAY (Continued)
front fog l amp uni t housi ng and through the access
hol e i nto the front wheel openi ng area.
(7) Pul l the bul b strai ght out of the front fog l amp
uni t socket.
INSTALLATION
result.
i n the front fog l amp uni t socket.
(2) Push the bul b strai ght i nto the front fog l amp
uni t socket unti l i t i s fi rml y seated.
(3) Posi ti on the socket and bul b through the access
hol e i n the front wheel house spl ash shi el d and al i gn
i t wi th the socket openi ng on the back of the front
fog l amp uni t housi ng (Fi g. 10).
front fog l amp uni t housi ng unti l i t i s fi rml y seated.
(6) Lower and snap shut the access cover over the
shi el d.
DESCRIPTION
The front fog l amp rel ay i s l ocated i n the Juncti on
the vehi cl e. The front fog l amp rel ay i s a conven-
The front fog l amp rel ay cannot be adjusted or
repl aced.
OPERATION
The front fog l amp rel ay i s an el ectromechani cal
put to the front fog l amps. The movabl e common feed
Fig. 10 Front Fog Lamp Bulb Remove/Install
2 - ACCESS HOLE
3 - SOCKET
4 - BULB Fig. 11 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
8Ls - 22 LAMPS KJ
FRONT FOG LAMP BULB (Continued)
The front fog l amp rel ay termi nal s are connected
outputs of the front fog l amp rel ay i ncl ude:
mi um Body Control Modul e (BCM) through a front
fog l amp rel ay control ci rcui t. The BCM control s
front fog l amp operati on by control l i ng a ground path
termi nal (87) i s connected to the front fog l amps
through a front fog l amp rel ay output ci rcui t and
provi des battery current to the front fog l amps when-
cati on.
The front fog l amp rel ay can be di agnosed usi ng
DIAGNOSIS AND TESTING - FRONT FOG LAMP
RELAY
The front fog l amp rel ay (Fi g. 12) i s l ocated i n the
and grounds.
PERSONAL INJURY.
(1) Remove the front fog l amp rel ay from the JB.
EXTERI OR/FRONT FOG LAMP RELAY - REMOV-
AL).
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
KJ LAMPS 8Ls - 23
REMOVAL
PERSONAL INJURY.
cabl e.
(3) Remove the front fog l amp rel ay by graspi ng i t
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the front fog l amp rel ay to the proper
(2) Al i gn the front fog l amp rel ay termi nal s wi th
FRONT FOG LAMP UNIT
REMOVAL
cabl e.
(4) Reach through the access hol e to remove the
three screws that secure the front fog l amp uni t to
the front bumper fasci a.
Rotate 180for RHD)
3 - LOW BEAM RELAY
7 - DOOR LOCK RELAY
8 - DEFOGGER RELAY
9 - SPARE
11 - HORN RELAY
12 - SPARE
13 - SPARE
8Ls - 24 LAMPS KJ
(5) From the front of the vehi cl e, pul l the front fog
l amp uni t out of the front bumper fasci a far enough
to access and di sconnect the wi re harness connector
for the front fog l amp uni t from the l amp socket con-
nector receptacl e (Fi g. 15).
(6) Remove the front fog l amp uni t from the front
bumper fasci a.
INSTALLATION
(1) Posi ti on the front fog l amp uni t to the front
bumper fasci a.
front fog l amp to the l amp socket connector recepta-
cl e (Fi g. 15).
(3) Posi ti on the front fog l amp uni t i nto the front
bumper fasci a.
(4) Reach i nto the front wheel openi ng and
through the access hol e to i nstal l and ti ghten the
three screws that secure the front fog l amp uni t
housi ng to the front bumper fasci a (Fi g. 14). Ti ghten
shi el d.
(7) Confi rm proper front fog l amp uni t al i gnment.
EXTERI OR/FRONT FOG LAMP UNI T - ADJUST-
MENTS).
ADJ USTMENTS
ADJUSTMENT - FRONT FOG LAMP UNIT
VEHICLE PREPARATION FOR FOG LAMP ALIGNMENT
(3) Cl ean the front fog l amp l enses.
(4) Veri fy that the cargo area i s not heavi l y l oaded.
FOG LAMP ALIGNMENT
Prepare an al i gnment screen as i l l ustrated. A prop-
erl y al i gned front fog l amp wi l l project a pattern on
the al i gnment screen 100 mi l l i meters (4 i nches)
bel ow the fog l amp centerl i ne and strai ght ahead of
the l amp.
the front of the front fog l amp l ens (Fi g. 16). I f nec-
essary, tape a l i ne on the fl oor 7.62 meters (25 feet)
away from and paral l el to the wal l .
Fig. 14 Front Fog Lamp Unit Remove/Install
2 - SCREW (3)
5 - ACCESS HOLE
Fig. 15 Front Fog Lamp Unit
1 - ADJUSTING SCREW
3 - HOUSING
4 - SOCKET & BULB
5 - LENS
KJ LAMPS 8Ls - 25
tance from the center of the front fog l amp l ens to
the fl oor. Transfer thi s measurement to the al i gn-
ment screen and tape a hori zontal l i ne on the wal l at
thi s mark. Thi s l i ne wi l l be used for up-and-down
adjustment reference.
vehi cl e to the center of each front fog l amp bei ng
al i gned. Transfer these measurements to the al i gn-
ment screen and tape a verti cal l i ne thi s di stance to
each si de of the vehi cl e centerl i ne. These l i nes wi l l be
used for l eft/ri ght reference.
(5) Rotate the front fog l amp adjusti ng screws to
adjust the beam hei ght as requi red (Fi g. 17).
Fig. 16 Front Fog Lamp Alignment - Typical
2 - CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS
3 - HIGH-INTENSITY AREA
4 - FLOOR TO CENTER OF FOG LAMP LENS
5 - 100 MILLIMETERS (4 INCHES)
6 - 7.62 METERS (25 FEET)
7 - FRONT OF FOG LAMP
Fig. 17 Front Fog Lamp Adjusting Screw
2 - ADJUSTING SCREW
8Ls - 26 LAMPS KJ
FRONT LAMP BULB
REMOVAL
The front l amp uni t may contai n ei ther one or two
bul bs, dependi ng upon the market for whi ch the
vehi cl e was manufactured. The servi ce procedures for
one bul b or for both bul bs i s the same, onl y the bul b
si zes and types may di ffer. Be certai n any removed
bul b i s repl aced wi th the same bul b si ze and type
that was removed.
cabl e.
REMOVAL).
front l amp uni t housi ng for the bul b that i s bei ng
removed (Fi g. 18).
uni t housi ng countercl ockwi se about 30 degrees.
back of the front l amp uni t housi ng.
(6) Pul l the bul b strai ght out of the front l amp
uni t socket.
INSTALLATION
i n the front l amp uni t socket.
(2) Push the bul b strai ght i nto the front l amp uni t
(3) Al i gn the socket and bul b wi th the socket openi ng
on the back of the front l amp uni t housi ng (Fi g. 18).
front l amp uni t housi ng unti l i t i s fi rml y seated.
(6) Rei nstal l the front l amp uni t i nto the front
I NSTALLATI ON).
FRONT LAMP UNIT
REMOVAL
cabl e.
(2) Remove the screw that secures the outboard
end of the front l amp uni t to the front bumper fasci a
(Fi g. 19).
(3) Pul l the outboard end of the front l amp uni t
away from the front bumper fasci a far enough to di s-
engage the tab on the i nboard end of the front l amp
uni t housi ng from the receptacl e i n the fasci a.
(4) Pul l the front l amp uni t away from the front
bumper fasci a far enough to access and di sconnect
the wi re harness connector(s) for the front l amp uni t
from the l amp socket pi gtai l wi re(s).
bumper fasci a.
Fig. 18 Front Lamp Bulb Remove/Install
1 - FRONT LAMP UNIT
2 - SIDE MARKER SOCKET
3 - FRONT FASCIA
4 - HEADLAMP & DASH WIRE HARNESS
5 - MOUNTING TAB
6 - PARK/TURN SIGNAL SOCKET
Fig. 19 Front Lamp Unit Remove/Install
1 - FRONT LAMP UNIT
3 - SCREW (1)
KJ LAMPS 8Ls - 27
INSTALLATION
(1) Posi ti on the front l amp uni t to the front
bumper fasci a.
(2) Reconnect the wi re harness connector(s) for the
front l amp uni t to the l amp socket pi gtai l wi re(s).
(3) Engage the tab on the i nboard end of the front
l amp uni t housi ng i nto the receptacl e i n the front
bumper fasci a.
(4) Posi ti on the outboard end of the front l amp
uni t housi ng to the front bumper fasci a.
outboard end of the front l amp uni t housi ng to the
front bumper fasci a (Fi g. 19). Ti ghten the screw to 2
Nm (20 i n. l bs.).
REMOVAL
cabl e.
(2) Remove the headl amp uni t from the front gri l l e
- REMOVAL).
bottom of the headl amp uni t housi ng countercl ock-
wi se about 30 degrees (Fi g. 20).
(5) Pul l the bul b strai ght out of the front posi ti on
l amp socket.
INSTALLATION
i n the front posi ti on l amp socket.
(2) Push the bul b strai ght i nto the front posi ti on
l amp socket unti l i t i s fi rml y seated.
i ng near the bottom of the headl amp uni t housi ng
(Fi g. 20).
headl amp uni t housi ng unti l i t i s fi rml y seated
bottom of the headl amp uni t housi ng cl ockwi se about
30 degrees.
- I NSTALLATI ON).
HAZARD SWITCH
DESCRIPTION
The hazard swi tch i s i ntegral to the hazard swi tch
modul e, whi ch i s secured near the center of i nstru-
ment panel just above the radi o (Fi g. 21). Onl y the
hazard swi tch button i s vi si bl e through a dedi cated,
round, bevel ed openi ng on the outer surface of the
i nstrument panel between the two center panel out-
l ets of the heater and ai r condi ti oni ng system. A red,
stenci l -l i ke I nternati onal Control and Di spl ay Symbol
i con for Hazard Warni ng i denti fi es the hazard
swi tch button. On the opposi te end of the bl ack,
mol ded pl asti c hazard swi tch modul e housi ng from
the swi tch button i s an i ntegral connector receptacl e
and a stamped steel mounti ng bracket wi th two l atch
feature tabs that extend downward, whi l e a short
dowel -l i ke al i gnment pi n i s i ntegral to each si de of
the housi ng just bel ow the swi tch button. The swi tch
modul e i s connected to the vehi cl e el ectri cal system
through a dedi cated take out and connector of the
i nstrument panel wi re harness. Wi thi n the hazard
Fig. 20 Front Position Lamp Bulb Remove/Install
2 - SOCKET
3 - BULB
8Ls - 28 LAMPS KJ
FRONT LAMP UNIT (Continued)
swi tch modul e housi ng i s the hazard swi tch ci rcui try
and an el ectroni c ci rcui t board wi th the i ntegral com-
bi nati on fl asher ci rcui try. The el ectroni c combi nati on
fl asher ci rcui try performs both the hazard fl asher
and turn si gnal fl asher functi ons.
The hazard swi tch modul e cannot be adjusted or
repl aced.
OPERATION
The hazard swi tch button i s sl i ghtl y recessed i n
the i nstrument panel when the swi tch i s i n the Off
posi ti on, and l atches at a posi ti on that i s fl ush wi th
the outer surface of the i nstrument panel when i n
the On posi ti on. The hazard swi tch modul e produces
an audi bl e cl i cki ng sound that emul ates the sound of
a conventi onal fl asher whenever the turn si gnal s or
the hazard warni ng system are acti vated. The hazard
swi tch modul e recei ves battery current on a fused
B(+) ci rcui t from a fuse i n the Juncti on Bl ock (JB) at
al l ti mes for operati on of the hazard warni ng, and on
a fused i gni ti on swi tch output (run) ci rcui t from
another fuse i n the JB whenever the i gni ti on swi tch
i s i n the On posi ti on for operati on of the turn si gnal s.
The modul e recei ves a path to ground through a
i nstrument panel end bracket near the JB. I nputs to
and outputs from the hazard swi tch modul e i ncl ude:
Panel Lamps Dimmer Input - A non-servi ce-
abl e i ncandescent bul b sol dered onto the hazard
swi tch modul e ci rcui t board provi des i l l umi nati on of
the swi tch button when the exteri or l i ghti ng i s
turned On through an i nput recei ved on the fused
panel l amps di mmer swi tch si gnal ci rcui t. However,
thi s bul b fl ashes on and off at ful l i ntensi ty whenever
the hazard swi tch button i s i n the On posi ti on,
regardl ess of the status of the exteri or l i ghti ng.
Hazard Switch Input - The combi nati on
fl asher ci rcui try of the hazard swi tch modul e recei ves
an i nternal ground i nput from the hazard swi tch to
request hazard fl asher operati on.
Multi-Function Switch Input - The combi na-
ti on fl asher ci rcui try of the hazard swi tch modul e
recei ves separate ground i nputs from the turn si gnal
swi tch ci rcui try of the mul ti -functi on swi tch on ri ght
and l eft turn swi tch sense ci rcui ts to request ri ght or
l eft turn si gnal fl asher operati on.
Body Control Module Input - The Body Con-
trol Modul e (BCM) can request hazard fl asher opera-
ti on by provi di ng a ground path to the combi nati on
fl asher ci rcui try of the hazard swi tch modul e through
a hazard l amp control ci rcui t.
Turn Signal Output - The combi nati on fl asher
ci rcui try wi thi n the hazard swi tch modul e responds
to the fl asher request i nputs by energi zi ng and
de-energi zi ng two mi ni ature rel ays on the modul e
ci rcui t board. These rel ays control the swi tch output
through the ri ght and l eft turn si gnal ci rcui ts. One
rel ay control s the ri ght l amps, whi l e the other con-
trol s the l eft.
hazard swi tch modul e, i t cannot be tested wi th con-
hazard swi tch modul e i s bel i eved to be faul ty, repl ace
the swi tch wi th a known good uni t to confi rm system
operati on.
REMOVAL
PERSONAL INJURY.
cabl e.
Fig. 21 Hazard Switch
1 - HAZARD SWITCH BUTTON
2 - SCREW (1)
3 - MOUNTING BRACKET TABS
KJ LAMPS 8Ls - 29
(2) Remove the radi o from the i nstrument panel .
REMOVAL).
(3) Remove the screw at the top of the i nstrument
panel radi o openi ng that secures the hazard swi tch
to the i nstrument panel tri m (Fi g. 22).
radi o openi ng to access the two l atch tabs of the
stamped metal hazard swi tch mounti ng bracket.
(5) Usi ng two fi ngerti ps, pul l rearward and down-
ward on the l atch tabs on the back of the hazard
swi tch unti l i t i s di sengaged from the i nstrument
panel tri m.
(6) Push the hazard swi tch button through the
button openi ng of the i nstrument panel far enough to
di sengage the al i gnment pi ns on each si de of the
swi tch housi ng from the saddl e formati ons of the two
stanchi ons on the back of the i nstrument panel tri m,
just bel ow and to ei ther si de of the button openi ng.
connector for the hazard swi tch from the swi tch con-
nector receptacl e.
(8) Remove the hazard swi tch through the i nstru-
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the hazard swi tch through the i nstru-
connector for the hazard swi tch to the swi tch connec-
tor receptacl e.
radi o openi ng to posi ti on the hazard swi tch for
i nstal l ati on.
(4) Gui de the hazard swi tch button through the
button openi ng of the i nstrument panel , whi ch wi l l
engage the al i gnment pi ns on each si de of the swi tch
housi ng wi th the saddl e formati ons of the two stan-
chi ons on the back of the i nstrument panel tri m, just
bel ow and to ei ther si de of the button openi ng.
(5) Usi ng hand pressure, press upward on the
back of the hazard swi tch unti l the l atch tabs of the
mounti ng bracket on the back of the swi tch are both
engaged wi th the i nstrument panel tri m (Fi g. 22).
(6) I nstal l and ti ghten the screw at the top of the
i nstrument panel radi o openi ng that secures the haz-
ard swi tch to the i nstrument panel tri m. Ti ghten the
(7) Rei nstal l the radi o i nto the i nstrument panel .
I NSTALLATI ON).
HEADLAMP BULB
REMOVAL
NORTH AMERICA
cabl e.
(2) Reach behi nd the headl amp uni t from the
engi ne compartment si de of the upper radi ator cross-
member to access the headl amp bul b l ock ri ng (Fi g.
23).
(3) Fi rml y grasp the l ock ri ng on the back of the
Fig. 22 Hazard Switch Remove/Install
2 - HAZARD SWITCH
3 - ALIGNMENT PIN (2)
4 - STANCHION (2)
6 - SCREW (1)
7 - MOUNTING BRACKET LATCH TAB (2)
8Ls - 30 LAMPS KJ
degrees.
result.
(5) Pul l the l ock ri ng, socket, and bul b strai ght out
of the headl amp uni t housi ng and up from behi nd
the upper radi ator crossmember (Fi g. 24).
(6) Di sconnect the gri l l e openi ng rei nforcement
wi re harness connector for the headl amp bul b from
the connector receptacl e on the bul b socket.
(7) Remove the bul b and bul b socket from the l ock
ri ng as a uni t.
REST-OF-WORLD
cabl e.
- REMOVAL).
(3) Fi rml y grasp the tab of the headl amp boot seal
on the back of the headl amp uni t housi ng (Fi g. 25).
(4) Pul l the tab away from the back of the head-
l amp uni t housi ng to remove the boot seal from the
housi ng and the bul b base.
l amp bul b retai ner cl i p together and di sengage them
from the sl ots i n the fl ange of the refl ector (Fi g. 26).
(6) Pi vot the headl amp bul b retai ner cl i p up off of
the bul b fl ange and out of the way.
result.
Fig. 23 Headlamp Bulb Lock Ring
1 - HEADLAMP UNIT HOUSING
2 - LOCK RING
3 - SOCKET & BULB
1 - HEADLAMP BULB
2 - SOCKET
3 - LOCK RING
Fig. 25 Headlamp Bulb Boot Seal Remove
2 - BOOT SEAL
3 - FRONT POSITION LAMP
4 - ADJUSTING SCREW
5 - TAB
6 - BULB BASE
KJ LAMPS 8Ls - 31
(7) Pul l the bul b strai ght out of the headl amp uni t
refl ector (Fi g. 27).
INSTALLATION
NORTH AMERICA
result.
(1) Posi ti on the headl amp bul b and socket uni t
i nto the l ock ri ng (Fi g. 24).
(2) Reconnect the gri l l e openi ng rei nforcement
wi re harness connector for the headl amp bul b to the
connector receptacl e on the bul b socket.
(3) Posi ti on the l ock ri ng, socket, and bul b down
behi nd the upper radi ator crossmember and al i gn
them wi th the socket openi ng on the back of the
headl amp uni t housi ng unti l they are fi rml y seated.
(5) Posi ti on the l ock ri ng over the socket and
engage i t wi th the fl ange on the back of the head-
REST-OF-WORLD
result.
(1) Posi ti on the bul b i nto the headl amp uni t refl ec-
tor (Fi g. 27).
(2) Pi vot the headl amp bul b retai ner cl i p back over
the bul b fl ange.
l amp bul b retai ner cl i p together and engage them
i nto the sl ots i n the fl ange of the refl ector (Fi g. 26).
(4) Posi ti on the center openi ng of the boot seal
over the base of the headl amp bul b and pul l i t down-
ward unti l the seal i s ful l y engaged over the bul b
base (Fi g. 25).
Fig. 26 Headlamp Bulb Retainer Clip Engage/
Disengage
1 - RETAINER CLIP
2 - BULB BASE
4 - REFLECTOR
5 - BULB FLANGE
6 - RETAINER SLOTS
1 - BULB BASE
2 - RETAINER CLIP
4 - REFLECTOR
6 - BULB FLANGE
8Ls - 32 LAMPS KJ
(5) Posi ti on the outer ci rcumference of the boot
seal over the fl ange on the back of the headl amp uni t
housi ng and pul l i t downward unti l the seal i s ful l y
engaged over the fl ange.
- I NSTALLATI ON).
HEADLAMP HIGH BEAM
RELAY
DESCRIPTION
The headl amp hi gh beam rel ay i s l ocated i n the
of the i nstrument panel i n the passenger compart-
ment of the vehi cl e. The headl amp hi gh beam rel ay
i s omi tted from vehi cl es manufactured for sal e i n
Canada, whi ch have a Dayti me Runni ng Lamp (DRL)
sol i d state rel ay i nstal l ed i n the JB that al so per-
forms the functi on of the headl amp hi gh beam rel ay.
The headl amp hi gh beam rel ay i s a conventi onal
the rel ay base.
The headl amp hi gh beam rel ay cannot be adjusted
be repl aced.
OPERATION
The headl amp hi gh beam rel ay i s an el ectrome-
chani cal swi tch that uses a l ow current i nput from
the Body Control Modul e (BCM) to control a hi gh
current output to the headl amp hi gh beam fi l aments.
The movabl e common feed contact poi nt i s hel d
agai nst the fi xed normal l y cl osed contact poi nt by
spri ng pressure. When the rel ay coi l i s energi zed, an
el ectromagneti c fi el d i s produced by the coi l wi nd-
i ngs. Thi s el ectromagneti c fi el d draws the movabl e
rel ay contact poi nt away from the fi xed normal l y
cl osed contact poi nt, and hol ds i t agai nst the fi xed
normal l y open contact poi nt. When the rel ay coi l i s
de-energi zed, spri ng pressure returns the movabl e
contact poi nt back agai nst the fi xed normal l y cl osed
contact poi nt. A resi stor i s connected i n paral l el wi th
the rel ay coi l i n the rel ay, and hel ps to di ssi pate vol t-
age spi kes and el ectromagneti c i nterference that can
be generated as the el ectromagneti c fi el d of the rel ay
coi l col l apses.
The headl amp hi gh beam rel ay termi nal s are con-
i nputs and outputs of the headl amp hi gh beam rel ay
i ncl ude:
Control Modul e (BCM) through a head l amp rel ay
control ci rcui t. The BCM control s head l amp opera-
ti on by control l i ng a ground path through thi s ci rcui t
Body Control Modul e (BCM) and to the momentary
opti cal horn (fl ash-to-pass) output of the mul ti -func-
ti on swi tch through a hi gh beam rel ay control ci rcui t.
The BCM and/or the mul ti -functi on swi tch control s
headl amp hi gh beam operati on by control l i ng a
ground path through thi s ci rcui t.
termi nal (87) i s connected to the headl amp hi gh
beam fi l aments through the hi gh beam rel ay output
ci rcui t and provi des battery current to the headl amp
hi gh beams whenever the rel ay i s energi zed.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
KJ LAMPS 8Ls - 33
cati on.
The headl amp hi gh beam rel ay can be di agnosed
DIAGNOSIS AND TESTING - HEADLAMP HIGH
BEAM RELAY
The headl amp hi gh beam rel ay (Fi g. 29) i s l ocated
i n the Juncti on Bl ock (JB) on the dri ver si de out-
PERSONAL INJURY.
(1) Remove the headl amp hi gh beam rel ay from
the JB. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR/HEADLAMP HI GH BEAM RELAY
- REMOVAL).
REMOVAL
PERSONAL INJURY.
cabl e.
(3) Remove the headl amp hi gh beam rel ay by
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
8Ls - 34 LAMPS KJ
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the headl amp hi gh beam rel ay to the
(2) Al i gn the headl amp hi gh beam rel ay termi nal s
l amp hi gh beam rel ay unti l the termi nal s are ful l y
DESCRIPTION
The headl amp l evel i ng motor i s l ocated on the rear
i nboard si de of each headl amp uni t on model s
equi pped wi th the headl amp l evel i ng system, whi ch
i s avai l abl e onl y i n certai n markets where requi red
(Fi g. 31). The motor i s encased wi thi n a mol ded pl as-
ti c housi ng and i s secured by an i ntegral wedge-type
mounti ng boss on i ts forward surface to a fl anged
receptacl e on the back of the headl amp uni t housi ng.
A rubber seal around the ci rcumference of the
mounti ng boss i s compressed and seal s the motor to
the headl amp uni t when the boss i s properl y
i nstal l ed i n the fl anged receptacl e. The outsi de of the
motor housi ng features an i ntegral mol ded connector
receptacl e on i ts rearward surface, a hex-headed
adjusti ng screw extends from the top of the housi ng,
and a pl asti c pushrod wi th a bal l formati on on i ts
free end extends from the center of the mounti ng
boss at the front. Wi thi n the motor housi ng i s a
12-vol t Di rect Current (DC) servo motor, an el ec-
troni c control l er board that i ncl udes the motor l ogi c
ci rcui ts, and an i ntegral screw-dri ve transmi ssi on.
The headl amp l evel i ng motor i s connected to the
out and connector of the front fasci a wi re harness.
The headl amp l evel i ng motor cannot be repai red
and, i f faul ty or damaged, the uni t must be repl aced.
2 - HIGH BEAM RELAY
3 - DRL RELAY
Fig. 31 Headlamp Unit - With Leveling
2 - BOOT SEAL
3 - ADJUSTING SCREW
4 - LOCATOR TAB
5 - HOUSING
7 - HEADLAMP BULB
KJ LAMPS 8Ls - 35
OPERATION
The control l er board and l ogi c ci rcui try of the
headl amp l evel i ng motor wi l l energi ze the motor and
extend or retract the motor pushrod through the
i ntegral screw-dri ve transmi ssi on based upon the
vol tage si gnal i nput recei ved from the resi stor mul ti -
pl exed headl amp l evel i ng swi tch. The bal l formati on
on the end of the headl amp l evel i ng motor pushrod i s
snapped i nto a socket formati on on the back of the
movabl e refl ector wi thi n the headl amp uni t housi ng.
The headl amp l evel i ng motors and swi tch have a
path to ground at al l ti mes. The headl amp l evel i ng
components operate on battery current recei ved
through the fused park l amp rel ay output ci rcui t so
that the system wi l l onl y operate when the exteri or
l i ghti ng i s turned On.
headl amp l evel i ng motor, i t cannot be tested wi th
conventi onal automoti ve el ectri cal test equi pment. I f
the headl amp l evel i ng motor i s bel i eved to be faul ty,
repl ace the motor wi th a known good uni t to confi rm
system operati on.
REMOVAL
cabl e.
(2) Remove the headl amp bul b from the headl amp
REMOVAL).
back of the headl amp uni t housi ng countercl ockwi se
about 30 degrees (Fi g. 32).
(4) Fi rml y grasp the motor wi th one hand whi l e
stabi l i zi ng the headl amp uni t housi ng wi th the other
hand.
(5) Fi rml y, steadi l y, and forceful l y pul l the head-
l amp l evel i ng motor strai ght away from the back of
the headl amp uni t housi ng to unsnap the bal l forma-
ti on on the end of the motor pushrod from the socket
on the headl amp uni t refl ector (Fi g. 33).
(6) Remove the headl amp l evel i ng motor and push-
rod from the back of the headl amp uni t housi ng.
INSTALLATION
(1) Posi ti on the headl amp l evel i ng motor and
pushrod from to the mounti ng hol e on the back of the
(2) I nsert two fi ngers through the bul b mounti ng
hol e i n the center of the headl amp refl ector and pul l
the refl ector upwards toward the headl amp l evel i ng
motor.
(3) Al i gn the bal l formati on on the end of the l ev-
el i ng motor pushrod wi th the socket on the headl amp
uni t refl ector (Fi g. 33).
(4) Whi l e conti nui ng to pul l i ng the refl ector
toward the motor, fi rml y, steadi l y, and forceful l y push
the headl amp l evel i ng motor strai ght i nto the back of
the headl amp uni t housi ng to snap the bal l formati on
on the end of the motor pushrod i nto the socket on
the headl amp uni t refl ector.
(5) After the pushrod i s engaged to the refl ector,
remove your fi ngers from the bul b mounti ng hol e i n
Fig. 32 Headlamp Leveling Motor Remove/Install
1 - LEVELING MOTOR
3 - PUSHROD
Fig. 33 Leveling Motor Pushrod - Typical
1 - REFLECTOR PUSHROD SOCKET
2 - PUSHROD
3 - LEVELING MOTOR
8Ls - 36 LAMPS KJ
the center of the headl amp refl ector and thoroughl y
cl ean any fi ngerpri nts from the refl ector.
(6) Push the mounti ng fl ange of the headl amp l ev-
el i ng motor i nto the mounti ng hol e on the back of
headl amp uni t housi ng uni t the motor i s fi rml y
seated (Fi g. 32).
back of the headl amp uni t housi ng cl ockwi se about
30 degrees.
(8) Rei nstal l the headl amp bul b i nto the headl amp
I NSTALLATI ON).
HEADLAMP LEVELING
SWITCH
DESCRIPTION
The headl amp l evel i ng swi tch (Fi g. 34) i s used onl y
on vehi cl es manufactured for certai n markets where
the headl amp l evel i ng system i s requi red. The head-
l amp l evel i ng swi tch i s mounted i n the dri ver si de
i nboard tri m bezel on the i nstrument panel , where i t
i s secured by mol ded l atch features that are i ntegral
to the swi tch housi ng. Onl y the swi tch bezel and
thumbwheel are vi si bl e on the outer surface of the
i nstrument panel tri m bezel . The bl ack pl asti c swi tch
thumbwheel i s marked wi th whi te numbers 0, 1,
2, and 3, each of whi ch i ndi cates one of the four
swi tch detent posi ti ons. Each hi gher number repre-
sents a l ower ai mi ng posi ti on of the headl amp beam
rel ati ve to the road surface. The bl ack, mol ded pl as-
ti c swi tch housi ng has an i ntegral connector recepta-
cl e on the back, a si ngl e l atch feature on the top, and
two l atch features (one on each si de) on the bottom.
The swi tch i s connected to the vehi cl e el ectri cal sys-
the i nstrument panel wi re harness. Wi thi n the
swi tch housi ng i s the l evel i ng swi tch ci rcui try i ncl ud-
i ng the swi tch contacts and a seri es resi stor confi gu-
rati on.
The headl amp l evel i ng swi tch cannot be adjusted
be repl aced.
OPERATION
The headl amp l evel i ng swi tch recei ves battery cur-
rent on a fused park l amp rel ay output ci rcui t from a
fuse i n the Juncti on Bl ock (JB) whenever the park
l amp rel ay i s energi zed (park l amps are turned On).
The swi tch recei ves a path to ground through a spl i ce
bl ock l ocated i n the i nstrument panel wi re harness
wi th an eyel et termi nal connector that i s secured by
a nut to a ground stud on the dri ver si de i nstrument
panel end bracket near the JB. The onl y output from
the swi tch i s a vol tage si gnal that i t provi des to the
headl amp l evel i ng motors on a headl amp adjust si g-
nal ci rcui t. Each swi tch posi ti on sel ects a di fferent
tap on a seri es resi stor wi thi n the swi tch to provi de a
di fferent vol tage si gnal to the l evel i ng motors. The
hi gher the swi tch posi ti on number, the hi gher the
output vol tage l evel .
The headl amp l evel i ng swi tch can be tested usi ng
LEVELING SWITCH
PERSONAL INJURY.
Fig. 34 Headlamp Leveling Switch
1 - SWITCH
2 - UPPER LATCH FEATURE (1)
4 - LOWER LATCH FEATURE (2)
5 - THUMBWHEEL
KJ LAMPS 8Ls - 37
(2) Usi ng an ohmmeter, perform the resi stance
tests at the termi nal pi ns i n the headl amp l evel i ng
swi tch connector receptacl e (Fi g. 35) as shown i n the
Headl amp Level i ng Swi tch Tests tabl e.
HEADLAMP LEVELING SWITCH TESTS
SWITCH POSITION
RESISTANCE (OHMS)
BETWEEN PINS 1 & 3
0 0.5 0.5
1 301 1
2 595 1
3 739 1
(3) I f the swi tch fai l s any of the resi stance tests,
repl ace the faul ty headl amp l evel i ng swi tch as
requi red.
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Remove the dri ver si de i nboard bezel from the
SI DE BEZEL - REMOVAL).
two l ower l atch features on the headl amp l evel i ng
swi tch housi ng and rock the bottom of the swi tch out
through the face of the bezel .
upper l atch feature on the headl amp l evel i ng swi tch
housi ng and push the swi tch out through the face of
the bezel .
INSTALLATION
Fig. 35 Headlamp Leveling Switch Connector
Receptacle
Fig. 36 Headlamp Leveling Switch Remove/Install
1 - HEADLAMP LEVELING SWITCH
2 - UPPER LATCH TAB
3 - RECEPTACLE
4 - DRIVER SIDE INBOARD BEZEL
5 - LOWER LATCH TAB (2)
8Ls - 38 LAMPS KJ
PERSONAL INJURY.
(1) From the face of the dri ver si de i nboard bezel ,
al i gn the headl amp l evel i ng swi tch housi ng to the
mounti ng hol e i n the bezel (Fi g. 36).
(2) Push the headl amp l evel i ng swi tch i nto the
mounti ng hol e unti l i t i s ful l y seated and the upper
l atch and two l ower l atch features on the swi tch
housi ng are engaged on the back of the bezel .
(3) Posi ti on the swi tch and bezel uni t to the
i nstrument panel .
connector for the headl amp l evel i ng swi tch to the
(5) Rei nstal l the dri ver si de i nboard bezel onto the
SI DE BEZEL - I NSTALLATI ON).
DESCRIPTION
The headl amp l ow beam rel ay i s l ocated i n the
Juncti on Bl ock (JB) bel ow the dri ver si de outboard
end of the i nstrument panel i n the passenger com-
partment of the vehi cl e. The headl amp l ow beam
rel ay i s a conventi onal I nternati onal Standards
Organi zati on (I SO) mi cro rel ay (Fi g. 37). Rel ays con-
formi ng to the I SO speci fi cati ons have common phys-
i cal di mensi ons, current capaci ti es, termi nal
patterns, and termi nal functi ons. The rel ay i s con-
tai ned wi thi n a smal l , rectangul ar, mol ded pl asti c
The headl amp l ow beam rel ay cannot be adjusted
be repl aced.
OPERATION
The headl amp l ow beam rel ay i s an el ectromechan-
i cal swi tch that uses a l ow current i nput from the
Body Control Modul e (BCM) to control a hi gh current
output to the headl amp l ow beam fi l aments. The
movabl e common feed contact poi nt i s hel d agai nst
the fi xed normal l y cl osed contact poi nt by spri ng
pressure. When the rel ay coi l i s energi zed, an el ectro-
magneti c fi el d i s produced by the coi l wi ndi ngs. Thi s
el ectromagneti c fi el d draws the movabl e rel ay con-
tact poi nt away from the fi xed normal l y cl osed con-
tact poi nt, and hol ds i t agai nst the fi xed normal l y
open contact poi nt. When the rel ay coi l i s de-ener-
gi zed, spri ng pressure returns the movabl e contact
poi nt back agai nst the fi xed normal l y cl osed contact
poi nt. A resi stor i s connected i n paral l el wi th the
rel ay coi l i n the rel ay, and hel ps to di ssi pate vol tage
spi kes and el ectromagneti c i nterference that can be
generated as the el ectromagneti c fi el d of the rel ay
coi l col l apses.
The headl amp l ow beam rel ay termi nal s are con-
i nputs and outputs of the headl amp l ow beam rel ay
i ncl ude:
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
KJ LAMPS 8Ls - 39
Body Control Modul e (BCM) through a l ow beam
rel ay control ci rcui t. The BCM control s headl amp l ow
beam operati on by control l i ng a ground path through
thi s ci rcui t.
termi nal (87) i s connected to the headl amp l ow beam
fi l aments through the l ow beam rel ay output ci rcui t
and provi des battery current to the headl amp l ow
beams whenever the rel ay i s energi zed.
cati on.
The headl amp l ow beam rel ay can be di agnosed
BEAM RELAY
The headl amp l ow beam rel ay (Fi g. 38) i s l ocated
i n the Juncti on Bl ock (JB) under the dri ver si de out-
PERSONAL INJURY.
(1) Remove the headl amp l ow beam rel ay from the
JB. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG -
EXTERI OR/HEADLAMP LOW BEAM RELAY -
REMOVAL).
REMOVAL
PERSONAL INJURY.
cabl e.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
8Ls - 40 LAMPS KJ
(3) Remove the headl amp l ow beam rel ay by
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the headl amp l ow beam rel ay to the
(2) Al i gn the headl amp l ow beam rel ay termi nal s
l amp l ow beam rel ay unti l the termi nal s are ful l y
HEADLAMP UNIT
REMOVAL
cabl e.
(2) Remove the gri l l e panel from the gri l l e openi ng
rei nforcement. (Refer to 23 - BODY/EXTERI OR/
GRI LLE - REMOVAL).
(3) Remove the two screws that secure the mount-
i ng tabs on the i nboard si de of the headl amp uni t
housi ng to the gri l l e openi ng rei nforcement (Fi g. 40).
Rotate 180for RHD)
3 - LOW BEAM RELAY
7 - DOOR LOCK RELAY
8 - DEFOGGER RELAY
9 - SPARE
11 - HORN RELAY
12 - SPARE
13 - SPARE
Fig. 40 Headlamp Unit Remove/Install
1 - FENDER PANEL
2 - HEADLAMP UNIT
4 - MOUNTING PANEL
5 - LOCATOR TAB
KJ LAMPS 8Ls - 41
(4) Pul l the i nboard si de of the headl amp uni t
away from the gri l l e openi ng rei nforcement far
enough to di sengage the l ocator tab on the outboard
si de of the uni t (Fi g. 41) or (Fi g. 42) from the engage-
ment sl ot i n the outboard edge of the rei nforcement.
(5) Pul l the headl amp uni t away from the gri l l e
openi ng rei nforcement far enough to di sconnect the
wi re harness connectors from the headl amp bul b
socket (North Ameri ca), the headl amp bul b base
(Rest-Of-Worl d), the front posi ti on l amp socket (i f
equi pped), and the headl amp l evel i ng motor (i f
equi pped).
INSTALLATION
(1) Posi ti on the headl amp uni t to the gri l l e open-
i ng rei nforcement.
(2) Reconnect the wi re harness connectors to the
headl amp bul b socket (North Ameri ca), the headl amp
bul b base (Rest-Of-Worl d), the front posi ti on l amp
socket (i f equi pped), and the headl amp l evel i ng motor
(i f equi pped) (Fi g. 41) or (Fi g. 42).
(3) Engage the l ocator tab on the outboard si de of
the headl amp uni t i nto the engagement sl ot i n the
outboard edge of the gri l l e openi ng rei nforcement.
(4) Al i gn the two mounti ng tabs on the i nboard
si de of the headl amp uni t housi ng to the mounti ng
hol es i n the gri l l e openi ng rei nforcement (Fi g. 40).
the mounti ng tabs on the i nboard si de of the head-
l amp uni t housi ng to the gri l l e openi ng rei nforce-
ment. Ti ghten the screws to 3 Nm (30 i n. l bs.).
(6) Rei nstal l the gri l l e panel onto the gri l l e open-
i ng rei nforcement. (Refer to 23 - BODY/EXTERI OR/
GRI LLE - I NSTALLATI ON).
ADJ USTMENTS
ADJUSTMENT - HEADLAMP UNIT
VEHICLE PREPARATION FOR HEADLAMP ALIGNMENT
(1) Veri fy headl amp di mmer (mul ti -functi on)
swi tch and hi gh beam i ndi cator operati on.
(2) I f the vehi cl e i s equi pped wi th headl amp l evel -
i ng, be certai n that the headl amp l evel i ng swi tch i s
i n the 0 posi ti on.
(5) Cl ean headl amp l enses.
(6) Veri fy that cargo area i s not heavi l y l oaded.
Fig. 41 Headlamp Unit - North America
2 - ADJUSTING SCREW
3 - LOCK RING
4 - HOUSING
5 - LOCATOR TAB
6 - SOCKET & BULB
Fig. 42 Headlamp Unit - Rest-Of-World
2 - BOOT SEAL
3 - ADJUSTING SCREW
4 - LOCATOR TAB
5 - HOUSING
7 - HEADLAMP BULB
8Ls - 42 LAMPS KJ
HEADLAMP ALIGNMENT SCREEN PREPARATION
Prepare an al i gnment screen as i l l ustrated.
the front of the headl amp l ens for North Ameri can
vehi cl es, or 10.0 meters (32.81 feet) away from the
front of the headl amp l ens for Rest-Of-Worl d vehi cl es
(Fi g. 43). I f necessary, tape a l i ne on the fl oor at the
appropri ate di stance away from and paral l el to the
wal l .
tance from the center of the headl amp l ens to the
fl oor. Transfer thi s measurement to the al i gnment
screen and tape a hori zontal l i ne on the wal l at thi s
mark. Thi s l i ne wi l l be used for up-and-down adjust-
ment reference.
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer these measurements to the al i gnment
screen and tape a verti cal l i ne thi s di stance to each
si de of the vehi cl e centerl i ne. These l i nes wi l l be used
for l eft/ri ght reference.
HEADLAMP ADJUSTMENT
A properl y al i gned headl amp wi l l project a pattern
on the al i gnment screen from just bel ow hori zontal to
75 mi l l i meters (3 i nches) bel ow the headl amp center-
l i ne for vehi cl es i n North Ameri ca, or from just bel ow
hori zontal to 125 mi l l i meters (5 i nches) bel ow the
headl amp hori zontal centerl i ne for vehi cl es i n Rest-
Of-Worl d.
(1) Vehi cl es for al l markets except Japan shoul d
have the headl amp l ow beams sel ected wi th the di m-
mer (mul ti -functi on) swi tch duri ng the adjustment
procedure. Vehi cl es for the Japanese market shoul d
have the headl amp hi gh beams sel ected.
(2) Cover the l ens of the headl amp that i s not
bei ng adjusted.
(3) Turn the adjusti ng screw (Fi g. 44) unti l the top
edge of the beam i ntensi ty pattern i s posi ti oned from
just bel ow hori zontal to 75 mi l l i meters (3 i nches)
Fig. 43 Headlamp Alignment Screen - Typical
1 - CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS
2 - FLOOR TO CENTER OF HEADLAMP LENS
3 - 7.62 METERS (25 FEET) NORTH AMERICA/10.0 METERS
(32.81 FEET) REST-OF-WORLD
4 - FRONT OF HEADLAMP
KJ LAMPS 8Ls - 43
bel ow the headl amp hori zontal centerl i ne for vehi cl es
i n North Ameri ca, or from just bel ow hori zontal to
125 mi l l i meters (5 i nches) bel ow the headl amp hori -
zontal centerl i ne for vehi cl es i n Rest-Of-Worl d.
(4) Repeat the adjustment procedure for the oppo-
si te headl amp.
REMOVAL
NORTH AMERICA
cabl e.
access and fi rml y grasp the socket on the back of the
l i cense pl ate l amp uni t housi ng (Fi g. 45).
back of the l i cense pl ate l amp uni t housi ng.
l amp uni t socket.
REST-OF-WORLD
cabl e.
(2) Unsnap and l i ft up the bottom of the l i cense
mounti ng pl ate far enough to access and remove the
two screws that secure the l i cense pl ate bracket to
the speci al l ug nuts on the spare ti re (Fi g. 46).
(3) Swi ng the l i cense pl ate bracket away from the
spare ti re far enough to access the l i cense pl ate l amp
bul b sockets.
(4) Fi rml y grasp the socket on the top of the
l i cense pl ate l amp uni t housi ng for the bul b that i s
bei ng removed (Fi g. 47).
degrees.
(6) Pul l the socket and bul b strai ght out of the top
of the l i cense pl ate l amp uni t housi ng.
l amp uni t socket.
Fig. 44 Headlamp Adjusting Screw
1 - HEADLAMP UNIT
2 - FENDER PANEL
3 - ADJUSTING SCREW ACCESS HOLE
North America
2 - LICENSE PLATE LAMP
3 - SOCKET
4 - BULB
Fig. 46 License Plate Bracket - Rest-Of-World
1 - SPARE TIRE
2 - SPECIAL LUG NUT (2)
4 - SCREW (2)
8Ls - 44 LAMPS KJ
INSTALLATION
NORTH AMERICA
al i gn the socket and bul b wi th the socket openi ng on
the back of the l amp uni t housi ng (Fi g. 45).
seated.
REST-OF-WORLD
i ng on the top of the l i cense pl ate l amp uni t housi ng
(Fi g. 47).
seated.
(6) Swi ng the l i cense pl ate bracket back agai nst
the spare ti re (Fi g. 46).
(7) Li ft up the bottom of the l i cense mounti ng
pl ate far enough to i nstal l and ti ghten the two
screws that secure the l i cense pl ate bracket to the
speci al l ug nuts on the spare ti re. Ti ghten the screws
to 28 Nm (21 ft. l bs.).
(8) Lower the bottom of the l i cense mounti ng pl ate
and, usi ng hand pressure, snap i t i nto pl ace on the
l i cense pl ate bracket.
REMOVAL
NORTH AMERICA
cabl e.
pl ate l amp uni t to the rear bumper fasci a (Fi g. 48).
(3) Pul l the l i cense pl ate l amp uni t down and out
through the mounti ng hol e i n the rear bumper fasci a
connector for the l amp socket pi gtai l wi re.
rear bumper fasci a.
Rest-Of-World
1 - LAMP UNIT (2)
3 - SCREW (4)
Fig. 48 License Plate Lamp Unit Remove/Install
3 - SCREW (2)
KJ LAMPS 8Ls - 45
LICENSE PLATE LAMP BULB (Continued)
REST-OF-WORLD
cabl e.
(2) Remove the bul b and socket uni t from the
removed. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
REMOVAL - REST-OF-WORLD).
pl ate l amp uni t to the back of the l i cense pl ate
bracket (Fi g. 49).
back of the l i cense pl ate bracket.
INSTALLATION
NORTH AMERICA
(1) Posi ti on the l i cense pl ate l amp uni t to the rear
bumper fasci a.
l i cense pl ate l amp uni t to the l amp socket pi gtai l
wi re.
(3) Posi ti on the l i cense pl ate l amp uni t i nto the
mounti ng hol e i n the rear bumper fasci a (Fi g. 48).
the l i cense pl ate l amp uni t housi ng to the rear
bumper fasci a. Ti ghten the screws to 2 Nm (20 i n.
l bs.).
REST-OF-WORLD
(1) Posi ti on the l i cense pl ate l amp uni t onto the
back of the l i cense pl ate bracket (Fi g. 49).
the l i cense pl ate l amp uni t to the back of the l i cense
pl ate bracket. Ti ghten the screws to 2 Nm (20 i n.
l bs.).
(3) Rei nstal l the bul b and socket uni t i nto the
repl aced. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NSTALLATI ON - REST-OF-WORLD).
DESCRIPTION
The mul ti -functi on swi tch i s l ocated on the steeri ng
col umn, just bel ow the steeri ng wheel (Fi g. 50). The
onl y vi si bl e components of the mul ti -functi on swi tch
are two l evers, or control stal ks that extend through
dedi cated openi ngs i n each si de of the steeri ng col -
umn shrouds. The remai nder of the swi tch, i ts
mounti ng provi si ons, and i ts el ectri cal connecti ons
are al l conceal ed beneath the steeri ng col umn
shrouds. The swi tch housi ng and control s are con-
structed of mol ded bl ack pl asti c. A saddl e-l i ke forma-
ti on i n the center of the mul ti -functi on swi tch
housi ng straddl es the steeri ng col umn tube just
bel ow the col umn l ock housi ng, and two posts i nte-
gral to the l ower surface of the swi tch housi ng
engage two hol es on the forward-faci ng si de of the
l ock housi ng. Two i ntegral l edge-l i ke l ocati ng tabs
near the top of the rearward faci ng swi tch housi ng
surface are supported and l ocated by two upri ght
stanchi ons that extend upward from the top of the
l ock housi ng. Al so on the rearward faci ng swi tch
housi ng surface near the center, an i ntegral l edge-
l i ke mounti ng tab rests on a si mi l ar l edge-l i ke tab
that extends from each si de of the steeri ng col umn
l ock housi ng. When the steeri ng col umn shrouds are
i nstal l ed on the col umn, the swi tch mounti ng tabs
are cl amped al ong wi th the mounti ng tabs of the
cl ockspri ng between the i ntegral mounti ng stan-
chi ons of the upper shroud and the l ock housi ng tabs,
and are secured to the steeri ng col umn l ock housi ng
by the same two screws that secure the two shroud
hal ves to each other and the col umn.
There are several versi ons of the mul ti -functi on
swi tch to support both opti onal equi pment and equi p-
ment that i s requi red onl y i n certai n markets. Each
mul ti -functi on swi tch control stal k has both whi te
nomencl ature and I nternati onal Control and Di spl ay
Symbol graphi cs appl i ed to i t, whi ch cl earl y i denti fy
i ts many functi ons. Each control stal k has a control
Rest-Of-World
1 - LAMP UNIT (2)
3 - SCREW (4)
8Ls - 46 LAMPS KJ
LICENSE PLATE LAMP UNIT (Continued)
knob on i ts end wi th a fl attened face to al l ow i t to be
easi l y rotated. On vehi cl es equi pped wi th opti onal
front fog l amps, the knob on the end of l eft control
stal k can al so be pul l ed outward to sel ect those
l amps. Each control stal k al so features a knurl ed
control ri ng l ocated just bel ow the control knob. The
l eft control stal k i s dedi cated to provi di ng dri ver con-
trol s for the i nteri or and exteri or l i ghti ng systems,
whi l e the ri ght control stal k i s dedi cated to provi di ng
dri ver control s for the front and rear wi per systems.
Two i ntegral connector receptacl es on the forward
faci ng surface of the mul ti -functi on swi tch housi ng
connect the swi tch two the vehi cl e el ectri cal system
through two take outs and connectors of the i nstru-
ment panel wi re harness. The l eft connector recepta-
cl e contai ns ni ne termi nal pi ns for the l i ghti ng
control ci rcui ts of the swi tch, whi l e the ri ght connec-
tor receptacl e contai ns si x termi nal pi ns for the
wi per control ci rcui ts of the swi tch. The mul ti -func-
ti on swi tch cannot be adjusted or repai red and, i f
stal k of the mul ti -functi on swi tch supports the fol -
l owi ng functi ons and features:
detent swi tchi ng for the opti onal front fog l amps.
Headlamps - The i nternal ci rcui try and hard-
trol stal k provi de detent swi tchi ng for the
headl amps.
Headlamp Beam Selection - The i nternal ci r-
(l i ghti ng) control stal k provi de detent swi tchi ng for
sel ecti on of the headl amp hi gh or l ow beams.
Headlamp Optical Horn - The i nternal ci r-
(l i ghti ng) control stal k i ncl udes momentary swi tchi ng
of the headl amp hi gh beam ci rcui ts to provi de an
opti cal horn feature (someti mes referred to as fl ash-
to-pass), whi ch al l ows the vehi cl e operator to momen-
tari l y fl ash the headl amp hi gh beams as an opti cal
si gnal l i ng devi ce.
Interior Lamps Defeat - The i nternal ci rcui try
i ng) control stal k provi de detent swi tchi ng to defeat
the i l l umi nati on of al l i nteri or courtesy l amps when a
door, the rear fl i p-up gl ass, or the tai l gate are
opened.
Interior Lamps On - The i nternal ci rcui try and
hardware of the mul ti -functi on swi tch l eft (l i ghti ng)
control stal k provi de detent swi tchi ng to si mul ta-
neousl y i l l umi nate al l i nteri or courtesy l amps.
Panel Lamps Dimming - The i nternal ci r-
(l i ghti ng) control stal k provi de si mul taneous adjust-
abl e control of the i l l umi nati on i ntensi ty of al l i nstru-
ment panel l i ghti ng at one of si x avai l abl e
i l l umi nati on i ntensi ty l evel s.
Fig. 50 Multi-Function Switch
2 - RIGHT (WIPER) CONTROL STALK
3 - LEFT (LIGHTING) CONTROL STALK
4 - TURN SIGNAL CANCEL ACTUATOR
5 - RIGHT (WIPER) CONTROL KNOB
6 - RIGHT (WIPER) CONTROL RING
7 - LEFT (LIGHTING) CONTROL RING
8 - LEFT (LIGHTING) CONTROL KNOB
KJ LAMPS 8Ls - 47
Parade Mode - The i nternal ci rcui try and hard-
trol stal k provi de detent swi tchi ng for a parade mode
that maxi mi zes the i l l umi nati on i ntensi ty of al l
i nstrument panel l i ghti ng for vi si bi l i ty when dri vi ng
i n dayl i ght wi th the exteri or l amps turned on.
Park Lamps - The i nternal ci rcui try and hard-
trol stal k provi de detent swi tchi ng for the park
l amps.
detent swi tchi ng for the opti onal rear fog l amps.
Rear fog l amps are opti onal onl y for vehi cl es manu-
factured for certai n markets, where they are
requi red.
Turn Signal Control - The i nternal ci rcui try
i ng) control stal k provi de both momentary non-detent
swi tchi ng and detent swi tchi ng wi th automati c can-
cel l ati on for both the l eft and ri ght turn si gnal
l amps.
trol stal k of the mul ti -functi on swi tch supports the
fol l owi ng functi ons and features:
Continuous Front Wipe Modes - The i nternal
ri ght (wi per) control stal k provi de two conti nuous
front wi pe swi tch posi ti ons, l ow speed or hi gh speed.
Continuous Rear Wipe Mode - The i nternal
ri ght (wi per) control stal k provi de one conti nuous
rear wi pe swi tch posi ti on.
Front Washer Mode - The i nternal ci rcui try
and hardware of the mul ti -functi on swi tch ri ght
(wi per) control stal k swi tch provi de front washer sys-
tem operati on.
Front Wipe-After-Wash Mode - The i nternal
ri ght (wi per) control stal k provi de a wi pe-after-wash
mode.
Front Wiper Mist Mode - The i nternal ci r-
cui try and hardware of the mul ti -functi on swi tch
ri ght (wi per) control stal k provi de a front wi per sys-
tem mi st mode.
Intermittent Front Wipe Mode - The i nternal
ri ght (wi per) control stal k provi de an i ntermi ttent
front wi pe mode wi th fi ve del ay i nterval posi ti ons.
Intermittent Rear Wipe Mode - The i nternal
ri ght (wi per) control stal k provi de one fi xed i nterval
i ntermi ttent rear wi pe mode swi tch posi ti on.
Rear Washer Mode - The i nternal ci rcui try and
hardware of the mul ti -functi on swi tch ri ght (wi per)
control stal k provi de rear washer system operati on.
OPERATION
The mul ti -functi on swi tch uses a combi nati on of
resi stor mul ti pl exed and conventi onal l y swi tched out-
puts to control the many functi ons and features i t
provi des. The swi tch recei ves battery current on a
fused i gni ti on swi tch output (run-acc) ci rcui t from a
fuse i n the Juncti on Bl ock (JB) whenever the i gni ti on
swi tch i s i n the On or Accessory posi ti ons. The swi tch
recei ves a path to ground at al l ti mes through a
i nstrument panel end bracket near the Juncti on
Bl ock (JB). Fol l owi ng are descri pti ons of how each of
the two mul ti -functi on swi tch control stal ks operate
to control the functi ons and features they provi de.
stal k of the mul ti -functi on swi tch operates as fol l ows:
swi tch l eft (l i ghti ng) control stal k i s pul l ed outward
to acti vate the opti onal front fog l amps. The control
knob i s mechani cal l y keyed so that i t cannot be
pul l ed outward unl ess i t i s fi rst rotated to turn on
the exteri or l i ghti ng. The mul ti -functi on swi tch pro-
vi des a resi stor mul ti pl exed output to the Body Con-
trol Modul e (BCM) on a fog l amp swi tch sense
energi zi ng the front fog l amp rel ay i n the Juncti on
Headlamps - The control knob on the end of the
rotated forward (countercl ockwi se) to i ts second detent
posi ti on to acti vate the headl amps. The mul ti -functi on
Body Control Modul e (BCM) on a headl amp swi tch
sense ci rcui t, and the BCM responds by energi zi ng or
de-energi zi ng the sel ected l ow or hi gh beam rel ay
(Dayti me Runni ng Lamp rel ay i n Canadi an vehi cl es)
i n the Juncti on Bl ock (JB) as requi red.
Headlamp Beam Selection - The l eft (l i ghti ng)
towards the steeri ng wheel past a detent to actuate
the i ntegral beam sel ect swi tch ci rcui try. Each ti me the
control stal k i s acti vated i n thi s manner, the opposi te
headl amp beam from what i s currentl y sel ected wi l l be
energi zed. The mul ti -functi on swi tch provi des a ground
output to the Body Control Modul e (BCM) on a hi gh
beam swi tch sense ci rcui t, and the BCM responds by
energi zi ng or de-energi zi ng the sel ected l ow or hi gh
beam rel ay (Dayti me Runni ng Lamp rel ay i n Canadi an
vehi cl es) i n the Juncti on Bl ock (JB) as requi red.
8Ls - 48 LAMPS KJ
Headlamp Optical Horn - The l eft (l i ghti ng)
towards the steeri ng wheel to just before a detent, to
momentari l y acti vate the headl amp opti cal horn fea-
ture. The hi gh beams wi l l remai n i l l umi nated unti l
the control stal k i s rel eased. The mul ti -functi on
swi tch provi des a ground output on a hi gh beam
rel ay control ci rcui t to energi ze the headl amp hi gh
beam rel ay (Dayti me Runni ng Lamp rel ay i n Cana-
di an vehi cl es) i n the Juncti on Bl ock (JB) as requi red.
Interior Lamps Defeat - The control ri ng on
i s rotated to a ful l rearward (cl ockwi se) detent to
defeat the i l l umi nati on of al l i nteri or courtesy l amps.
a panel l amps di mmer swi tch mux ci rcui t, and the
BCM responds by de-energi zi ng i ts i nternal courtesy
l amp dri ver ci rcui t.
Interior Lamps On - The control ri ng on the
rotated to a ful l forward (countercl ockwi se) detent to
i l l umi nate al l i nteri or courtesy l amps. The mul ti -
put to the Body Control Modul e (BCM) on a panel
responds by energi zi ng i ts i nternal courtesy l amp
dri ver ci rcui t.
Panel Lamps Dimming - The control ri ng on
i s rotated to one of si x mi nor i ntermedi ate detents to
si mul taneousl y sel ect the desi red i l l umi nati on i nten-
si ty of al l adjustabl e i nstrument panel and i nstru-
ment cl uster l i ghti ng. The control ri ng i s rotated
rearward (cl ockwi se) to di m, or forward (counter-
cl ockwi se) to bri ghten. The mul ti -functi on swi tch pro-
vi des a resi stor mul ti pl exed output to the Body
Control Modul e (BCM) on a panel l amps di mmer
swi tch mux ci rcui t, and the BCM responds by send-
i ng an el ectroni c panel l amps di mmi ng l evel message
(PCI ) data bus. The EMI C el ectroni c ci rcui try then
provi des the proper PWM output to the cl uster i l l u-
mi nati on l amps and the VFD on the EMI C ci rcui t
board, then provi des a matchi ng PWM output on the
hard wi red fused panel l amps di mmer swi tch si gnal
ci rcui t.
Parade Mode - The control ri ng on the mul ti -
functi on swi tch l eft (l i ghti ng) control stal k i s rotated
to an i ntermedi ate detent that i s one detent rear-
ward (cl ockwi se) from the ful l forward (countercl ock-
wi se) detent to sel ect the Parade mode. The mul ti -
functi on swi tch provi des a resi stor mul ti pl exed
output to the Body Control Modul e (BCM) on a panel
responds by sendi ng an el ectroni c panel l amps di m-
mi ng l evel message to the El ectroMechani cal I nstru-
ment Cl uster (EMI C) over the Programmabl e
Communi cati ons I nterface (PCI ) data bus. The EMI C
el ectroni c ci rcui try then provi des the proper PWM
output to the cl uster i l l umi nati on l amps and the
VFD on the EMI C ci rcui t board, then provi des a
matchi ng PWM output on the hard wi red fused panel
l amps di mmer swi tch si gnal ci rcui t to i l l umi nate al l
l amps at ful l (dayl i ght) i ntensi ty wi th the exteri or
l amps turned On.
Park Lamps - The control knob on the end of
i s rotated forward (countercl ockwi se) to i ts fi rst
detent from the Off posi ti on to acti vate the park
l amps. The mul ti -functi on swi tch provi des a resi stor
mul ti pl exed output to the Body Control Modul e
(BCM) on a headl amp swi tch sense ci rcui t, and the
park l amp rel ay i n the Juncti on Bl ock (JB) as
requi red.
swi tch l eft (l i ghti ng) control stal k i s rotated forward
(countercl ockwi se) to i ts thi rd detent posi ti on to acti -
vate the rear fog l amps. The mul ti -functi on swi tch
Control Modul e (BCM) on a headl amp swi tch sense
energi zi ng the rear fog l amp rel ay i n the Juncti on
Bl ock (JB) as requi red. Rear fog l amps are opti onal
onl y for vehi cl es manufactured for certai n markets,
where they are requi red.
Turn Signal Control - The l eft (l i ghti ng) con-
trol stal k of the mul ti -functi on swi tch i s moved
upward to acti vate the ri ght turn si gnal ci rcui try,
and, downward to acti vate the l eft turn si gnal ci r-
cui try. The turn si gnal swi tch has a detent posi ti on
i n each di recti on that provi des turn si gnal s wi th
automati c cancel l ati on, and an i ntermedi ate, momen-
tary posi ti on i n each di recti on that provi des turn si g-
nal s onl y unti l the l eft mul ti -functi on swi tch control
stal k i s rel eased. When the control stal k i s moved to
a turn si gnal swi tch detent posi ti on, the cancel
actuator extends toward the center of the steeri ng
col umn. A turn si gnal cancel cam that i s i ntegral to
the cl ockspri ng rotates wi th the steeri ng wheel and
the cam l obes contact the cancel actuator when i t i s
extended from the l eft mul ti -functi on swi tch. When
the steeri ng wheel i s rotated duri ng a turni ng
maneuver, one of the two turn si gnal cancel cam
l obes wi l l contact the turn si gnal cancel actuator. The
cancel actuator l atches agai nst the cancel cam rota-
ti on i n the di recti on opposi te that whi ch i s si gnal ed.
I n other words, i f the l eft turn si gnal detent i s
sel ected, the l obes of the cancel cam wi l l ratchet past
KJ LAMPS 8Ls - 49
the cancel actuator when the steeri ng wheel i s
rotated to the l eft, but wi l l unl atch the cancel actua-
tor as the steeri ng wheel rotates to the ri ght and
returns to center, whi ch wi l l cancel the turn si gnal
event and rel ease the control stal k from the detent so
i t returns to the neutral Off posi ti on. When a turn
si gnal i s acti vated, the mul ti -functi on swi tch provi des
a ground output on a ri ght or l eft turn swi tch sense
ci rcui t to the combi nati on fl asher ci rcui try wi thi n the
hazard swi tch, and the combi nati on fl asher fl ashes
the turn si gnal l amps.
trol stal k of the mul ti -functi on swi tch operates as fol -
l ows:
Continuous Front Wipe Modes - The control
(wi per) control stal k i s rotated to an i ntermedi ate
detent that i s one detent rearward (countercl ockwi se)
from the ful l forward (cl ockwi se) detent to sel ect the
l ow speed conti nuous front wi per mode, or to i ts ful l
forward (cl ockwi se) detent to sel ect the hi gh speed
conti nuous front wi per mode. The mul ti -functi on
Body Control Modul e (BCM) on a front wi per swi tch
mux ci rcui t, and the BCM responds by energi zi ng the
(PDC) for the front l ow speed conti nuous wi pe mode,
or the wi per on/off rel ay and the wi per hi gh/l ow rel ay
i n the PDC for the front hi gh speed conti nuous wi pe
mode as requi red.
Continuous Rear Wipe Mode - The control
trol stal k i s rotated to the most forward (cl ockwi se)
detent to sel ect the conti nuous rear wi per mode. The
mul ti -functi on swi tch provi des a battery current out-
put to the rear wi per motor on a rear wi per on dri ver
ci rcui t to si gnal the rear wi per motor to operate i n
the conti nuous wi pe mode.
Front Washer Mode - The ri ght (wi per) control
stal k of the mul ti -functi on swi tch i s pul l ed towards
the steeri ng wheel to momentari l y acti vate the
washer pump i n the front washer mode. The washer
pump wi l l conti nue to operate i n the front washer
mode unti l the control stal k i s rel eased. The mul ti -
functi on swi tch provi des a ground output on a
washer pump sense ci rcui t, and battery current on a
washer pump dri ver ci rcui t to energi ze the washer
pump i n the front washer mode.
Front Wiper Mist Mode - The ri ght (wi per)
control stal k of the mul ti -functi on swi tch i s pushed
towards the fl oor to momentari l y acti vate the front
wi per motor i n the mi st mode. The front wi per motor
wi l l conti nue to operate i n the mi st mode unti l the
control stal k i s rel eased. The mul ti -functi on swi tch
Control Modul e (BCM) on a front wi per swi tch mux
ci rcui t, and the BCM responds by energi zi ng the
(PDC) to operate the front wi per motor momentari l y
at l ow speed to provi de the front wi per mi st mode.
Intermittent Front Wipe Mode - The control
(wi per) control stal k i s rotated to one of fi ve mi nor
i ntermedi ate detents to sel ect the desi red i ntermi t-
tent front wi pe del ay i nterval . The control knob i s
rotated rearward (countercl ockwi se) to i ncrease the
del ay, or forward (cl ockwi se) to decrease the del ay.
a front wi per swi tch mux ci rcui t, and the BCM
responds by energi zi ng the wi per on/off rel ay i n the
Power Di stri buti on Center (PDC) to operate the front
wi per motor at the sel ected del ay i nterval s.
Intermittent Rear Wipe Mode - The control
trol stal k i s rotated to the center detent to sel ect the
i ntermi ttent rear wi per mode. The mul ti -functi on
swi tch provi des a battery current output to the rear
wi per motor on a rear wi per i ntermi ttent dri ver ci r-
cui t to si gnal the rear wi per motor to operate i n the
i ntermi ttent wi pe mode.
Rear Washer Mode - The control ri ng on the
mul ti -functi on swi tch ri ght (wi per) control stal k i s
rotated to ei ther the ful l forward (cl ockwi se) or ful l
rearward (countercl ockwi se) momentary posi ti ons to
acti vate the washer pump i n the rear washer mode.
The washer pump wi l l conti nue to operate i n the rear
washer mode unti l the control ri ng i s rel eased. The
mul ti -functi on swi tch provi des a ground output on a
washer pump dri ver ci rcui t, and battery current on a
washer pump sense ci rcui t to energi ze the washer
pump i n the rear washer mode.
DIAGNOSIS AND TESTING - MULTI-FUNCTION
SWITCH
8Ls - 50 LAMPS KJ
PERSONAL INJURY.
cabl e.
steeri ng col umn. (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/MULTI -FUNCTI ON
SWI TCH - REMOVAL).
and resi stance tests at the termi nal s (Fi g. 51) i n the
mul ti -functi on swi tch connector receptacl es as shown
i n the Mul ti -Functi on Swi tch Tests tabl e.
Fig. 51 Multi-Function Switch Connector Receptacle Pin-Out
2 - C-1 (LIGHTING) CONNECTOR RECEPTACLE
3 - C-2 (WIPER) CONNECTOR RECEPTACLE
KJ LAMPS 8Ls - 51
MULTI-FUNCTION SWITCH TESTS
EXTERIOR LIGHTING FUNCTIONS
Off 4 & 5 3781
Park Lamps On 4 & 5 911
Headlamp Low Beams On 4 & 5 349
Rear Fog Lamps On 4 & 5 75
Headlamp High Beams On 8 & 9 0 - 1
Front Fog Lamps On 2 & 4 0 - 1
Optical Horn (Flash-to-Pass) On 7 & 8 0 - 1
Turn Signal Neutral 6 & 8, 8 & 10 Infinite (Open)
Turn Signal Left 6 & 8 0 - 1
Turn Signal Right 8 & 10 0 - 1
INTERIOR LIGHTING FUNCTIONS
Off (Courtesy Disable) 1 & 4 63
Dimming 1 1 & 4 200
Dimming 2 1 & 4 557
Dimming 3 1 & 4 914
Dimming 4 1 & 4 1271
Dimming 5 1 & 4 1628
Dimming 6 1 & 4 1985
Parade Mode On 1 & 4 3565
Courtesy On 1 & 4 7885
FRONT WIPER FUNCTIONS
SWITCH POSITION
CONNECTOR C-1 & C-2
PINS
RESISTANCE (OHMS) 10%
Front Wiper Off C-1 Pin 4 & C-2 Pin 4 4587
Delay 1 C-1 Pin 4 & C-2 Pin 4 1267
Delay 2 C-1 Pin 4 & C-2 Pin 4 792
Delay 3 C-1 Pin 4 & C-2 Pin 4 531
Delay 4 C-1 Pin 4 & C-2 Pin 4 369
Delay 5 C-1 Pin 4 & C-2 Pin 4 262
Front Wiper Low C-1 Pin 4 & C-2 Pin 4 125
Front Wiper High C-1 Pin 4 & C-2 Pin 4 38
Front Wiper Mist C-1 Pin 4 & C-2 Pin 4 125
Front Washer On C-2 Pins 5 & 7 0 - 1
REAR WIPER FUNCTIONS
Rear Wiper Off 1 & 5, 2 & 5 Infinite (Open)
Rear Wiper Intermittent 2 & 5 0 - 1
Rear Wiper On 1 & 5 0 - 1
Rear Washer On 2 & 5, 3 & 5 0 - 1
8Ls - 52 LAMPS KJ
(4) I f the mul ti -functi on swi tch fai l s any of the
conti nui ty or resi stance tests, repl ace the faul ty
swi tch uni t as requi red.
REMOVAL
PERSONAL INJURY.
cabl e.
shroud (Fi g. 52).
other.
ness connectors for the mul ti -functi on swi tch from
the two connector receptacl es on the back of the
swi tch housi ng.
steeri ng col umn l ock housi ng by careful l y rocki ng the
swi tch and pul l i ng the swi tch housi ng upward far
enough to di sengage i ts al i gnment posts and l ocator
tabs from the l ock housi ng.
INSTALLATION
PERSONAL INJURY.
CAUTION: Before attempting to install the multi-
function switch, be certain that the left control stalk
is in the neutral turn signal position and the turn
signal cancel actuator is in the retracted (neutral)
position.
(1) Posi ti on the mul ti -functi on swi tch to the steer-
i ng col umn.
ness connectors for the mul ti -functi on swi tch to the
two connector receptacl es on the back of the swi tch
Fig. 52 Multi-Function Switch Remove/Install
1 - UPPER SHROUD
3 - CLOCKSPRING
4 - LOWER SHROUD
5 - SCREW (2)
6 - STEERING COLUMN
KJ LAMPS 8Ls - 53
(3) Posi ti on the mul ti -functi on swi tch onto the
steeri ng col umn l ock housi ng. Be certai n that the
swi tch al i gnment posts and l ocator tabs are ful l y
seated on the l ock housi ng.
steeri ng col umn.
i n. l bs.).
l ever i nto the l ocked (up) posi ti on.
PARK LAMP RELAY
DESCRIPTION
The park l amp rel ay i s l ocated i n the Juncti on
Bl ock (JB) bel ow the dri ver si de outboard end of the
the vehi cl e. The park l amp rel ay i s a conventi onal
the rel ay base.
The park l amp rel ay cannot be adjusted or
repl aced.
OPERATION
The park l amp rel ay i s an el ectromechani cal
put to the park l amps. The movabl e common feed
The park l amp rel ay termi nal s are connected to
outputs of the park l amp rel ay i ncl ude:
termi nal (30) i s connected to the park l amps through
the park l amp rel ay output ci rcui t and provi des
ground to the park l amps when the rel ay i s de-ener-
gi zed, and battery current to the park l amps when-
Control Modul e (BCM) through a park l amp rel ay con-
trol ci rcui t. The BCM control s park l amp operati on by
control l i ng a ground path through thi s ci rcui t.
a fuse i n the PDC through a fused B(+) ci rcui t.
cl osed termi nal (87A) i s connected to ground at al l
ti mes through a ground ci rcui t that recei ves ground
through a spl i ce bl ock l ocated i n the i nstrument
panel wi re harness wi th an eyel et termi nal connector
that i s secured by a nut to a ground stud on the
dri ver si de i nstrument panel end bracket near the
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
8Ls - 54 LAMPS KJ
The park l amp rel ay can be di agnosed usi ng con-
RELAY
The park l amp rel ay (Fi g. 54) i s l ocated i n the
and grounds.
PERSONAL INJURY.
(1) Remove the park l amp rel ay from the JB.
EXTERI OR/PARK LAMP RELAY - REMOVAL).
REMOVAL
PERSONAL INJURY.
cabl e.
(3) Remove the park l amp rel ay by graspi ng i t
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
KJ LAMPS 8Ls - 55
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the park l amp rel ay to the proper
(2) Al i gn the park l amp rel ay termi nal s wi th the
(3) Push fi rml y and evenl y on the top of the park
l amp rel ay unti l the termi nal s are ful l y seated i n the
REAR FOG LAMP RELAY
DESCRIPTION
The rear fog l amp rel ay i s l ocated i n the Juncti on
the vehi cl e. The rear fog l amp rel ay i s a conventi onal
the rel ay base.
The rear fog l amp rel ay cannot be adjusted or
repl aced.
Rotate 180for RHD)
3 - LOW BEAM RELAY
7 - DOOR LOCK RELAY
8 - DEFOGGER RELAY
9 - SPARE
11 - HORN RELAY
12 - SPARE
13 - SPARE
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
8Ls - 56 LAMPS KJ
OPERATION
The rear fog l amp rel ay i s an el ectromechani cal
put to the rear fog l amps. The movabl e common feed
The rear fog l amp rel ay termi nal s are connected to
outputs of the rear fog l amp rel ay i ncl ude:
mi um Body Control Modul e (BCM) through a rear
fog l amp rel ay control ci rcui t. The BCM control s rear
fog l amp operati on by control l i ng a ground path
termi nal (87) i s connected to the rear fog l amps
through a rear fog l amp rel ay output ci rcui t and pro-
vi des battery current to the rear fog l amps whenever
the rel ay i s energi zed.
cati on.
The rear fog l amp rel ay can be di agnosed usi ng
DIAGNOSIS AND TESTING - REAR FOG LAMP
RELAY
The rear fog l amp rel ay (Fi g. 57) i s l ocated i n the
and grounds.
PERSONAL INJURY.
(1) Remove the rear fog l amp rel ay from the JB.
EXTERI OR/REAR FOG LAMP RELAY - REMOVAL).
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
KJ LAMPS 8Ls - 57
REMOVAL
PERSONAL INJURY.
cabl e.
(3) Remove the rear fog l amp rel ay by graspi ng i t
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the rear fog l amp rel ay to the proper
(2) Al i gn the rear fog l amp rel ay termi nal s wi th
(3) Push fi rml y and evenl y on the top of the rear
Rotate 180for RHD)
3 - LOW BEAM RELAY
7 - DOOR LOCK RELAY
8 - DEFOGGER RELAY
9 - SPARE
11 - HORN RELAY
12 - SPARE
13 - SPARE
8Ls - 58 LAMPS KJ
REAR LAMP BULB
REMOVAL
The rear l amp uni t may contai n up to four bul bs,
dependi ng upon the market for whi ch the vehi cl e was
manufactured. The servi ce procedures for each bul b
i s the same, onl y the bul b si zes and types may di ffer.
Be certai n any removed bul b i s repl aced wi th the
same bul b si ze and type that was removed.
cabl e.
(2) Remove the rear l amp uni t from the end of the
REMOVAL).
(3) Fi rml y grasp the socket on the socket pl ate at
the back of the rear l amp uni t housi ng for the bul b
that i s bei ng removed (Fi g. 59).
back of the rear l amp uni t housi ng countercl ockwi se
about 30 degrees.
back of the rear l amp uni t housi ng.
(6) Pul l the bul b strai ght out of the rear l amp uni t
socket.
INSTALLATION
i n the rear l amp uni t socket.
(2) Push the bul b strai ght i nto the rear l amp uni t
(3) Al i gn the socket and bul b wi th the openi ng i n
the socket pl ate on the back of the rear l amp uni t
(4) Push the socket and bul b strai ght i nto the rear
l amp uni t housi ng unti l the socket i s fi rml y seated
agai nst the socket pl ate.
back of the rear l amp uni t housi ng cl ockwi se about
30 degrees.
(6) Rei nstal l the rear l amp uni t onto the end of the
I NSTALLATI ON).
REAR LAMP UNIT
REMOVAL
cabl e.
(2) Open the tai l gate to access and remove the two
screws that secure the i nboard si de of the rear l amp
uni t to the si de jamb of the tai l gate openi ng (Fi g. 60).
(3) Pul l the outboard si de of the rear l amp uni t
rearward (away from the end of the quarter panel )
far enough to unsnap the two bal l studs on the out-
board si de of the l amp housi ng from the pl asti c nuts
i n the quarter panel .
Fig. 59 Rear Lamp Bulb Remove/Install
1 - REAR LAMP HOUSING
2 - BULB HOLDER
3 - BULB
4 - SOCKET PLATE
Fig. 60 Rear Lamp Unit Remove/Install
1 - PLASTIC NUT (2)
3 - PLASTIC NUT (2)
4 - REAR LAMP UNIT
5 - SCREW (2)
KJ LAMPS 8Ls - 59
(4) Pul l the rear l amp uni t away from the quarter
panel far enough to access and di sconnect the wi re
harness connector for the l amp uni t from the connec-
tor receptacl e on the l amp socket pl ate.
(5) Remove the rear l amp uni t from the quarter
panel .
(6) Remove the pl asti c nuts from the quarter panel
and di scard.
INSTALLATION
(1) I nstal l new pl asti c nuts i nto the quarter panel
(Fi g. 60).
(2) Posi ti on the rear l amp uni t to the quarter
panel .
rear l amp uni t to the connector receptacl e on the
l amp socket pl ate.
(4) Al i gn the two bal l studs on the outboard si de of
the quarter panel .
(5) Usi ng hand pressure, push the outboard si de of
the rear l amp uni t forward (towards the end of the
quarter panel ) far enough to snap the two bal l studs
on the outboard si de of the l amp housi ng i nto the
pl asti c nuts i n the quarter panel .
(6) Al i gn the mounti ng hol es on the i nboard si de of
the si de jamb of the tai l gate openi ng.
the i nboard si de of the rear l amp uni t housi ng to the
pl asti c nuts i n the si de jamb of the tai l gate openi ng.
REPEATER LAMP BULB
REMOVAL
requi red.
cabl e.
REMOVAL).
l ens countercl ockwi se about 30 degrees (Fi g. 61).
repeater l amp l ens.
(5) Pul l the bul b strai ght out of the repeater l amp
socket.
INSTALLATION
requi red.
i n the repeater l amp socket.
(2) Push the bul b strai ght i nto the repeater l amp
i ng i n the repeater l amp l ens (Fi g. 61).
repeater l amp l ens unti l i t i s fi rml y seated
l ens cl ockwi se about 30 degrees.
(6) Rei nstal l the repeater l amp uni t onto the front
I NSTALLATI ON).
Fig. 61 Repeater Lamp Bulb Remove/Install
1 - FRONT FENDER
2 - SOCKET
3 - BULB
4 - LENS
8Ls - 60 LAMPS KJ
REAR LAMP UNIT (Continued)
REPEATER LAMP UNIT
REMOVAL
requi red.
cabl e.
fl at-bl aded tool , careful l y pry at the cl earance notch
i n the l ower edge of the repeater l amp l ens to di sen-
gage the snap features of the l ens from the mounti ng
hol e i n the front fender panel (Fi g. 62).
(3) Pul l the repeater l amp uni t out from the front
fender panel far enough to access and di sconnect the
repeater l amp wi re harness connector from the con-
nector receptacl e on the back of the repeater l amp
uni t socket.
fender panel .
INSTALLATION
requi red.
(1) Posi ti on the repeater l amp uni t to the front
fender panel (Fi g. 62).
(2) Reconnect the repeater l amp wi re harness con-
nector to the connector receptacl e on the back of the
repeater l amp uni t socket.
(3) Posi ti on the repeater l amp uni t i nto the mount-
i ng hol e i n the front fender panel . Be certai n that the
cl earance notch on the edge of the repeater l amp l ens
i s ori ented toward the bottom.
(4) Usi ng hand pressure, press on the repeater
l amp uni t fi rml y and evenl y unti l the snap features
of the l ens are ful l y engaged i n the mounti ng hol e of
the front fender panel .
REMOVAL
cabl e.
(2) Remove the four screws that secure the trai l er
tow connector to the bracket on the trai l er hi tch
recei ver (Fi g. 63).
(3) Pul l the trai l er tow connector rearward from
the bracket on the trai l er hi tch recei ver far enough to
access and di sconnect the rear body wi re harness
connector from the receptacl e on the back of the
trai l er tow connector.
(4) Remove the trai l er tow connector from the
trai l er hi tch recei ver.
INSTALLATION
(1) Posi ti on the trai l er tow connector to the trai l er
hi tch recei ver (Fi g. 63).
tor to the receptacl e on the back of the trai l er tow
connector.
(3) Posi ti on the trai l er tow connector i nto the
the trai l er tow connector to the bracket on the trai l er
hi tch recei ver. Ti ghten the screws to 4 Nm (35 i n.
l bs.).
Fig. 62 Repeater Lamp Unit Remove/Install
1 - REPEATER LAMP UNIT
2 - FRONT FENDER PANEL
3 - INNER FENDER
4 - FRONT FASCIA WIRE HARNESS
Fig. 63 Trailer Tow Connector Remove/Install
1 - HITCH RECEIVER
2 - 7-WAY TRAILER TOW CONNECTOR
3 - SCREW (4)
4 - BRACKET
KJ LAMPS 8Ls - 61
TRAILER TOW RELAY
DESCRIPTION
The trai l er tow rel ays are l ocated i n a connector
bank above the ri ght rear wheel house and behi nd the
quarter tri m panel on vehi cl es equi pped wi th the
opti onal factory-i nstal l ed trai l er towi ng package.
Four i ndi vi dual rel ays are used, one each for fused
i gni ti on swi tch output (run), brake l amps, ri ght turn
si gnal , and l eft turn si gnal outputs to a trai l er
through the rear body wi ri ng and connectors. The
trai l er tow rel ays are conventi onal I nternati onal
Standards Organi zati on (I SO) mi cro rel ays (Fi g. 64).
Rel ays conformi ng to the I SO speci fi cati ons have
common physi cal di mensi ons, current capaci ti es, ter-
mi nal patterns, and termi nal functi ons. The rel ay i s
contai ned wi thi n a smal l , rectangul ar, mol ded pl asti c
The trai l er tow rel ays cannot be adjusted or
repai red and, i f faul ty or damaged, the i noperati ve
rel ay must be repl aced.
OPERATION
The trai l er tow rel ays are el ectromechani cal
swi tches. The rel ays each use an i nput from the ci r-
cui t that they i sol ate from the trai l er wi ri ng to con-
trol a hi gh current output to the trai l er. The movabl e
common feed contact poi nt i s hel d agai nst the fi xed
normal l y cl osed contact poi nt by spri ng pressure.
When the rel ay coi l i s energi zed, an el ectromagneti c
fi el d i s produced by the coi l wi ndi ngs. Thi s el ectro-
magneti c fi el d draws the movabl e rel ay contact poi nt
away from the fi xed normal l y cl osed contact poi nt,
and hol ds i t agai nst the fi xed normal l y open contact
The termi nal s of each trai l er tow rel ay are con-
nector bank i n the rear l i ghti ng wi re harness above
the ri ght rear wheel house. Refer to the appropri ate
and grounds. The trai l er tow rel ays can be di agnosed
RELAY
The trai l er tow rel ays (Fi g. 65) are l ocated i n a
connector bank above the ri ght rear wheel house.
PERSONAL INJURY.
Fig. 64 Trailer Tow Relays
3 - LEFT TURN RELAY
8Ls - 62 LAMPS KJ
(1) Remove the trai l er tow rel ay from the connec-
tor bank. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR/TRAI LER TOW RELAY -
REMOVAL).
and 30. I f OK, test the i nput and output ci rcui ts of
the rel ay. Refer to the appropri ate wi ri ng i nforma-
ti on.
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Remove the tri m from the ri ght si de quarter
TER TRI M PANEL - REMOVAL).
l ocate and retri eve the trai l er tow rel ay connector
bank, whi ch i s envel oped i n foam rubber and pl aced
on the top of the ri ght rear wheel house between the
quarter i nner and outer panel s (Fi g. 66).
(4) Pul l the trai l er tow rel ay connector bank i nto
the cargo area far enough to access the uni t for ser-
vi ce.
(5) Careful l y remove the trai l er tow rel ay connec-
tor bank from the foam wrap.
(6) Remove the trai l er tow rel ay by graspi ng i t
fi rml y and pul l i ng i t strai ght out from the connector
bank (Fi g. 67).
INSTALLATION
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
Fig. 66 Trailer Tow Relay Wrap
1 - FOAM WRAP
KJ LAMPS 8Ls - 63
PERSONAL INJURY.
(1) Posi ti on the trai l er tow rel ay to the proper con-
nector i n the connector bank (Fi g. 67).
(2) Al i gn the trai l er tow rel ay termi nal s wi th the
(3) Push fi rml y and evenl y on the top of the trai l er
tow rel ay unti l the termi nal s are ful l y seated i n the
(4) Careful l y restore the foam wrap around the
trai l er tow rel ay connector bank (Fi g. 66).
pl ace the trai l er tow rel ay connector bank on the top
of the ri ght rear wheel house between the quarter
i nner and outer panel s.
(6) Rei nstal l the tri m onto the ri ght si de quarter
TER TRI M PANEL - I NSTALLATI ON).
TRAILER TOW WIRING
DESCRIPTION
Vehi cl es equi pped wi th an opti onal factory-i n-
stal l ed (not deal er-i nstal l ed or port-i nstal l ed) trai l er
towi ng package have a rear body wi re harness that
i ncl udes an i ntegral trai l er tow wi ri ng take out that
connects to a heavy duty, seal ed, 7-pi n trai l er tow
connector l ocated on a bracket on the trai l er hi tch
recei ver (Fi g. 68). Thi s harness i ncl udes a second
take out wi th a trai l er tow rel ay connector bank and
four trai l er tow rel ays that i sol ate the ri ght turn si g-
nal , l eft turn si gnal , and brake l amp ci rcui ts of the
vehi cl e from the el ectri cal system of the trai l er. The
fourth rel ay i n the connector bank provi des a fused
i gni ti on swi tch output (run) source of battery current
to the trai l er tow connector through a trai l er tow
rel ay output ci rcui t. The package al so i ncl udes an
adapter harness (stored beneath the l eft rear seat
cushi on of the vehi cl e when i t i s shi pped from the
factory) that adapts the 7-pi n trai l er tow connector to
a standard, l i ght-duty, 4-pi n trai l er tow connector.
Fig. 67 Trailer Tow Relay Remove/Install
3 - LEFT TURN RELAY
Fig. 68 Trailer Tow Wiring
2 - REAR BODY HARNESS (TRAILER TOW TAKE OUT)
8Ls - 64 LAMPS KJ
LAMP BAR
DESCRIPTION
The l amp bar i s used to better i l l umi nate the dri v-
ers fi el d of vi si on under certai n dri vi ng condi ti ons. I t
consi sts of a cover, two or four l amp assembl i es
(dependi ng upon whi ch market), and a wi ri ng har-
ness. These components are mounted to a rei nforce-
ment, then seal ed and secured to the roof panel .
Lamp bar i l l umi nati on i s control l ed by a manual l y
operated momentary rocker swi tch, mounted to the
i nstrument panel . The l amps are adjustabl e i n the
verti cal posi ti on onl y.
OPERATION
Battery and i gni ti on vol tage are suppl i ed to the
l amp bar swi tch assembl y. When the swi tch i s i n the
on posi ti on the i nternal rel ay contacts cl ose, compl et-
i ng the ci rcui t through the l amp bar bul bs, to
ground. The l amp bar assembl y i s grounded to the
chassi s. The hard wi red ci rcui ts of the l amp bar may
be di agnosed and tested usi ng conventi onal methods
and procedures.
DIAGNOSIS AND TESTING - LAMP BAR
LAMP BAR LAMPS
INOPERATIVE
Faulty or missing fuse Test and replace lamp bar fuse
as required
Faulty feed circuit Test and repair open battery or
ignition feed circuit.
Faulty ground circuit Test and repair high resistance
or open lamp bar ground circuit
Faulty lamp bar sense circuit Test and repair short to voltage
in lamp bar sense circuit
Faulty switch Test and replace lamp bar
switch
LAMP BAR LAMPS ON AT
ALL TIMES
Faulty switch Test and replace lamp bar
switch
Lamp bar feed circuit Test and repair short to voltage
in lamp bar feed circuit
ONE OR MORE LAMPS
INOPERATIVE
Faulty or missing bulb Test and repair lamp bar lamp
bulb(s) as required
Faulty lamp bar wiring harness Test and repair short/open lamp
bar wiring harness
STANDARD PROCEDURE - LAMP BAR AIMING
NOTE: The lamp bar lamps are adjustable to the
vertical position only.
(1) Remove l amp bar cover.
(2) Usi ng a fai rl y dark and l evel area, dri ve the
vehi cl e perpendi cul ar to and 25 ft. away from a wal l .
(3) Measure up the wal l 7ft. 9i n. and pl ace tape on
the wal l paral l el to the ground.
(4) Turn on the l amp bar l amps.
(5) Usi ng the adjustment screw i n the rear of each
l amp, adjust the l amp beam to the center of the tape.
REMOVAL
REMOVAL - LAMP BAR
(1) Di sconnect the negati ve battery cabl e.
(2) Remove the l amp bar cover retai ni ng screws,
sl i de the cover forward and up to remove.
(3) Di sconnect l amp el ectri cal connector.
(4) Remove the l amp bar rei nforcement to roof
stud retai ners.
CAUTION: The reinforcement is held to the roof by
protective tape. Remove the tape carefully to pre-
vent damage to roof panel. After removal, the area
must be cleaned with the appropriate solvent.
KJ LAMPS 8Ls - 65
(5) Remove l amp bar rei nforcement from roof.
REMOVAL - LAMP
(2) Remove the l amp bar cover screws, sl i de the
cover forward and up to remove (Fi g. 69).
NOTE: There is a hook arrangement for the forward
lamp attachment. Pick the lamp up by the bulb con-
nector.
(3) Remove the l amp to base retai ni ng screws.
(4) Li ft the l amp up and sl i de backward to remove.
INSTALLATION
INSTALLATION - LAMP BAR
NOTE: Lamp bar is held to roof by protective tape.
Mounting area must be clean and dry before instal-
lation.
(1) Remove tape protecti ve stri ps on new l amp bar.
(2) Posi ti on l amp bar over roof studs (Fi g. 69).
(3) Press the l amp bar rei nforcement i nto pl ace
maki ng sure the tape stri ps are securel y seated on
roof.
(4) I nstal l the rei nforcement nuts and ti ghten to
20 l bs. i n.
(5) Connect el ectri cal connector.
(6) Reconnect negati ve battery cabl e.
(7) Ai m l amps (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/LAMP BAR - STANDARD
PROCEDURE) .
(8) Posi ti on the cover over l amp bar, sl i de rear-
ward and secure wi th screws.
INSTALLATION - LAMP
NOTE: There is a hook arrangement for the forward
lamp attachment. Pick the lamp up by the bulb con-
nector.
(1) Posi ti on the l amp assembl y on the base (Fi g.
69).
(2) Sl i de the l amp forward and seat.
(3) I nstal l the l amp retai ni ng screws.
(5) Al i gn the l amps (Refer to 8 - ELECTRI CAL/
LAMPS/LI GHTI NG - EXTERI OR/LAMP BAR -
(6) I nstal l the l amp bar cover.
Fig. 69 LAMP BAR
1 - Cover
2 - Electrical Connector
3 - Lamp Bar
8Ls - 66 LAMPS KJ
LAMP BAR (Continued)
LAMP BAR SWITCH
DESCRIPTION
The l amp bar swi tch i s i ntended to cl ose the el ec-
tri cal ci rcui t whi ch feeds the l amp bar. The swi tch
assembl y contai ns a rel ay uni t that i s energi zed or
de-energi zed by a manual l y operated momentary
rocker swi tch. The swi tch i s mounted on the i nstru-
ment panel l eft of the steeri ng wheel .
REMOVAL
CAUTION: Care must be taken not to damage the
dash or instrument panel when removing the lamp
bar switch bezel.
(2) Usi ng a sui tabl e pry tool , careful l y remove the
l amp bar swi tch bezel from the i nstrument panel .
(3) Di sconnect the el ectri cal connector.
(4) Depress the l amp bar swi tch retai ni ng tabs and
remove the swi tch from the bezel .
INSTALLATION
(1) Press the l amp bar swi tch i nto the i nstrument
panel bezel and assure that the swi tch i s seated
properl y (Fi g. 70).
(2) Connect the el ectri cal connector.
(3) Press the i nstrument panel bezel i nto posi ti on
and seat the bezal retai ni ng cl i ps.
Fig. 70 LAMP BAR SWITCH
1 - Bezel
2 - Lamp Bar Switch
KJ LAMPS 8Ls - 67
MESSAGE SYSTEMS
TABLE OF CONTENTS
page page
OVERHEAD CONSOLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - CMTC LAMP
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - COURTESY
LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - COMPASS
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . 2
DEMAGNETIZING . . . . . . . . . . . . . . . . . . . . . . 2
VARIATION ADJUSTMENT. . . . . . . . . . . . . . . . 3
REMOVAL
OVERHEAD CONSOLE - REMOVAL . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPASS/MINI-TRIP COMPUTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - COMPASS
MINI-TRIP COMPUTER . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UNIVERSAL TRANSMITTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - ERASING
TRANSMITTER CODES. . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - SETTING
TRANSMITTER CODES. . . . . . . . . . . . . . . . . . 9
AMBIENT TEMP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR . . . . . . . . . . . . . . . . 9
TEMPERATURE SENSOR CIRCUIT. . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OVERHEAD CONSOLE
DESCRIPTION
An overhead consol e i s standard factory-i nstal l ed
equi pment on thi s model . The avai l abl e overhead
consol es can i ncl ude the Compass Mi ni -Tri p Com-
puter wi th uni versal transmi tter (Fi g. 2), wi thout the
uni versal transmi tter (Fi g. 1), or base consol e wi th
onl y two readi ng and courtesy l amps (Fi g. 3). Al l
overhead consol es are equi pped wi th two readi ng and
courtesy l amps. On vehi cl es equi pped wi th a power
Fig. 1 Overhead Console Without Universal
Transmitter
Fig. 2 Overhead Console With Universal Transmitter
KJ MESSAGE SYSTEMS 8M - 1
sunroof, the sunroof swi tch i s l ocated between the
two readi ng and courtesy l amps. The overhead con-
sol e i s mounted wi th one screw and two snap cl i ps to
a mol ded pl asti c retai ner bracket l ocated above the
headl i ner.
OPERATION
Refer to the vehi cl e Owners Manual for speci fi c
operati on of each overhead consol e and i ts systems.
STANDARD PROCEDURE
STANDARD PROCEDURE - CMTC LAMP
REPLACEMENT
(1) Open hood, di sconnect and i sol ate the negati ve
battery cabl e.
(2) Remove overhead consol e (Refer to 8 - ELEC-
TRI CAL/OVERHEAD CONSOLE - REMOVAL).
(3) Usi ng a fl at bl ade screwdri ver twi st out the
l amp socket.
(4) Repl ace l amp(s) as necessary.
STANDARD PROCEDURE - COURTESY LAMP
REPLACEMENT
battery cabl e.
l i ner (Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE - REMOVAL).
(3) Remove the l amp and socket assembl y from the
overhead consol e.
(4) Remove the l amp bul b by pul l i ng i t strai ght
out of i ts socket.
CALIBRATION
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of
the compass. Do not use magnetic tools when ser-
vicing the overhead console.
The el ectroni c compass uni t features a sel f-cal i -
brati ng desi gn, whi ch si mpl i fi es the cal i brati on pro-
cedure. Thi s feature automati cal l y updates the
compass cal i brati on whi l e the vehi cl e i s bei ng dri ven.
Thi s al l ows the compass uni t to compensate for smal l
changes i n the resi dual magneti sm that the vehi cl e
may acqui re duri ng normal use. I f the compass read-
i ngs appear to be errati c or out of cal i brati on, per-
form the fol l owi ng cal i brati on procedure. Al so, new
servi ce repl acement Compass Mi ni -Tri p Computer
(CMTC) modul es must have thei r compass cal i brated
usi ng thi s procedure. Do not attempt to cal i brate the
compass near l arge metal objects such as other vehi -
cl es, l arge bui l di ngs, or bri dges; or, near overhead or
underground power l i nes.
NOTE: Whenever the compass is calibrated manu-
ally, the variance number must also be reset. Refer
to Compass Variation Adjustment in this group.
Cal i brate the compass manual l y as fol l ows:
(1) Turn the i gni ti on swi tch to the On posi ti on. I f
the compass/thermometer data i s not currentl y bei ng
di spl ayed, momentari l y depress and rel ease the C/T
push button to reach the compass/thermometer di s-
pl ay.
(2) Depress the Reset push button and hol d the
button down unti l CAL appears i n the di spl ay. Thi s
takes about ten seconds, and appears about fi ve sec-
onds after VARI ANCE = XX i s di spl ayed.
(3) Rel ease the Reset push button.
(4) Dri ve the vehi cl e on a l evel surface, away from
l arge metal objects and power l i nes, through three or
more compl ete ci rcl es at between fi ve and ei ght ki l o-
meters-per-hour (three and fi ve mi l es-per-hour) i n
not l ess than 48 seconds. The CAL message wi l l
di sappear from the di spl ay to i ndi cate that the com-
pass i s now cal i brated.
NOTE: If the CAL message remains in the display,
either there is excessive magnetism near the com-
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.
DEMAGNETIZING
A degaussi ng tool (Speci al Tool 6029) i s used to
demagneti ze, or degauss, the overhead consol e for-
ward mounti ng screw and the roof panel above the
overhead consol e. Equi val ent uni ts must be rated as
Fig. 3 Base Console
8M - 2 MESSAGE SYSTEMS KJ
OVERHEAD CONSOLE (Continued)
conti nuous duty for 110/115 vol ts and 60 Hz. They
must al so have a fi el d strength of over 350 gauss at 7
mi l l i meters (0.25 i nch) beyond the ti p of the probe.
To demagneti ze the roof panel and the overhead
consol e forward mounti ng screw, proceed as fol l ows:
(1) Be certai n that the i gni ti on swi tch i s i n the Off
posi ti on, before you begi n the demagneti zi ng proce-
dure.
(2) Connect the degaussi ng tool to an el ectri cal
outl et, whi l e keepi ng the tool at l east 61 centi meters
(2 feet) away from the compass uni t.
(3) Sl owl y approach the head of the overhead con-
sol e forward mounti ng screw wi th the degaussi ng
tool connected.
(4) Contact the head of the screw wi th the pl asti c
coated ti p of the degaussi ng tool for about two sec-
onds.
(5) Wi th the degaussi ng tool sti l l energi zed, sl owl y
back i t away from the screw. When the ti p of the tool
i s at l east 61 centi meters (2 feet) from the screw
head, di sconnect the tool .
(6) Pl ace a pi ece of paper approxi matel y 22 by 28
centi meters (8.5 by 11 i nches), ori ented on the vehi cl e
l engthwi se from front to rear, on the center l i ne of
the roof at the wi ndshi el d header (Fi g. 4). The pur-
pose of the paper i s to protect the roof panel from
scratches, and to defi ne the area to be demagneti zed.
(7) Connect the degaussi ng tool to an el ectri cal
outl et, whi l e keepi ng the tool at l east 61 centi meters
(2 feet) away from the compass uni t.
(8) Sl owl y approach the center l i ne of the roof
panel at the wi ndshi el d header, wi th the degaussi ng
tool connected.
(9) Contact the roof panel wi th the pl asti c coated
ti p of the degaussi ng tool . Be sure that the templ ate
i s i n pl ace to avoi d scratchi ng the roof panel . Usi ng a
sl ow, back-and-forth sweepi ng moti on, and al l owi ng
13 mi l l i meters (0.50 i nch) between passes, move the
tool at l east 11 centi meters (4 i nches) to each si de of
the roof center l i ne, and 28 centi meters (11 i nches)
back from the wi ndshi el d header.
(10) Wi th the degaussi ng tool sti l l energi zed,
sl owl y back i t away from the roof panel . When the
ti p of the tool i s at l east 61 centi meters (2 feet) from
the roof panel , di sconnect the tool .
(11) Cal i brate the compass and adjust the compass
vari ance (Refer to 8 - ELECTRI CAL/OVERHEAD
CONSOLE - STANDARD PROCEDURE).
VARIATION ADJUSTMENT
Compass vari ance, al so known as magneti c decl i -
nati on, i s the di fference i n angl e between magneti c
north and true geographi c north. I n some geographi c
l ocati ons, the di fference between magneti c and geo-
graphi c north i s great enough to cause the compass
to gi ve fal se readi ngs. I f thi s probl em occurs, the
compass vari ance setti ng may need to be changed.
To set the compass vari ance:
(1) Usi ng the Vari ance Setti ngs map, fi nd your
geographi c l ocati on and note the zone number (Fi g.
5).
(2) Turn the i gni ti on swi tch to the On posi ti on. I f
the compass/thermometer data i s not currentl y bei ng
di spl ayed, momentari l y depress and rel ease the C/T
push button to reach the compass/thermometer di s-
pl ay.
(3) Depress the Reset push button and hol d the
button down unti l VARI ANCE = XX appears i n the
di spl ay. Thi s takes about fi ve seconds.
(4) Rel ease the Reset push button. VARI ANCE
=XX wi l l remai n i n the di spl ay. XX equal s the cur-
rent vari ance zone setti ng.
(5) Momentari l y depress and rel ease the Step push
button to step through the zone numbers, unti l the
zone number for your geographi c l ocati on appears i n
the di spl ay.
(6) Momentari l y depress and rel ease the Reset
push button to enter the di spl ayed zone number i nto
the CMTC modul e memory.
(7) Confi rm that the correct di recti ons are now
i ndi cated by the compass.
Fig. 4 Roof Demagnetizing Pattern
REMOVAL
OVERHEAD CONSOLE - REMOVAL
cabl e.
(2) Remove the overhead consol e retai ni ng screw,
l ocated i n the front of consol e near the wi ndshi el d.
(3) Usi ng your fi ngerti ps, grasp the si des of the
overhead consol e and pul l strai ght down evenl y to
di sengage the two snap cl i ps at the rear of the uni t.
(4) Lower the overhead consol e far enough to
access the wi re harness connectors.
(5) Di sconnect the control modul e, courtesy l amps
and power sunroof swi tch el ectri cal connectors, i f
equi pped.
(6) Remove the overhead consol e assembl y from
the vehi cl e.
INSTALLATION
(1) Posi ti on the overhead consol e i n the vehi cl e
and connect the wi re harness connectors.
(2) Connect the control modul e, courtesy l amps
and power sunroof swi tch el ectri cal connectors, i f
equi pped.
(3) Grasp the si des of the overhead consol e and
push strai ght up evenl y to engage the two snap cl i ps
at the rear of the uni t.
(4) I nstal l the overhead consol e retai ni ng screw,
l ocated i n the front of consol e near the wi ndshi el d.
Torque the screw to 1.2 Nm (10 i n. l bs.).
COMPASS/MINI-TRIP
COMPUTER
DESCRIPTION
The Compass Mi ni -Tri p Computer (CMTC) i s
l ocated i n the overhead consol e on model s equi pped
wi th thi s opti on. The Compass Mi ni -Tri p Computer
modul e features a l arge Vacuum Fl uorescent Di spl ay
(VFD) screen for di spl ayi ng i nformati on, and four
back-l i t push button functi on swi tches l abel ed C/T
(compass/thermometer), RESET, STEP, and US/M
(Uni ted States/Metri c Scal e).
The Compass Mi ni -Tri p Computer modul e contai ns
a central processi ng uni t and i nterfaces wi th other
el ectroni c modul es i n the vehi cl e over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus net-
work. The PCI data bus network al l ows the shari ng
of sensor i nformati on. Thi s hel ps to reduce wi re har-
ness compl exi ty, reduce i nternal control l er hardware,
and reduce component sensor current l oads. At the
same ti me, thi s system provi des i ncreased rel i abi l i ty,
enhanced di agnosti cs, and al l ows the addi ti on of
many new feature capabi l i ti es.
The Compass Mi ni -Tri p Computer modul e contai ns
si x i nformati onal di spl ays whi ch can be di spl ayed
usi ng the four outer buttons on the overhead consol e.
When the vehi cl e i s fi rst turned ON:
CMTC bl anks the di spl ay for a hal f second
Di spl ays whatever was bei ng vi ewed when the
i gni ti on was l ast turned OFF
Fig. 5 Variance Settings
The CMTC may al so be i ntegrated wi th the Uni -
versal Transmi tter. I f so, your CMTC modul e wi l l
have three buttons centered together between the
outer four buttons. Bel ow the three buttons are cor-
respondi ng dots to i ndi cate whi ch button you are
usi ng.
The Compass Mi ni -Tri p Computer i ncl udes the fol -
l owi ng di spl ay opti ons:
Compass and thermometer - provi des the out-
si de temperature and one of ei ght compass readi ngs
to i ndi cate the di recti on the vehi cl e i s faci ng.
Average fuel economy - shows the average
fuel economy si nce the l ast tri p computer reset.
Distance to empty - shows the esti mated di s-
tance that can be travel l ed wi th the fuel remai ni ng
i n the fuel tank. Thi s esti mated di stance i s computed
usi ng the average mi l es-per-gal l on from the l ast 30
gal l ons of fuel used.
Instant fuel economy - shows the present fuel
economy based upon the current vehi cl e di stance and
fuel used i nformati on.
Trip odometer - shows the di stance travel l ed
si nce the l ast tri p computer reset.
Elapsed time - shows the accumul ated i gni -
ti on-on ti me si nce the l ast tri p computer reset.
Blank screen - the CMTC compass/thermome-
ter/tri p computer VFD i s turned off.
I f the vehi cl e i s equi pped wi th the opti onal Uni ver-
sal Transmi tter transcei ver, the CMTC wi l l al so di s-
pl ay messages and an i con i ndi cati ng when the
Uni versal Transmi tter i s bei ng trai ned, whi ch of the
three transmi tter buttons i s transmi tti ng, and when
the transcei ver i s cl eared.
Data i nput for al l CMTC functi ons, i ncl udi ng VFD
di mmi ng l evel , i s recei ved through PCI data bus
messages. The CMTC modul e uses i ts i nternal pro-
grammi ng and al l of i ts data i nputs to cal cul ate and
di spl ay the requested data. I f the data di spl ayed i s
i ncorrect, perform the sel f-di agnosti c tests as
descri bed i n thi s group. I f these tests prove i nconcl u-
si ve, the use of a DRBI I I scan tool and the proper
Di agnosti c Procedures manual are recommended for
further testi ng of the CMTC modul e and the PCI
data bus.
The CMTC modul e cannot be repai red, and i s
avai l abl e for servi ce onl y as a uni t. Thi s uni t
i ncl udes the push button swi tches and the pl asti c
modul e and di spl ay l ens. I f any of these components
i s faul ty or damaged, the compl ete CMTC modul e
must be repl aced. The i ncandescent bul bs used for
CMTC push button back-l i ghti ng are avai l abl e for
servi ce repl acement.
DESCRIPTION - COMPASS
Whi l e i n the compass/thermometer mode, the com-
pass wi l l di spl ay the di recti on i n whi ch the vehi cl e i s
poi nted usi ng the ei ght major compass headi ngs
(Exampl es: north i s N, northeast i s NE). The sel f-cal -
i brati ng compass uni t requi res no adjusti ng i n nor-
mal use. The onl y cal i brati on that may prove
necessary i s to dri ve the vehi cl e i n three compl ete
ci rcl es at 5 to 8 ki l ometers-per-hour (3 to 5 mi l es-per-
hour), on l evel ground, i n not l ess than forty-ei ght
seconds. Thi s wi l l reori ent the compass uni t to i ts
vehi cl e.
The compass uni t al so wi l l compensate for magne-
ti sm the body of the vehi cl e may acqui re duri ng nor-
mal use. However, avoi d pl aci ng anythi ng magneti c
di rectl y on the roof of the vehi cl e. Magneti c mounts
for an antenna, a repai r order hat, or a funeral pro-
cessi on fl ag can exceed the compensati ng abi l i ty of
the compass uni t i f pl aced on the roof panel . Mag-
neti c bi t dri vers used on the fasteners that hol d the
overhead consol e assembl y to the roof header can
al so affect compass operati on. I f the vehi cl e roof
shoul d become magneti zed, the demagneti zi ng and
cal i brati on procedures found i n thi s group may be
requi red to restore proper compass operati on.
DESCRIPTION - THERMOMETER
The thermometer di spl ays the outsi de ambi ent
temperature i n whol e degrees. The temperature di s-
pl ay can be toggl ed from Fahrenhei t to Cel si us by
usi ng the U.S./Metri c button. The di spl ayed temper-
ature i s not an i nstant readi ng of condi ti ons, but an
average temperature. I t may take the thermometer
di spl ay several mi nutes to respond to a major tem-
perature change, such as dri vi ng out of a heated
garage i nto wi nter temperatures.
When the i gni ti on swi tch i s turned to the Off posi -
ti on, the l ast di spl ayed temperature readi ng stays i n
the Body Control Modul e (BCM) uni t memory. When
the i gni ti on swi tch i s turned to the On posi ti on
agai n, the CMTC wi l l di spl ay the memory tempera-
ture for one mi nute; then update the di spl ay to the
current average temperature readi ng wi thi n fi ve
mi nutes.
The thermometer functi on i s supported by an
ambi ent temperature sensor. The sensor i s mounted
outsi de the passenger compartment near the front
and center of the vehi cl e, and i s hard wi red to the
Body Control Modul e (BCM). The BCM sends tem-
perature status messages to the CMTC modul e over
the PCI data bus network. The ambi ent temperature
sensor i s avai l abl e as a separate servi ce i tem, refer to
addi ti onal i nformati on l ater i n thi s secti on.
OPERATION
The compass mi ni -tri p computer operates when the
i gni ti on i s i n the ON posi ti on. The VFD wi l l di spl ay
the l ast di spl ay before i gni ti on was turned OFF. The
four outer buttons operate:
COMPASS/MINI-TRIP COMPUTER (Continued)
STEP
C/T - Compass/Temperature
US/M - Engl i sh/Metri c
RESET
1. STEP BUTTON
Pressi ng the STEP button sel ects one of the fol l ow-
i ng 6 di spl ays:
Average fuel economy
Di stance to empty
I nstantaneous fuel economy
Tri p odometer
El apsed ti me
Bl ank Screen
2. C/T (COMPASS/TEMPERATURE)
BUTTON
Pressi ng the C/T button sel ects the Compass/Tem-
perature di spl ay.
3. US/M (ENGLISH/METRIC
MEASUREMENT) BUTTON
Pressi ng the US/M button swi tches the di spl ay
uni ts between Engl i sh and Metri c readi ngs.
4. RESET BUTTON
Pressi ng the RESET button resets the functi on on
the di spl ay, provi ded that functi on can be reset. The
functi ons whi ch can be reset are Average fuel econ-
omy, Tri p odometer and El apsed ti me.
Global Reset Thi s feature al l ows al l three di s-
pl ays (Average fuel economy, Tri p odometer and
El apsed ti me) to be reset easi l y, by pressi ng the
RESET button twi ce wi thi n three seconds wi th any
of the screens i n di spl ay. Thi s el i mi nates the need to
reset each di spl ay i ndi vi dual l y.
The RESET button i s al so used to set the vari ance
and/or cal i brate the compass. Refer to the Vari ance
Procedure and Cal i brati on Procedure i n thi s secti on.
For more i nformati on on the features, control func-
ti ons and setti ng procedures for the CMTC modul e,
see the owners manual i n the vehi cl e gl ove box.
DIAGNOSIS AND TESTING - COMPASS
MINI-TRIP COMPUTER
The fol l owi ng di agnosti c procedure can be used i f
the compass mi ni -tri p computer i s not operati onal i n
any way. I f the probl em i s speci fi c to a i ndi vi dual
CMTC di spl ay, go to the appropri ate di spl ay ti tl e
noted bel ow and di agnose usi ng the i nformati on pro-
vi ded on how these di spl ays are generated.
SOLE - REMOVAL).
(2) Usi ng a ohmmeter, check the ground ci rcui t
cavi ty of the compass mi ni -tri p computer el ectri cal
connector for proper conti nui ty to ground. Conti nui ty
shoul d be present, I f OK go to Step 3, I f not OK
repai r the open or shorted ground ci rcui t as requi red.
NOTE: Connect the negative battery cable before
proceeding.
(3) Usi ng a vol tmeter, check the fused (B+) ci rcui t
cavi ty of the compass mi ni -tri p computer el ectri cal
connector for 12v. Vol tage shoul d be present, I f OK go
to Step 4, I f not OK repai r the open or shorted fused
(B+) ci rcui t as requi red.
(4) Usi ng a vol tmeter, check the fused i gni ti on
swi tch output ci rcui t cavi ty of the compass mi ni -tri p
computer el ectri cal connector for 12v wi th Key ON.
Vol tage shoul d be present, I f OK, repl ace the i noper-
ati ve CMTC modul e, I f not OK repai r the open or
shorted fused i gni ti on swi tch output ci rcui t as
requi red.
TEMPERATURE
The compass mi ni -tri p computer recei ves Program-
mabl e Communi cati ons I nterface bus (PCI bus) mes-
sages from the Body Control Modul e (BCM) for al l
di spl ayed i nformati on except the compass di spl ay. I f
a dash (-) i s di spl ayed, the compass mi ni -tri p com-
puter i s not recei vi ng a PCI bus message from the
BCM. To check out the PCI bus l i ne and the BCM,
use the DRB l l l scan tool and proper Body Di agnos-
ti c Procedure Manual .
I f the compass mi ni -tri p computer di spl ays a tem-
perature more than 54 C (130 F), check for a short
ci rcui t between the temperature sensor and the
BCM.
I f the compass mi ni -tri p computer di spl ays a tem-
perature l ess than -40 C (-67 F), check for an open
ci rcui t between the temperature sensor and the
BCM.
AVERAGE FUEL ECONOMY
The compass mi ni -tri p computer recei ves average
fuel economy i nformati on from the BCM over the PCI
bus l i ne. I f the compass mi ni -tri p computer di spl ays
-.- i nstead of an average fuel economy val ue, i t i s not
recei vi ng a PCI bus message for the average fuel
economy from the BCM. To check out the PCI bus
l i ne and the BCM use the DRB l l l scan tool and
proper Body Di agnosti c Procedure Manual .
DISTANCE TO EMPTY
The compass mi ni -tri p computer recei ves di stance
to empty i nformati on from the BCM over the PCI bus
l i ne. I f compass mi ni -tri p computer di spl ays a dash
(-) i nstead of a di stance to empty val ue, i t i s not
recei vi ng a PCI bus message for the di stance to
empty from the BCM. To check out the PCI bus l i ne
and the BCM use the DRB l l l scan tool and proper
Body Di agnosti c Procedure Manual .
INSTANTANEOUS FUEL ECONOMY
The compass mi ni -tri p computer recei ves i nstanta-
neous fuel economy i nformati on from the BCM over
the PCI bus l i ne. I f compass mi ni -tri p computer di s-
pl ays a dash (-) i nstead of an i nstantaneous fuel
economy val ue, i t i s not recei vi ng a PCI bus message
for the i nstantaneous fuel economy from the BCM. To
check out the PCI bus l i ne and the BCM use the
DRB l l l scan tool and proper Body Di agnosti c Pro-
cedure Manual .
TRIP ODOMETER
The compass mi ni -tri p computer recei ves tri p
odometer i nformati on from the Cl uster over the PCI
bus l i ne. I f compass mi ni -tri p computer di spl ays
dashes - - i nstead of the tri p odometer val ue, i t i s not
recei vi ng a PCI bus message for the tri p odometer
from the cl uster. To check out the PCI bus l i ne and
the Cl uster, use the DRB l l l scan tool and proper
Body Di agnosti c Procedure Manual .
ELAPSED TIME
The compass mi ni -tri p computer recei ves a PCI
bus message contai ni ng el apsed ti me i nformati on. I f
compass mi ni -tri p computer di spl ays dashes --
i nstead of the el apsed ti me, i t i s not recei vi ng a PCI
bus message for the el apsed ti me from the BCM. To
check out the PCI bus l i ne and the BCM, use the
DRB l l l scan tool and proper Body Di agnosti c Pro-
cedure Manual .
COMPASS DISPLAY
To di spl ay the vehi cl e di recti on, the compass mi ni -
tri p computer processes i nformati on from a sensor
i nternal to the modul e. The compass mi ni -tri p com-
puter i s sel f- cal i brati ng and requi res onl y vari ance
adjustments dependent upon l ocati on. The compass
mi ni -tri p computer di spl ays the l abel CAL whenever
the compass i s i n the fast cal i brati on mode.
I f al l three of the fol l owi ng condi ti ons l i sted bel ow
occur, the vehi cl e must be demagneti zed.
Compass porti on of the di spl ay i s bl ank
Temperature porti on of the di spl ay i s OK
The l abel CAL i s i l l umi nated
I f demagneti zi ng the vehi cl e i s needed, refer to the
demagneti zi ng procedure i n thi s secti on. After
demagneti zi ng, to cal i brate the compass refer to Cal -
i brati on Procedure and to set the vari ance refer to
Vari ance Procedure, both wi thi n thi s secti on. I f the
compass porti on of the di spl ay i s sti l l bl ank, repl ace
the compass mi ni -tri p computer.
COMPASS MINI-TRIP COMPUTER - SELF
DIAGNOSTIC TEST
(1) Wi th the i gni ti on swi tch i n the OFF posi ti on
si mul taneousl y press the C/T and STEP buttons and
hol d.
(2) Turn the i gni ti on swi tch ON, then rel ease C/T
and STEP buttons.
(3) The Compass mi ni -tri p computer shoul d l i ght
al l segments on the VF Di spl ay Screen for 2-4 sec-
onds. Check for segments that are not i l l umi nated.
(4) I f the compass mi ni -tri p computer di spl ays
PASS, the modul e i s OK.
FAI L, repl ace the modul e.
bUS, check for an open or a short on the PCI bus
communi cati on ci rcui t.
(7) Press the C/T or the STEP button to exi t the
sel f-di agnosti c test.
REMOVAL
(1) Remove overhead consol e, refer to Consol e
Removal and I nstal l ati on i n thi s secti on.
(2) Remove mounti ng screws and rel ease the map
l amp wi re connector from the compass mi ni -tri p com-
puter. (Fi g. 6).
Fig. 6 Compass Mini-Trip Computer Retaining
Screws
1 - LAMPS
2 - MOUNTING SCREWS
(3) Remove the compass mi ni -tri p computer from
the overhead consol e.
INSTALLATION
(1) I nstal l the compass mi ni -tri p computer i n the
overhead consol e. Al i gn the compass mi ni -tri p com-
puter gui des on the housi ng wi th the grooves of the
consol e.
(2) I nstal l the mounti ng screws and i nstal l the
map l amp wi re connector on the compass mi ni -tri p
computer. Make sure the LOOP of wi re that was
cl i pped i nto the compass mi ni -tri p computer modul e
housi ng i s properl y cl i pped i nto the new modul e
before the consol e i s pl aced back i nto the headl i ner.
(3) I nstal l the overhead consol e, refer to Consol e
I nstal l ati on i n thi s secti on.
UNIVERSAL TRANSMITTER
DESCRIPTION
On some KJ model s a Uni versal Transmi tter trans-
cei ver i s standard factory-i nstal l ed equi pment. The
uni versal transmi tter transcei ver i s i ntegral to the
Compass Mi ni -Tri p Computer (CMTC), whi ch i s
l ocated i n the overhead consol e. The onl y vi si bl e com-
ponent of the uni versal transmi tter are the three
transmi tter push buttons (Fi g. 7) centered between
the four CMTC push buttons l ocated just rearward of
the CMTC di spl ay screen i n the overhead consol e.
The three uni versal transmi tter push buttons are
i denti fi ed wi th one, two or three l i ght i ndi cators so
that they be easi l y i denti fi ed by si ght or by feel .
Each of the three uni versal transmi tter push but-
tons control s an i ndependent radi o transmi tter chan-
nel . Each of these three channel s can be trai ned to
transmi t a di fferent radi o frequency si gnal for the
remote operati on of garage door openers, motori zed
gate openers, home or offi ce l i ghti ng, securi ty sys-
tems or just about any other devi ce that can be
equi pped wi th a radi o recei ver i n the 286 to 399
MegaHertz (MHz) frequency range for remote opera-
ti on. The uni versal transmi tter i s capabl e of operat-
i ng systems usi ng ei ther rol l i ng code or non-rol l i ng
code technol ogy.
The CMTC modul e di spl ays messages and a smal l
house-shaped i con wi th one, two or three dots corre-
spondi ng to the three transmi tter buttons to i ndi cate
the status of the Uni versal Transmi tter.
The Uni versal Transmi tter cannot be repai red, and
i s avai l abl e for servi ce onl y as a uni t wi th the CMTC
modul e. Thi s uni t i ncl udes the push button swi tches
and the pl asti c modul e and di spl ay l ens. I f any of
these components i s faul ty or damaged, the compl ete
CMTC modul e must be repl aced.
OPERATION
The uni versal transmi tter operates on a non-
swi tched source of battery current so the uni t wi l l
remai n functi onal , regardl ess of the i gni ti on swi tch
posi ti on. For more i nformati on on the features, pro-
grammi ng procedures and operati on of the uni versal
transmi tter, see the owners manual i n the vehi cl e
gl ove box.
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER
I f the Uni versal Transmi tter i s i noperati ve, but the
Compass Mi ni -Tri p Computer (CMTC) i s operati ng
normal l y, see the owners manual i n the vehi cl e gl ove
box for i nstructi ons on trai ni ng the uni versal trans-
mi tter. Retrai n the uni versal transmi tter wi th a
known good transmi tter as i nstructed i n the owners
manual and test the uni versal transmi tter operati on
agai n. I f the uni t i s sti l l i noperati ve, repl ace the
faul ty uni versal transmi tter and CMTC modul e as a
uni t. I f both the uni versal transmi tter and the CMTC
modul e are i noperati ve, refer to Diagnosis and
Testing the Compass Mini-Trip Computer i n thi s
secti on for further di agnosi s. For compl ete ci rcui t
di agrams, refer to Overhead Console i n Wi ri ng
Di agrams.
STANDARD PROCEDURE
STANDARD PROCEDURE - ERASING
TRANSMITTER CODES
To erase the uni versal transmi tter codes, si mpl y
hol d down buttons 1 and 3 unti l the two green dots
bel ow the house symbol begi n to fl ash.
Fig. 7 Overhead Console With Universal Transmitter
NOTE: Individual channels cannot be erased. Eras-
ing the transmitter codes will erase ALL pro-
grammed codes.
STANDARD PROCEDURE - SETTING
TRANSMITTER CODES
(1) Turn off the engi ne.
(2) Erase the factory test codes by pressi ng but-
tons 1 and 3. Rel ease the buttons when the two
green l i ghts begi n to fl ash (about 20 seconds).
(3) Choose one of the three buttons to trai n. Pl ace
the hand-hel d transmi tter wi thi n one i nch of the uni -
versal transmi tter and push the buttons on both
transmi tters. The green dot bel ow the house symbol
wi l l begi n to fl ash sl owl y.
(4) When the red l i ght on the uni versal transmi t-
ter begi ns to fl ash rapi dl y (thi s may take as l ong as
60 seconds), rel ease both buttons. Your uni versal
transmi tter i s now trai ned. To trai n the other but-
tons, repeat Step 3 and Step 4. Be sure to keep your
hand-hel d transmi tter i n case you need to retrai n the
uni versal transmi tter.
AMBIENT TEMP SENSOR
DESCRIPTION
Ambi ent ai r temperature i s moni tored by the Com-
pass Mi ni -Tri p Computer (CMTC) through ambi ent
temperature sensor messages recei ved from the Body
Control Modul e (BCM) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus network. The
BCM recei ves a hard wi red i nput from the ambi ent
temperature sensor. The ambi ent temperature sensor
(Fi g. 8) i s a vari abl e resi stor mounted i n front the
radi ator, behi nd the gri l l e, near the center of the
vehi cl e.
Refer to Body Control Module i n El ectroni c Con-
trol Modul es. For compl ete ci rcui t di agrams, refer to
the appropri ate wi ri ng i nformati on. The ambi ent
temperature sensor cannot be adjusted or repai red
OPERATION
The ambi ent temperature sensor i s a vari abl e
resi stor that operates on a fi ve-vol t reference si gnal
sent to i t by the BCM. The resi stance i n the sensor
changes as temperature changes, changi ng the tem-
perature sensor si gnal ci rcui t vol tage to the BCM.
Based upon the resi stance i n the sensor, the BCM
senses a speci fi c vol tage on the temperature sensor
si gnal ci rcui t, whi ch i t i s programmed to correspond
to a speci fi c temperature. The BCM then sends the
proper ambi ent temperature messages to the CMTC
over the PCI data bus.
The thermometer functi on i s supported by the
ambi ent temperature sensor, a wi ri ng ci rcui t, the
Body Control Modul e (BCM), the Programmabl e
Communi cati ons I nterface (PCI ) data bus, and a por-
ti on of the Compass Mi ni -Tri p Computer modul e.
The ambi ent temperature sensor ci rcui t can al so be
di agnosed by referri ng to Diagnosis and Testing -
Ambient Temperature Sensor, and Diagnosis
and Testing - Ambient Temperature Sensor Cir-
cuit. I f the temperature sensor and ci rcui t are con-
fi rmed to be OK, but the temperature di spl ay i s
i noperati ve or i ncorrect, refer to Diagnosis and
Testing - Compass Mini-Trip Computer i n thi s
secti on. For compl ete ci rcui t di agrams, refer to the
appropri ate wi ri ng i nformati on.
TEMPERATURE SENSOR
Di sconnect the ambi ent temperature sensor wi re har-
ness connector.
(2) Measure the resi stance of the ambi ent temper-
ature sensor. At 40 C (40 F), the sensor resi s-
tance i s 336 ki l ohms. At 55 C (140 F), the sensor
resi stance i s 2.488 ki l ohms. The sensor resi stance
shoul d read between these two val ues. I f OK, refer to
Diagnosis and Testing - Ambient Temperature
Sensor Circuit i n thi s group. I f not OK, repl ace the
faul ty ambi ent temperature sensor.
TEMPERATURE SENSOR CIRCUIT
Di sconnect the ambi ent temperature sensor wi re har-
ness connector and the Body Control Modul e wi re
harness connector.
(2) Connect a jumper wi re between the two termi -
nal s i n the body hal f of the ambi ent temperature sen-
sor wi re harness connector.
Fig. 8 Ambient Temperature Sensor
UNIVERSAL TRANSMITTER (Continued)
(3) Check for conti nui ty between the sensor return
ci rcui t and the ambi ent temperature sensor si gnal
ci rcui t cavi ti es of the BCM wi re harness connector.
OK, repai r the open sensor return ci rcui t or ambi ent
temperature sensor si gnal ci rcui t to the ambi ent tem-
perature sensor as requi red.
(4) Remove the jumper wi re from the body hal f of
the ambi ent temperature sensor wi re harness con-
nector. Check for conti nui ty between the sensor
return ci rcui t cavi ty of the BCM wi re harness con-
nector and a good ground. There shoul d be no conti -
nui ty. I f OK, go to Step 5. I f not OK, repai r the
shorted sensor return ci rcui t as requi red.
(5) Check for conti nui ty between the ambi ent tem-
perature sensor si gnal ci rcui t cavi ty of the BCM wi re
harness connector and a good ground. There shoul d
be no conti nui ty. I f OK, refer to Diagnosis and
Testing - Compass Mini-Trip Computer i n thi s
group. I f not OK, repai r the shorted ambi ent temper-
ature sensor si gnal ci rcui t as requi red.
REMOVAL
battery cabl e.
(2) Remove the gri l l e from the vehi cl e (Refer to 23
- BODY/EXTERI OR/GRI LLE - REMOVAL).
(3) Di sconnect the ambi ent temperature sensor
el ectri cal connector.
(4) Remove the ambi ent temperature sensor
retai ni ng screw and remove the sensor from the vehi -
cl e.
INSTALLATION
(1) Posi ti on the ambi ent temperature sensor and
i nstal l the retai ni ng screw.
(2) Connect the ambi ent temperature sensor el ec-
tri cal connector.
(3) I nstal l the gri l l e on the vehi cl e (Refer to 23 -
BODY/EXTERI OR/GRI LLE - I NSTALLATI ON).
AMBIENT TEMP SENSOR (Continued)
POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . 11
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
POWER WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . 21
POWER LOCKS
TABLE OF CONTENTS
page page
POWER LOCKS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - POWER LOCKS . . 3
DOOR LOCK / UNLOCK SWITCH
DIAGNOSIS AND TESTING - DOOR LOCK/
UNLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DOOR LOCK MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - DOOR LOCK
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLIP-UP GLASS RELEASE SWITCH
DIAGNOSIS AND TESTING - FLIP-UP GLASS
RELEASE SWITCH . . . . . . . . . . . . . . . . . . . . . 5
DOOR LOCK RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOTE KEYLESS ENTRY MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
KEYLESS ENTRY MODULE . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOTE KEYLESS ENTRY TRANSMITTER
KEYLESS ENTRY TRANSMITTER . . . . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - RKE
TRANSMITTER BATTERIES . . . . . . . . . . . . . . 8
TRANSMITTER CUSTOMER
PREFERENCES . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSMITTER PROGRAMING . . . . . . . . . . . . 9
SPECIFICATIONS - REMOTE KEYLESS
ENTRY TRANSMITTER . . . . . . . . . . . . . . . . . . 9
TAILGATE CYLINDER LOCK SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - TAILGATE
CYLINDER LOCK SWITCH . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
POWER LOCKS
DESCRIPTION
POWER LOCKS
A power operated door and tai l gate l ock system i s
avai l abl e factory-i nstal l ed equi pment on thi s model .
The power l ock system al l ows al l of the doors and the
tai l gate to be l ocked or unl ocked el ectri cal l y by oper-
ati ng a swi tch on ei ther front door tri m panel . The
power l ock system recei ves non-swi tched battery cur-
rent through a fuse i n the Juncti on Bl ock (JB), so
that the power l ocks remai n operati onal , regardl ess
of the i gni ti on swi tch posi ti on.
The Body Control Modul e (BCM) l ocks the doors
and tai l gate automati cal l y when the vehi cl e i s dri ven
beyond the speed of 25.7 Km/h (15 mph), al l doors
KJ POWER SYSTEMS 8N - 1
are cl osed and the accel erator pedal i s depressed.
The rol l i ng door l ock feature can be di sabl ed i f
desi red.
Thi s vehi cl e al so offers several customer program-
mabl e features, whi ch al l ows the sel ecti on of several
opti onal el ectroni c features to sui t i ndi vi dual prefer-
ences.
The power l ock system for thi s vehi cl e can al so be
operated remotel y usi ng the avai l abl e Remote Key-
l ess Entry (RKE) system radi o frequency transmi t-
ters, i f equi pped.
Certai n functi ons and features of the power l ock
system rel y upon resources shared wi th other el ec-
troni c modul es i n the vehi cl e over the Programmabl e
Communi cati ons I nterface (PCI ) data bus network.
For proper di agnosi s of these el ectroni c modul es or of
the PCI data bus network, the use of a DRBI I I scan
tool and the appropri ate di agnosti c i nformati on are
requi red.
A Radi o Frequency (RF) type Remote Keyl ess
Entry (RKE) system i s an avai l abl e factory-i nstal l ed
opti on on thi s model . The RKE system al l ows the use
of a remote battery-powered radi o transmi tter to si g-
nal the Body Control Modul e (BCM) to actuate the
power l ock system. The RKE recei ver operates on
non-swi tched battery current through a fuse i n the
Juncti on Bl ock (JB), so that the system remai ns
operati onal , regardl ess of the i gni ti on swi tch posi ti on.
The RKE transmi tters are al so equi pped wi th a
Pani c button. I f the Pani c button on the RKE trans-
mi tter i s depressed, the horn wi l l sound and the
exteri or l i ghts wi l l fl ash on the vehi cl e for about
three mi nutes, or unti l the Pani c button i s depressed
a second ti me. A vehi cl e speed of about 25.7 ki l ome-
ters-per-hour (15 mi l es-per-hour) wi l l al so cancel the
pani c event.
The RKE system can al so perform other functi ons
on thi s vehi cl e. I f the vehi cl e i s equi pped wi th the
opti onal Vehi cl e Theft Securi ty System (VTSS), the
RKE transmi tter wi l l arm the VTSS when the Lock
button i s depressed, and di sarm the VTSS when the
Unl ock button i s depressed.
The RKE system i ncl udes two transmi tters when
the vehi cl e i s shi pped from the factory, but the sys-
tem can retai n the vehi cl e access codes of up to four
transmi tters. The transmi tter codes are retai ned i n
the RKE recei ver memory, even i f the battery i s di s-
connected. I f an RKE transmi tter i s faul ty or l ost,
new transmi tter vehi cl e access codes can be pro-
grammed i nto the system usi ng a DRBI I I scan tool .
Thi s vehi cl e al so offers several customer program-
mabl e features, whi ch al l ows the sel ecti on of several
opti onal el ectroni c features to sui t i ndi vi dual prefer-
ences. Customer programmabl e feature opti ons
affecti ng the RKE system i ncl ude:
Remote Unlock Sequence - Al l ows the opti on
of havi ng onl y the dri ver si de front door unl ock when
the RKE transmi tter Unl ock button i s depressed the
fi rst ti me. The remai ni ng doors and the tai l gate
unl ock when the button i s depressed a second ti me
wi thi n 5 seconds of the fi rst unl ock press. Another
opti on i s havi ng al l doors and the tai l gate unl ock
upon the fi rst depressi on of the RKE transmi tter
Unl ock button.
Sound Horn on Lock - Al l ows the opti on of
havi ng the horn sound a short chi rp as an audi bl e
veri fi cati on that the RKE system recei ved a val i d
Lock request from the RKE transmi tter, or havi ng no
audi bl e veri fi cati on.
Flash Lights with Lock and Unlock - Al l ows
the opti on of havi ng the l i ghts fl ash as an opti cal ver-
i fi cati on that the RKE system recei ved a val i d Lock
request or Unl ock request from the RKE transmi tter,
or havi ng no opti cal veri fi cati on.
Programming Additional Transmitters -
Al l ows up to four transmi tter vehi cl e access codes to
be stored i n the recei ver memory.
Certai n functi ons and features of the RKE system
rel y upon resources shared wi th other el ectroni c
modul es i n the vehi cl e over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus network. The
PCI data bus network al l ows the shari ng of sensor
i nformati on. Thi s hel ps to reduce wi re harness com-
pl exi ty, i nternal control l er hardware, and component
sensor current l oads. For di agnosi s of these el ectroni c
modul es or of the PCI data bus network, the use of a
DRBI I I scan tool and the appropri ate di agnosti c
i nformati on are requi red.
TAILGATE / FLIP-UP GLASS POWER RELEASE
SYSTEM
A power operated tai l gate / fl i p-up gl ass rel ease
system i s standard factory i nstal l ed equi pment on
thi s model . The enti re system i s control l ed by the
Body Control Modul e (BCM). The tai l gate / fl i p-up
gl ass power rel ease system al l ows the fl i p-up gl ass
l atch to be rel eased el ectri cal l y by actuati ng a swi tch
l ocated i ntegral to the outsi de tai l gate handl e. By
pul l i ng the handl e to the fi rst detent or turni ng the
key cyl i nder to unl ock, the fl i p-up gl ass wi l l open.
Pul l i ng the handl e to the second detent wi l l al l ow the
tai l gate to open.
The tai l gate /fl i p-up gl ass rel ease system operates
on non-swi tched battery current suppl i ed through a
fuse i n the juncti on bl ock so that the system remai ns
functi onal , regardl ess of the i gni ti on swi tch posi ti on.
However, the BCM prevents the fl i p-up gl ass l atch
from bei ng actuated when the tai l gate l atch i s
l ocked.
8N - 2 POWER LOCKS KJ
POWER LOCKS (Continued)
The tai l gate wi l l l ock and can not be unl ocked i f
the rear wi per swi tch i s acti vated. The tai l gate wi l l
al so l ock i f battery power i s l ost and then restored.
The tai l gate/fl i p-up gl ass wi l l not functi on wi th the
battery di scharged or di sconnected.
COMBINATION FLASHER
Thi s fl asher can be energi zed by the BCM to fl ash
al l of the park/turn si gnal l amps as a opti cal al ert for
the RKE pani c functi on and, i f the Fl ash Li ghts wi th
Lock programmabl e feature i s enabl ed, as an opti cal
veri fi cati on for the RKE l ock event.
HORN RELAY
Thi s rel ay can be energi zed by the BCM to sound
the horns as an audi bl e al ert for the RKE pani c func-
ti on and, i f the Sound Horn on Lock programmabl e
feature i s enabl ed, as an audi bl e veri fi cati on for the
RKE l ock event.
LOW BEAM HEADLAMP RELAY
Thi s rel ay can be energi zed by the BCM to fl ash
the headl amp l ow beams as an opti cal al ert for the
RKE pani c functi on.
OPERATION
POWER LOCKS
The Body Control Modul e (BCM) l ocks or unl ocks
the doors when an actuati on i nput si gnal from a door
l ock swi tch or Remote Keyl ess Entry Modul e (RKE)
i s recei ved. The BCM turns on the output dri vers
and provi des a vol tage l evel to the door l ock motor
for a speci fi ed ti me. Al l passenger doors can be
l ocked or unl ocked usi ng a mechani cal button
mounted on the door tri m panel . The front passenger
doors and tai l gate can be l ocked or unl ocked by usi ng
the key cyl i nder (tai l gate cyl i nder does not l ock/un-
l ock vehi cl e. I t onl y unl ocks the tai l gate). The tai l -
gate wi l l l ock and can not be unl ocked i f the rear
wi per swi tch i s acti vated (thi s prevents the wi per
from operati ng when the tai l gate i s ajar). The tai l -
gate wi l l al so l ock i f battery power i s l ost and then
restored.
AUTOMATIC DOOR LOCKS
When the automati c door l ocks are ENABLED the
door l ocks wi l l l ock when the vehi cl e i s movi ng at
about 25.7 Km/h (15 mph), al l doors are cl osed and
the accel erator pedal i s depressed. Thi s feature can
be swi tched ON or OFF as desi red. When the system
i s DI SABLED the door l ocks wi l l operate normal l y,
but wi l l not l ock automati cal l y when the vehi cl e i s
rol l i ng. Once the automati c door l ocks have been
actuated, they wi l l not try to l ock the doors agai n
unti l a door i s opened.
DOOR LOCK INHIBIT
I f the key i s i n the i gni ti on, i n any posi ti on, and
ei ther front door i s ajar, the doors can not be l ocked,
but the unl ock functi on sti l l operates. Pressi ng the
RKE l ock/unl ock button under these condi ti ons wi l l
resul t i n a normal l ock/unl ock acti vati on.
After the key i s removed from the I gni ti on Swi tch,
or the doors are cl osed, the power door l ocks wi l l
operate normal l y.
DOOR LOCK CIRCUIT PROTECTION
The BCM control s the door l ock rel ays. I f the door
l ock swi tch i s actuated conti nuousl y for more than
fi ve seconds the BCM wi l l turn the output dri ver
OFF (the BCM woul d consi der the swi tch stuck).
Each l ock motor i s protected wi th a Posi ti ve Temper-
ature Coeffi ci ent devi ce that prevents motor burn
out.
LOCK: Pressi ng the LOCK button l ocks al l
doors, sounds horn (chi rp) i f enabl ed, and arms the
Vehi cl e Theft Securi ty System, i f enabl ed. The chi rp
veri fi es that the RKE recei ver has sent a message to
the BCM for door l ock operati on. I f a door has not
been cl osed before pressi ng the LOCK button, the
vehi cl e may not be secured and the VTSS (i f
equi pped) wi l l not arm unti l the door i s cl osed.
UNLOCK: Pressi ng the UNLOCK button once
wi l l unl ock the dri vers door and acti vate the i l l umi -
nated entry system and di sarm Vehi cl e Theft Secu-
ri ty System, i f equi pped. Pressi ng the UNLOCK
button twi ce wi thi n fi ve seconds wi l l unl ock al l doors.
TAILGATE: Pressi ng the TAI LGATE BUTTON
unl ocks the tai l gate remotel y and opens the fl i p-up
gl ass.
PANIC: Pressi ng the PANI C button sounds the
horns at hal f second i nterval s, fl ashes the exteri or
l amps, and turns ON the i nteri or l amps. The pani c
al arm wi l l remai n on for three mi nutes, or unti l the
PANI C button i s actuated agai n or the i gni ti on
swi tch i s turned to the RUN posi ti on.
The Remote Keyl ess Entry Modul e i s capabl e of
retai ni ng the transmi tter Vehi cl e Access Code(s) i n
i ts memory even after vehi cl e power has been i nter-
rupted.
DIAGNOSIS AND TESTING - POWER LOCKS
The Body Control Module (BCM) enters a
reduced power mode after the key is turned
OFF. All diagnosis and testing of the power lock
system must be done with the key in the ON
position unless otherwise stated.
The most reliable, efficient, and accurate
means to diagnose the power lock system
requires the use of a DRBIII scan tool and the
KJ POWER LOCKS 8N - 3
proper Diagnostic Procedures manual. The
DRBIII scan tool can provide confirmation
that the PCI data bus is functional, that all of
the electronic modules are sending and receiv-
ing the proper messages on the PCI data bus,
and that the power lock motors are being sent
the proper hard wired outputs by the relays for
them to perform their power lock system func-
tions.
Fol l owi ng are tests that wi l l hel p to di agnose the
hard wi red components and ci rcui ts of the power l ock
system. However, these tests may not prove concl u-
si ve i n the di agnosi s of thi s system. I n order to
obtai n concl usi ve testi ng of the power l ock system,
the Programmabl e Communi cati ons I nterface (PCI )
data bus network and al l of the el ectroni c modul es
that provi de i nputs to, or recei ve outputs from the
power l ock system components must be checked.
The Body Control Modul e (BCM) wi l l set Di agnos-
ti c Troubl e Codes (DTC) for the power l ock system.
PRELIMINARY DIAGNOSIS
As a prel i mi nary di agnosi s for the power l ock sys-
tem, note the system operati on whi l e you actuate
both the Lock and Unl ock functi ons wi th the power
l ock swi tches and wi th the Remote Keyl ess Entry
(RKE) transmi tter. Then, proceed as fol l ows:
I f the enti re power l ock system fai l s to functi on
wi th ei ther the power l ock swi tches or the RKE
transmi tter, check the fused B(+) fuse i n the juncti on
Bl ock (JB).
I f the power l ock system functi ons wi th both
power l ock swi tches, but not wi th the RKE transmi t-
ter, proceed to di agnosi s of the Remote Keyl ess Entry
(RKE) system. (Refer to 8 - ELECTRI CAL/POWER
LOCKS/KEYLESS ENTRY TRANSMI TTER - DI AG-
NOSI S AND TESTI NG) or (Refer to 8 - ELECTRI -
CAL/POWER LOCKS/REMOTE KEYLESS ENTRY
MODULE - DI AGNOSI S AND TESTI NG).
I f the power l ock system functi ons wi th the RKE
transmi tter, but not wi th one or both power l ock
swi tches, proceed to di agnosi s of the door l ock
swi tches. (Refer to 8 - ELECTRI CAL/POWER
LOCKS/POWER LOCK SWI TCH - DI AGNOSI S AND
TESTI NG).
I f the dri ver si de power l ock swi tch operates
onl y the dri ver si de front door power l ock motor, but
al l other power l ock motors operate wi th the passen-
ger si de power l ock swi tch or the RKE transmi tter,
use a DRBI I I scan tool and the appropri ate di agnos-
ti c i nformati on to di agnose the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus.
I f onl y one power l ock motor fai l s to operate
wi th both power l ock swi tches and the RKE trans-
mi tter, proceed to di agnosi s of the power l ock motor.
(Refer to 8 - ELECTRI CAL/POWER LOCKS/POWER
LOCK MOTOR - DI AGNOSI S AND TESTI NG).
DOOR LOCK / UNLOCK
SWITCH
DIAGNOSIS AND TESTING - DOOR LOCK/
UNLOCK SWITCH
(1) Remove the swi tch to be tested (Refer to 8 -
ELECTRI CAL/POWER LOCKS/POWER LOCK
SWI TCH - REMOVAL).
(2) Usi ng an ohmmeter, Test swi tch for resi stance
val ues (Fi g. 1).
DOOR LOCK SWITCH TEST
SWITCH
POSITION
PINS RESISTANCE
VALUE
UNACTUATED 1 AND 4 5.0K OHM 10
%
LOCK 1 AND 4 1.4K OHM 10
%
UNLOCK 1 AND 4 426 OHM 10
%
(3) I f test resul ts are not obtai ned as shown i n the
test tabl e, repl ace the swi tch.
REMOVAL
cabl e.
Fig. 1 DOOR LOCK/UNLOCK SWITCH
(2) Remove the door tri m panel (Fi g. 2) (Refer to
23 - BODY/DOOR - FRONT/TRI M PANEL - REMOV-
AL).
(3) Di sconnect el ectri cal harness connector from
swi tch.
(4) From behi nd the door tri m panel , gentl y pry
the swi tch from the door tri m panel (Fi g. 3).
INSTALLATION
(1) Press the swi tch i nto pl ace.
(2) Connect the el ectri cal harness connector to the
swi tch.
(3) I nstal l the door tri m panel (Refer to 23 -
BODY/DOOR - FRONT/TRI M PANEL - I NSTALLA-
TI ON).
DOOR LOCK MOTOR
DESCRIPTION
The l ock mechani sms are actuated by a reversi bl e
el ectri c motor mounted wi thi n each door and tai l gate.
The power l ock motors are i ntegral to the door l atch
uni ts.
The power l ock motors cannot be adjusted or
repai red and, i f faul ty or damaged, the door l atch
OPERATION
The door l ock motors are control l ed by rel ays. A
posi ti ve and negati ve battery connecti on to the two
motor termi nal s wi l l cause the motor to move i n one
di recti on. Reversi ng the current wi l l cause the motor
to move i n the opposi te di recti on.
MOTOR
di agnose the power l ock system requi res the use of a
DRBI I I scan tool and the proper Di agnosti c Proce-
dures manual . The DRBI I I scan tool can provi de
confi rmati on that the PCI data bus i s functi onal , that
al l of the el ectroni c modul es are sendi ng and recei v-
i ng the proper messages on the PCI data bus, and
that the power l ock motors are bei ng sent the proper
hard wi red outputs by the door modul es for them to
perform thei r power l ock system functi ons.
FLIP-UP GLASS RELEASE
SWITCH
DIAGNOSIS AND TESTING - FLIP-UP GLASS
RELEASE SWITCH
cabl e.
(2) Remove the tai l gate tri m panel (Refer to 23 -
BODY/DECKLI D/HATCH/LI FTGATE/TAI LGATE/
TRI M PANEL - REMOVAL).
(3) Di sconnect the wi re harness connector.
Fig. 2 DOOR LOCK SWITCH
1 - DOOR TRIM PANEL
2 - DOOR LOCK SWITCH
3 - POWER MIRROR SWITCH
Fig. 3 DOOR LOCK/MIRROR SWITCH
1 - DOOR TRIM PANEL
DOOR LOCK / UNLOCK SWITCH (Continued)
(4) Usi ng an ohmmeter, check for conti nui ty
between the pi ns of the wi re harness connector whi l e
pul l i ng on the tai l gate handl e.
(5) I f no conti nui ty i s found, repl ace the tai l gate
handl e assembl y (Refer to 23 - BODY/DECKLI D/
HATCH/LI FTGATE/TAI LGATE/EXTERI OR HAN-
DLE - REMOVAL).
DOOR LOCK RELAY
DESCRIPTION
The power door l ock system uses the fol l owi ng
rel ays for the front and rear passenger doors onl y:
Dri ver door unl ock rel ay
Door l ock rel ay
Passenger Doors unl ock rel ay
The tai l gate uses outputs from the Body Control
Modul e (BCM).
The rel ays are el ectromechani cal devi ces that
swi tch battery current to the door l ock ci rcui t when
the Body Control Modul e (BCM) grounds the rel ay
coi l . These rel ays are l ocated i n the Juncti on Bl ock
(JB). For compl ete ci rcui t di agrams, refer to the
The rel ays are a I nternati onal Standards Organi -
zati on (I SO) mi cro-rel ay. Rel ays conformi ng to the
I SO speci fi cati ons have common physi cal di mensi ons,
current capaci ti es, termi nal patterns, and termi nal
functi ons. The I SO mi cro-rel ay termi nal functi ons
are the same as a conventi onal I SO rel ay. However,
the I SO mi cro-rel ay termi nal pattern (or footpri nt) i s
di fferent, the current capaci ty i s l ower, and the phys-
i cal di mensi ons are smal l er than those of the conven-
ti onal I SO rel ay.
The rel ay cannot be repai red or adjusted and, i f
OPERATION
resi stor and three (two fi xed and one movabl e) el ec-
tri cal contacts. The movabl e (common feed) rel ay con-
tact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When the el ec-
tromagneti c coi l i s energi zed, i t draws the movabl e
contact away from the normal l y cl osed fi xed contact,
and hol ds i t agai nst the other (normal l y open) fi xed
contact.
When the el ectromagneti c coi l i s de-energi zed,
spri ng pressure returns the movabl e contact to the
normal l y cl osed posi ti on. The resi stor i s connected i n
paral l el wi th the el ectromagneti c coi l i n the rel ay,
and hel ps to di ssi pate vol tage spi kes that are pro-
duced when the coi l i s de-energi zed.
RELAY
The power l ock rel ays (Fi g. 4) are l ocated i n the
Juncti on Bl ock (JB) under the i nstrument panel . For
compl ete ci rcui t di agrams, refer to the appropri ate
and grounds.
INJURY.
(1) Remove suspected faul ty rel ay from the (JB).
and 30. I f not OK, repl ace the faul ty rel ay.
REMOVAL
cabl e.
(2) Reach up under i nstrument panel and remove
the rel ay from Juncti on Bl ock (JB).
FLIP-UP GLASS RELEASE SWITCH (Continued)
INSTALLATION
(1) Posi ti on the horn rel ay i n the proper receptacl e
i n the Juncti on Bl ock (JB).
(2) Push down fi rml y on the rel ay unti l the termi -
nal s are ful l y seated.
MODULE
DESCRIPTION
When an RKE l ock message i s sent to the Body
Control Modul e (BCM), the BCM actuates the doors
and the tai l gate l ock, the i nteri or l i ghti ng i s turned
off, the horn chi rps (i f thi s feature i s enabl ed), the
exteri or l amps fl ash (i f thi s feature i s enabl ed) and, i f
the vehi cl e i s so equi pped, the Vehi cl e Theft Securi ty
System (VTSS) i s armed. When an RKE unl ock mes-
sage i s sent to the BCM, the BCM actuates the
dri ver si de front door (or al l doors and the tai l gate i f
thi s feature i s enabl ed) unl ock, the i nteri or l i ghti ng
i s turned on and, i f the vehi cl e i s so equi pped, the
VTSS i s di sarmed.
When an RKE pani c message i s sent to the BCM,
the BCM actuates the dri ver si de front door (or al l
doors and the tai l gate i f thi s feature i s enabl ed)
unl ock, the i nteri or l i ghti ng i s turned on and, i f the
vehi cl e i s so equi pped, the VTSS i s di sarmed. The
pani c message wi l l al so cause the exteri or l amps
(i ncl udi ng the headl i ghts) to fl ash, and the horn to
pul se for about three mi nutes, or unti l a second pani c
message i s sent to the BCM. A vehi cl e speed of about
25.7 ki l ometers-per-hour (15 mi l es-per-hour) wi l l al so
cancel the pani c event.
on the features, use and operati on of the RKE sys-
tem.
OPERATION
Whenever the vehi cl e battery power i s i nterrupted,
the Remote Keyl ess Modul e (RKE) Modul e wi l l retai n
al l vehi cl e access codes i n i ts memory. When repl ac-
i ng or addi ng a key fob transmi tter (maxi mum of 4) a
DRB I I I scan tool i s requi red to program the RKE
Modul e to accept the new Vehi cl e Access Code i f a
customer owned transmi tter i s not avai l abl e.
I f a functi oni ng transmi tter i s avai l abl e, (Refer to 8
- ELECTRI CAL/POWER LOCKS/KEYLESS ENTRY
TRANSMI TTER - STANDARD PROCEDURE)
DIAGNOSIS AND TESTING - REMOTE KEYLESS
ENTRY MODULE
ness connectors, spl i ces and grounds. Refer to the
proper Body Di agnosti c Procedures Manual for test-
i ng the Remote Keyl ess Entry system usi ng a DRB
I I I scan tool .
REMOVAL
cabl e.
(2) Remove the Juncti on Bl ock (JB) (Refer to 8 -
ELECTRI CAL/POWER DI STRI BUTI ON/JUNCTI ON
BLOCK - REMOVAL).
(3) Remove Remote Keyl ess Entry modul e from
Body Control Modul e (Fi g. 5).
INSTALLATION
(1) I nstal l Remote Keyl ess Entry modul e to Body
Control Modul e.
(2) I nstal l Juncti on Bl ock (JB) (Refer to 8 - ELEC-
TRI CAL/POWER DI STRI BUTI ON/JUNCTI ON
BLOCK - I NSTALLATI ON).
Fig. 4 Power Lock Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
DOOR LOCK RELAY (Continued)
TRANSMITTER
DIAGNOSIS AND TESTING - REMOTE KEYLESS
ENTRY TRANSMITTER
di agnose the remote keyl ess entry transmi tter
requi res the use of a DRBI I I scan tool and the
proper Di agnosti c Procedures manual . The DRBI I I
scan tool can provi de confi rmati on that the PCI data
bus i s functi onal , and that al l of the el ectroni c mod-
ul es are sendi ng and recei vi ng the proper messages
on the PCI data bus.
STANDARD PROCEDURE
STANDARD PROCEDURE - RKE TRANSMITTER
BATTERIES
The Remote Keyl ess Entry (RKE) transmi tter case
snaps open and shut for battery access. To repl ace
the RKE transmi tter batteri es:
(1) Usi ng a thi n coi n, gentl y pry at the notch i n
the center seam of the RKE transmi tter case hal ves
near the key ri ng unti l the two hal ves unsnap.
(2) Li ft the back hal f of the transmi tter case off of
the RKE transmi tter.
(3) Remove the two batteri es from the RKE trans-
mi tter.
(4) Repl ace the two batteri es wi th new Panasoni c
2016, or equi val ent. Be certai n that the batteri es are
i nstal l ed wi th thei r pol ari ty correctl y ori ented.
(5) Al i gn the two RKE transmi tter case hal ves
wi th each other, and squeeze them fi rml y and evenl y
together unti l they snap back i nto pl ace.
CUSTOMER PREFERENCES
AUTOMATIC (ROLLING) LOCKS
The rol l i ng l ocks feature can be toggl ed ON/OFF
by usi ng the DRB I I I onl y.
HORN CHIRP DISABLING / ENABLING
The horn chi rp can be toggl ed usi ng a DRB I I I or
by usi ng the Remote Keyl ess Entry (RKE) transmi t-
ter.
To DI SABLE (cancel ) the horn chi rp feature, press
and hol d the transmi tter LOCK button for four to ten
seconds. Whi l e pressi ng the LOCK button i n, press
the UNLOCK button. Rel ease both buttons.
To ENABLE the horn chi rp feature, repeat the
above procedure.
OPTICAL CHIRP (FLASH) DISABLING / ENABLING
The opti cal chi rp can be toggl ed usi ng a DRB I I I
or by usi ng the Remote Keyl ess Entry (RKE) trans-
mi tter.
To DI SABLE (cancel ) the opti cal chi rp feature,
press and hol d the transmi tter LOCK button for four
to ten seconds. Whi l e pressi ng the LOCK button i n,
press the TAI LGATE RELEASE button. Rel ease both
buttons.
To ENABLE the opti cal chi rp feature, repeat the
above procedure.
TAIL GATE RELEASE DELAY
Press the UNLOCK button for four to ten seconds.
Whi l e pressi ng the UNLOCK button, press the TAI L
GATE RELEASE button. Rel ease both buttons.
Thi s wi l l toggl e between PRESS AND HOLD and
PRESS (no del ay).
UNLOCK SEQUENCE
The unl ock sequence can be toggl ed usi ng a DRB
I I I or by usi ng the Remote Keyl ess Entry (RKE)
transmi tter.
Fig. 5 RKE Module Remove/Install
1 - SCREW (4)
2 - RKE MODULE
4 - JUNCTION BLOCK
REMOTE KEYLESS ENTRY MODULE (Continued)
Press and hol d the transmi tter UNLOCK button
for four to ten seconds. Whi l e pressi ng the UNLOCK
button i n, press the LOCK button. Rel ease both but-
tons.
Thi s wi l l toggl e between Dri ver door fi rst and
Unl ock al l doors functi on.
PROGRAMING
New Remote Keyl ess Entry (RKE) transmi tters can
be programed usi ng the DRBI I I scan tool and the
proper Di agnosti c Procedures manual . The DRBI I I
scan tool can provi de confi rmati on that the PCI data
bus i s functi onal , and that al l of the el ectroni c mod-
ul es are sendi ng and recei vi ng the proper messages
on the PCI data bus.
The fol l owi ng procedure can be used as l ong as one
functi oni ng transmi tter i s avai l abl e:
(1) Usi ng the ori gi nal transmi tter, press the
UNLOCK button for 4 to 10 seconds.
(2) Wi thout rel easi ng the UNLOCK button, press
the PANI C button (wi thi n the 4 to 10 second i nter-
val ).
(3) Rel ease both buttons.
(4) Press LOCK and UNLOCK si mul taneousl y on
the ori gi nal transmi tter.
(6) Press any button on the ORI GI NAL transmi t-
ter. A chi me tone from the i nstrument cl uster wi l l
confi rm the programmi ng of the ORI GI NAL trans-
mi tter.
(7) On NEW transmi tter, press LOCK and
UNLOCK si mul taneousl y.
(9) Press any button on the NEW transmi tter. A
chi me tone from the i nstrument cl uster wi l l confi rm
the programmi ng of the NEW transmi tter.
(10) Up to four transmi tters can be programed for
one vehi cl e.
SPECIFICATIONS - REMOTE KEYLESS ENTRY
TRANSMITTER
RANGE
Normal operati on range i s up to a di stance of 3 to
7 meters (10 to 23 ft.) of the vehi cl e. Range may be
better or worse dependi ng on the envi ronment
around the vehi cl e.
TAILGATE CYLINDER LOCK
SWITCH
DESCRIPTION
The tai l gate cyl i nder l ock swi tch i s i ntegral to the
key l ock cyl i nder i nsi de the tai l gate. The tai l gate cyl -
i nder l ock swi tch i s a normal l y-open momentary
swi tch that i s hard wi red di rectl y to the Body Con-
trol Modul e (BCM), and cl oses a path to ground
through an i nternal resi stor when the l ock cyl i nder i s
rotated to the unl ock or l ock posi ti on.
The tai l gate cyl i nder l ock swi tch cannot be
adjusted or repai red.
OPERATION
The tai l gate cyl i nder l ock swi tch i s actuated when
the key i s i nserted i n the l ock cyl i nder and turned to
the unl ock or l ock posi ti on. The tai l gate cyl i nder l ock
swi tch cl oses a path to ground through an i nternal
resi stor for the Body Control Modul e (BCM) when
the tai l gate key l ock cyl i nder i s i n the l ock or unl ock
posi ti on, and opens the ground path when the l ock
cyl i nder i s i n the neutral posi ti on. The BCM reads
the swi tch status, then sends the proper swi tch sta-
tus messages to other el ectroni c modul es over the
bus network. The tai l gate cyl i nder l ock swi tch unl ock
status message i s used by the BCM as an i nput for
Vehi cl e Theft Securi ty System (VTSS) operati on and
to tel l the BCM to l ock or unl ock the tai l gate. There
i s no mechani cal l i nkage between the tai l gate key
cyl i nder and the l atches.
DIAGNOSIS AND TESTING - TAILGATE
CYLINDER LOCK SWITCH
cabl e.
(2) Remove tai l gate tri m panel (Refer to 23 -
(3) Di sconnect tai l gate cyl i nder l ock swi tch har-
ness connector.
(4) Usi ng a ohmmeter, test for resi stances as
shown i n the Tai l gate Cyl i nder Lock Swi tch Tabl e.
REMOTE KEYLESS ENTRY TRANSMITTER (Continued)
TAILGATE CYLINDER LOCK SWITCH TABLE
SWITCH POSITION RESISTANCE
NEUTRAL 0 OHMS
LOCK (CLOCKWISE) 2 K OHMS 10 %
UNLOCK (COUNTER-
CLOCKWISE)
470 OHMS 10 %
(5) I f swi tch resi stance i s not correct, repl ace
swi tch.
REMOVAL
cabl e.
(2) Remove the tai l gate tri m panel .(Refer to 23 -
(3) Remove the retai ner cl i p from the pi n on the
back of the door l ock cyl i nder (Fi g. 6).
(4) Remove the washer from the pi n on the back of
the door l ock cyl i nder.
(5) Remove the door cyl i nder l ock swi tch from the
back of the l ock cyl i nder.
INSTALLATION
(1) Posi ti on the tai l gate cyl i nder l ock swi tch onto
the back of the l ock cyl i nder wi th the wi re harness
ori ented toward the bottom.
(2) Posi ti on the washer over the swi tch.
(3) I nstal l the retai ner cl i p onto the pi n on the
back of the tai l gate l ock cyl i nder. Be certai n that the
center tab of the retai ner i s engaged i n the retenti on
hol e on the l ock l ever.
(4) I nstal l the tri m panel (Refer to 23 - BODY/
DECKLI D/HATCH/LI FTGATE/TAI LGATE/TRI M
PANEL - I NSTALLATI ON).
Fig. 6 Lock Cylinder Switch Remove/Install -Typical
1 - LEVER
2 - RETAINER
3 - LOCK CYLINDER
4 - SWITCH
5 - PLIERS
6 - OUTSIDE DOOR HANDLE
TAILGATE CYLINDER LOCK SWITCH (Continued)
POWER MIRRORS
TABLE OF CONTENTS
page page
POWER MIRRORS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - POWER
MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
POWER MIRROR SWITCH
DIAGNOSIS AND TESTING - POWER MIRROR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
SIDEVIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
POWER MIRRORS
DESCRIPTION
The avai l abl e power operated si devi ew mi rrors
al l ow the dri ver to adjust both outsi de mi rrors el ec-
tri cal l y from the dri vers seat by operati ng a swi tch
on the dri ver si de front door tri m panel (Fi g. 1).
OPERATION
The power mi rrors recei ve i gni ti on current through
a fuse i n the juncti on bl ock, and wi l l onl y operate
when the i gni ti on swi tch i s i n the Run posi ti on.
DIAGNOSIS AND TESTING - POWER MIRRORS
WIRING VOLTAGE TEST
The fol l owi ng wi ri ng test determi nes whether or
not vol tage i s conti nuous through the body harness
to swi tch.
(1) Remove the power mi rror swi tch (Refer to 8 -
ELECTRI CAL/POWER MI RRORS/POWER MI RROR
SWI TCH - REMOVAL).
(2) Di sconnect wi re connector from back of power
mi rror swi tch.
(3) Swi tch i gni ti on to the RUN posi ti on.
(4) Connect the cl i p end of a 12 vol t test l i ght to
Pi n 5 i n the harness connector at the mi rror swi tch.
Touch the test l i ght probe to Pi n 3.
I f the test l i ght i l l umi nates, the wi ri ng ci rcui t
between the battery and swi tch i s OK.
I f the l amp does not i l l umi nate, fi rst check fuse 25
i n the Juncti on Bl ock (JB). I f fuse 25 i s OK, then
check for a broken wi re.
POWER MIRROR MOTOR TEST
I f the power mi rror swi tch i s recei vi ng proper cur-
rent and ground and mi rrors do not operate, proceed
wi th power mi rror motor test. Refer to the appropri -
Fig. 1 POWER MIRROR SWITCH
1 - DOOR TRIM PANEL
KJ POWER MIRRORS 8N - 11
(1) Remove front door tri m panel to gai n access to
power mi rror wi re connector (Refer to 23 - BODY/
DOOR - FRONT/TRI M PANEL - REMOVAL).
(2) Di sconnect wi re harness connector to power
mi rror swi tch (Fi g. 2).
(3) Usi ng two jumper wi res:
Connect one to a 12 vol t source
Connect the other to a good body ground
Refer to the Mi rror Motor Test Chart for proper
wi re connecti ons at the swi tch connector
MIRROR MOTOR TEST CHART
12 VOLTS GROUND MIRROR REACTION
SWITCH CONNECTOR RIGHT LEFT
PIN 2 PIN 6 - UP
PIN 6 PIN 1 - LEFT
PIN 6 PIN 2 - DOWN
PIN 1 PIN 6 - RIGHT
PIN 9 PIN 6 UP -
PIN 6 PIN 10 LEFT -
PIN 6 PIN 9 DOWN -
PIN 10 PIN 6 RIGHT -
(4) I f resul ts shown i n tabl e are not obtai ned,
check for open or shorted ci rcui t. Repl ace mi rror
assembl y as necessary.
POWER MIRROR SWITCH
DIAGNOSIS AND TESTING - POWER MIRROR
SWITCH
(1) Remove power mi rror swi tch (Refer to 8 -
ELECTRI CAL/POWER MI RRORS/POWER MI RROR
SWI TCH - REMOVAL).
(2) Di sconnect wi ri ng harness connector from
swi tch.
(3) Usi ng a ohmmeter, test for conti nui ty between
the termi nal s of the swi tch (Fi g. 3).
(4) I f resul ts shown i n the tabl e are not obtai ned,
repl ace the swi tch.
POWER MIRROR SWITCH TEST
SWITCH POSITION CONTINUITY BETWEEN
MIRROR SELECT SWITCH IN LEFT POSITION
UP 5 AND 2
3 AND 6
DOWN 5 AND 6
3 AND 2
LEFT 5 AND 6
3 AND 1
RIGHT 5 AND 1
3 AND 6
MIRROR SELECT SWITCH IN RIGHT POSITION
UP 5 AND 9
3 AND 6
DOWN 5 AND 6
3 AND 9
LEFT 5 AND 6
3 AND 10
RIGHT 5 AND 10
3 AND 6
Fig. 2 POWER MIRROR SWITCH CONNECTOR
Fig. 3 POWER MIRROR SWITCH
8N - 12 POWER MIRRORS KJ
POWER MIRRORS (Continued)
REMOVAL
cabl e.
(2) Remove door tri m panel (Refer to 23 - BODY/
DOOR - FRONT/TRI M PANEL - REMOVAL).
(3) Di sconnect wi re harness connector from swi tch
(Fi g. 4).
(4) Remove swi tch from door tri m panel .
INSTALLATION
(1) I nstal l swi tch to door tri m panel .
(2) Connect wi re harness connector to swi tch.
(3) I nstal l door tri m panel (Refer to 23 - BODY/
DOOR - FRONT/TRI M PANEL - I NSTALLATI ON).
SIDEVIEW MIRROR
REMOVAL
(1) For removal procedures, (Refer to 23 - BODY/
EXTERI OR/SI DE VI EW MI RROR - REMOVAL).
Fig. 4 DOOR LOCK/MIRROR SWITCH
1 - DOOR TRIM PANEL
KJ POWER MIRRORS 8N - 13
POWER MIRROR SWITCH (Continued)
POWER SEATS
TABLE OF CONTENTS
page page
POWER SEATS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - POWER SEATS . . 15
SEAT TRACK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - SEAT TRACK . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
LEFT POWER SEAT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - LEFT POWER
SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
RIGHT POWER SEAT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - RIGHT POWER
SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
POWER SEATS
DESCRIPTION
I ndi vi dual l y control l ed, el ectri cal l y powered front
seats are avai l abl e as factory-i nstal l ed equi pment on
thi s model . Vehi cl es wi th thi s opti on can be vi sual l y
i denti fi ed by the two separate power seat swi tches,
mounted on each of the front seat cushi on si de
shi el ds (Fi g. 1). The power seat system opti on al l ows
the front seati ng posi ti ons to be el ectri cal l y adjusted
for opti mum vehi cl e control and comfort. The power
seat cushi on can be adjusted forward, rearward, front
up, front down, rear up, or rear down. The power
seat system for thi s vehi cl e i ncl udes the fol l owi ng
major components, whi ch are descri bed i n further
detai l l ater i n thi s secti on:
Power Seat Switches - Two power seat
swi tches are used per vehi cl e, one for the dri ver and
one for the front seat passenger. Refer to the l eft and
ri ght power seat swi tch i nformati on l ater i n thi s sec-
ti on.
Power Seat Tracks - Two power seat tracks
are used per vehi cl e, one for the dri ver and one for
the front seat passenger seats. Refer to the power
seat track i nformati on l ater i n thi s secti on.
Circuit Breaker - An automati c resetti ng ci r-
cui t breaker (# 1) i s l ocated i n the Juncti on Bl ock
and i s used to protect the power seat system from
current overl oad.
Hard wi red ci rcui try connects the power seat sys-
tem components to each other through the el ectri cal
system of the vehi cl e. These hard wi red ci rcui ts are
i ntegral to several wi re harnesses, whi ch are routed
throughout the vehi cl e and retai ned by many di ffer-
ent methods. These ci rcui ts may be connected to each
other, to the vehi cl e el ectri cal system and to the
power seat system components through the use of a
combi nati on of sol dered spl i ces, spl i ce bl ock connec-
tors and many di fferent types of wi re harness termi -
nal connectors and i nsul ators. Refer to the Wiring
secti on of thi s manual for more i nformati on. The wi r-
Fig. 1 KJ Heated/Power Seat
8N - 14 POWER SEATS KJ
OPERATION
The power seat system recei ves battery current
through a fuse i n the Power Di stri buti on Center
(PDC) and a ci rcui t breaker i n the Juncti on Bl ock,
regardl ess of the i gni ti on swi tch posi ti on.
When a power seat swi tch control knob or knobs
are actuated, a battery feed and a ground path are
appl i ed through the swi tch contacts to the appropri -
ate power seat track adjuster motor. The sel ected
adjuster motor operates to move the seat track
through i ts dri ve uni t i n the sel ected di recti on unti l
the swi tch i s rel eased, or unti l the travel l i mi t of the
seat track i s reached. When the swi tch i s moved i n
the opposi te di recti on, the battery feed and ground
path to the motor are reversed through the swi tch
contacts. Thi s causes the adjuster motor to run i n the
opposi te di recti on.
Refer to the owners manual i n the vehi cl e gl ove
box for more i nformati on on the features, use and
operati on of the power seat system.
DIAGNOSIS AND TESTING - POWER SEATS
Before any testi ng of the power seat system i s
attempted, the battery shoul d be ful l y-charged and
al l wi re harness connecti ons and pi ns cl eaned and
ti ghtened to ensure proper conti nui ty and grounds.
pi n-out and joi nt connector l ocati on vi ews for the var-
i ous wi re harness connectors, spl i ces and grounds.
(1) I f al l power seats are i noperati ve, check the
automati c resetti ng ci rcui t breaker i n the Juncti on
Bl ock. (Refer to 8 - ELECTRI CAL/POWER DI STRI -
BUTI ON/CI RCUI T BREAKER - DI AGNOSI S AND
TESTI NG).
(2) Wi th the dome l amp on, appl y the power seat
swi tch i n the di recti on of the fai l ure.
(3) I f the dome l amp di ms, the seat or the power
seat track may be jammed. Check under and behi nd
the seat for bi ndi ng or obstructi ons.
(4) I f the dome l amp does not di m, proceed wi th
testi ng of the i ndi vi dual power seat system compo-
nents and ci rcui ts.
SEAT TRACK
DESCRIPTION
The si x-way power seat opti on i ncl udes a power
seat track assembl y l ocated under each front seat
(Fi g. 2). The power seat track assembl y repl aces the
standard manual l y operated seat tracks. The l ower
hal f of the power seat track i s secured at the front
wi th two bol ts to the fl oor panel seat cross member,
and at the rear wi th one bol t and one nut to the fl oor
panel . Four bol ts secure the bottom of the seat cush-
i on frame to the upper hal f of the power seat track
uni t.
The power seat track assembl y cannot be repai red,
and i s servi ced onl y as a compl ete assembl y. I f any
component i n thi s assembl y i s faul ty or damaged, the
enti re power seat track must be repl aced.
OPERATION
The power seat track uni t i ncl udes three reversi bl e
el ectri c motors that are secured to the upper hal f of
the track uni t. Each motor moves the seat adjuster
through a combi nati on of worm-dri ve gearboxes and
screw-type dri ve uni ts. Each of the three dri ver si de
power seat track motors al so has a posi ti on potenti -
ometer i ntegral to the motor assembl y, whi ch el ec-
troni cal l y moni tors the motor posi ti on.
The front and rear of the seat are operated by two
separate verti cal adjustment motors. These motors
can be operated i ndependentl y of each other, ti l ti ng
the enti re seat assembl y forward or rearward; or,
they can be operated i n uni son by sel ecti ng the
proper power seat swi tch functi ons, whi ch wi l l rai se
or l ower the enti re seat assembl y. The thi rd motor i s
the hori zontal adjustment motor, whi ch moves the
seat track i n the forward and rearward di recti ons.
Fig. 2 Power Seat Track - Typical
1 - POWER SEAT ADJUSTER AND MOTORS
2 - SEAT CUSHION FRAME
3 - POWER SEAT TRACK ASSEMBLY
KJ POWER SEATS 8N - 15
POWER SEATS (Continued)
DIAGNOSIS AND TESTING - SEAT TRACK
(1) Remove the power seat swi tch from the seat
(Refer to 8 - ELECTRI CAL/POWER SEATS/DRI VER
SEAT SWI TCH - REMOVAL).
(2) Checki ng the body harness si de of the power
seat swi tch el ectri cal connector (Fi g. 3), check Pi n 1
for ground and Pi n 5 for battery vol tage. I f ei ther of
these two are not present repai r the body harness as
requi red.
(3) To test the seat motors and veri fy proper seat
responses, refer to the Seat Motor Test tabl e bel ow.
Usi ng two jumper wi res, connect one to a battery
suppl y and the second to a ground. Connect the other
ends to the seat wi re harness connector as descri bed
i n the Seat Motor Test tabl e.
SEAT MOTOR TEST
SEAT SWITCH CONNECTOR
CONNECT JUMPER SEAT ACTION
B(+) B() LEFT SIDE RIGHT SIDE
PIN 9 PIN 8 FRONT
RISER UP
FRONT
RISER
DOWN
PIN 8 PIN 9 FRONT
RISER
DOWN
FRONT
RISER UP
PIN 3 PIN 6 FORWARD FORWARD
PIN 6 PIN 3 REARWARD REARWARD
PIN 10 PIN 7 REAR
RISER UP
REAR RISER
DOWN
PIN 7 PIN 10 REAR
RISER
DOWN
REAR RISER
UP
REMOVAL
(1) Remove the appropri ate seat from the vehi cl e.
(Refer to 23 - BODY/SEATS/SEAT - REMOVAL).
(2) Remove the seat cushi on si de shi el d from the
seat (Refer to 23 - BODY/SEATS/SEAT CUSHI ON
(3) Remove four seat track mounti ng bol ts from
cushi on pan.
(4) Di sconnect the power seat el ectri cal and
remove the seat track from the seat cushi on.
INSTALLATION
(1) Posi ti on the seat track and i nstal l the retai ni ng
bol ts i n the seat cushi on pan. Torque the bol ts to
45-60 Nm.
(2) Route and connect the power seat el ectri cal on
the seat track and cushi on pan.
(3) I nstal l the seat cushi on si de shi el d on the seat.
Refer to the Body secti on for the procedure.
(4) I nstal l the seat i n the vehi cl e (Refer to 23 -
BODY/SEATS/SEAT - I NSTALLATI ON).
LEFT POWER SEAT SWITCH
DESCRIPTION
Vehi cl es equi pped wi th the power seat opti on uti -
l i ze a si x-way power seat swi tch. Thi s si x-way power
seat swi tch features one seat cushi on shaped knob,
vi si bl e on the outboard seat cushi on si de shi el d (Fi g.
4).
The swi tch i s secured to the back of the seat cush-
i on si de shi el d wi th two screws. However, the control
knob must be removed before the seat swi tch can be
removed from the si de shi el d.
Fig. 3 POWER SEAT SWITCH HARNESS PIN
IDENTIFICATION
1 - CONNECTOR RETAINING TAB
2 - VIEWED FROM BODY HARNESS END
Fig. 4 KJ Heated/Power Seat
SEAT TRACK (Continued)
The i ndi vi dual swi tches i nternal to the power seat
swi tch cannot be repai red. I f one swi tch i s damaged
or faul ty, the enti re power seat swi tch uni t must be
repl aced.
OPERATION
The power seat tracks can be adjusted i n si x di ffer-
ent ways usi ng the power seat swi tches. See the own-
ers manual i n the vehi cl e gl ove box for more
i nformati on on the power seat swi tch functi ons and
the seat adjusti ng procedures.
appl i ed through the swi tch contacts to the power seat
track adjuster motor. The sel ected adjuster motor
operates to move the seat track through i ts dri ve
uni t i n the sel ected di recti on unti l the swi tch i s
rel eased, or unti l the travel l i mi t of the seat track i s
reached. When the swi tch i s moved i n the opposi te
di recti on, the battery feed and ground path to the
motor are reversed through the swi tch contacts. Thi s
causes the adjuster motor to run i n the opposi te
di recti on.
No power seat swi tch shoul d be hel d appl i ed i n any
di recti on after the seat track has reached i ts travel
l i mi t. The power seat adjuster motors each contai n a
sel f-resetti ng ci rcui t breaker to protect them from
overl oad. However, consecuti ve or frequent resetti ng
of the ci rcui t breaker must not be al l owed to con-
ti nue, or the motor may be damaged.
DIAGNOSIS AND TESTING - LEFT POWER
SEAT SWITCH
For compl ete ci rcui t di agrams, refer to Power
Seat i n Wi ri ng Di agrams.
cabl e.
(2) Remove the power seat swi tch from the out-
board seat cushi on si de shi el d.
(3) Use an ohmmeter to test the conti nui ty of the
power seat swi tch i n each swi tch posi ti on. See the
Power Seat Swi tch Conti nui ty chart (Fi g. 5) and
swi tch (Fi g. 6) bel ow. I f OK, refer to Diagnosis and
Testing the Power Seat Track i n thi s secti on. I f
not OK, repl ace the faul ty power seat swi tch uni t.
Fig. 5 SIX-WAY POWER SEAT SWITCH CONTINUITY
Fig. 6 DIAGNOSING POWER SEAT SWITCH
1 - UP
2 - REARWARD
3 - DOWN
4 - FORWARD
5 - FRONT RISER SWITCH
6 - CENTER SEAT SWITCH
7 - REAR RISER SWITCH
LEFT POWER SEAT SWITCH (Continued)
SWITCH
POSITION
CONTINUITY BETWEEN PINS
DRIVER SEAT PASSENGER
SEAT
OFF PIN 1 to 3 PIN 1 to 3
PIN 1 to 6 PIN 1 to 6
FRONT RISER
UP
FRONT RISER
DOWN
CENTER
SWITCH
FORWARD
CENTER
SWITCH
REARWARD
REAR RISER
UP
REAR RISER
DOWN
REMOVAL
cabl e.
(2) Usi ng a push pi n remover or another sui tabl e
wi de fl at-bl aded tool , gentl y pry the power seat
swi tch knob off of the swi tch control l evers (Fi g. 7).
(3) Remove the two forward-most screws that
secure the outboard seat cushi on si de shi el d to the
seat cushi on frame.
(4) Remove the recl i ner handl e retai ni ng screw
and remove the recl i ner handl e.
(5) Pul l the outboard seat cushi on si de shi el d away
from the seat cushi on frame far enough to access the
power seat swi tch wi re harness ti estrap and connec-
tor. Cut the ti estrap, i f equi pped.
(6) Di sconnect the power seat wi re harness connec-
tor from the power seat swi tch connector receptacl e.
Depress the connector retai ni ng tab and pul l strai ght
apart.
(7) Usi ng a very short phi l l i ps-headed screwdri ver,
remove the two screws that secure the power seat
swi tch to the i nsi de of the outboard seat cushi on si de
shi el d.
INSTALLATION
(1) Reconnect the power seat wi re harness connec-
tor to the power seat swi tch connector receptacl e.
(2) Posi ti on the power seat swi tch onto the out-
board seat cushi on si de shi el d. Make certai n the
al i gnment dowel i s i nserted i nto the correspondi ng
hol e i n the power seat swi tch.
the power seat swi tch to the i nsi de of the outboard
seat cushi on si de shi el d. Ti ghten the screws to 1.5
Nm (14 i n. l bs.).
(4) Posi ti on the outboard seat cushi on si de shi el d
onto the seat cushi on frame
the outboard seat cushi on si de shi el d to the seat
cushi on frame. Ti ghten the screws to 1.5 Nm (14 i n.
l bs.).
(6) I nstal l the recl i ner handl e and retai ni ng screw.
Ti ghten the screws to 1.5 Nm (14 i n. l bs.).
(7) Posi ti on the power seat swi tch knob onto the
swi tch control l evers and push fi rml y and evenl y
unti l i t snaps i nto pl ace.
Fig. 7 REMOVING SWITCH CONTROL KNOB -
TYPICAL
LEFT POWER SEAT SWITCH (Continued)
RIGHT POWER SEAT SWITCH
DESCRIPTION
Vehi cl es equi pped wi th the power seat opti on uti -
l i ze a si x-way power seat swi tch. Thi s si x-way power
seat swi tch features one seat cushi on shaped knob,
vi si bl e on the outboard seat cushi on si de shi el d.
The swi tch i s secured to the back of the seat cush-
i on si de shi el d wi th two screws. However, the control
knob must be removed before the seat swi tch can be
removed from the si de shi el d.
The i ndi vi dual swi tches i nternal to the power seat
swi tch cannot be repai red. I f one swi tch i s damaged
or faul ty, the enti re power seat swi tch uni t must be
repl aced.
OPERATION
The power seat tracks can be adjusted i n si x di ffer-
ent ways usi ng the power seat swi tches. See the own-
ers manual i n the vehi cl e gl ove box for more
i nformati on on the power seat swi tch functi ons and
the seat adjusti ng procedures.
appl i ed through the swi tch contacts to the power seat
track adjuster motor. The sel ected adjuster motor
operates to move the seat track through i ts dri ve
uni t i n the sel ected di recti on unti l the swi tch i s
rel eased, or unti l the travel l i mi t of the seat track i s
reached. When the swi tch i s moved i n the opposi te
di recti on, the battery feed and ground path to the
motor are reversed through the swi tch contacts. Thi s
causes the adjuster motor to run i n the opposi te
di recti on.
No power seat swi tch shoul d be hel d appl i ed i n any
di recti on after the seat track has reached i ts travel
l i mi t. The power seat adjuster motors each contai n a
sel f-resetti ng ci rcui t breaker to protect them from
overl oad. However, consecuti ve or frequent resetti ng
of the ci rcui t breaker must not be al l owed to con-
ti nue, or the motor may be damaged.
DIAGNOSIS AND TESTING - RIGHT POWER
SEAT SWITCH
For compl ete ci rcui t di agrams, refer to Power
Seat i n Wi ri ng Di agrams.
cabl e.
(3) Use an ohmmeter to test the conti nui ty of the
power seat swi tch i n each swi tch posi ti on. See the
Power Seat Swi tch Conti nui ty chart (Fi g. 8) and
swi tch (Fi g. 9) bel ow. I f OK, refer to Diagnosis and
Testing the Power Seat Track i n thi s secti on. I f
not OK, repl ace the faul ty power seat swi tch uni t.
Fig. 8 SIX-WAY POWER SEAT SWITCH CONTINUITY
Fig. 9 DIAGNOSING POWER SEAT SWITCH
1 - UP
2 - REARWARD
3 - DOWN
4 - FORWARD
5 - FRONT RISER SWITCH
6 - CENTER SEAT SWITCH
7 - REAR RISER SWITCH
SWITCH
POSITION
CONTINUITY BETWEEN PINS
DRIVER SEAT PASSENGER
SEAT
OFF PIN 1 to 3 PIN 1 to 3
FRONT RISER
UP
FRONT RISER
DOWN
CENTER
SWITCH
FORWARD
CENTER
SWITCH
REARWARD
REAR RISER
UP
REAR RISER
DOWN
REMOVAL
cabl e.
(2) Usi ng a push pi n remover or another sui tabl e
wi de fl at-bl aded tool , gentl y pry the power seat
swi tch knob off of the swi tch control l evers (Fi g. 10).
(3) Remove the two forward-most screws that
secure the outboard seat cushi on si de shi el d to the
seat cushi on frame.
(4) Remove the recl i ner handl e retai ni ng screw
and remove the recl i ner handl e.
(5) Pul l the outboard seat cushi on si de shi el d away
from the seat cushi on frame far enough to access the
power seat swi tch wi re harness ti estrap and connec-
tor. Cut the ti estrap, i f equi pped.
(6) Di sconnect the power seat wi re harness connec-
tor from the power seat swi tch connector receptacl e.
Depress the connector retai ni ng tab and pul l strai ght
apart.
(7) Usi ng a very short phi l l i ps-headed screwdri ver,
remove the two screws that secure the power seat
swi tch to the i nsi de of the outboard seat cushi on si de
shi el d.
INSTALLATION
(1) Reconnect the power seat wi re harness connec-
tor to the power seat swi tch connector receptacl e.
(2) Posi ti on the power seat swi tch onto the out-
board seat cushi on si de shi el d. Make certai n the
al i gnment dowel i s i nserted i nto the correspondi ng
hol e i n the power seat swi tch.
the power seat swi tch to the i nsi de of the outboard
seat cushi on si de shi el d. Ti ghten the screws to 1.5
Nm (14 i n. l bs.).
(4) Posi ti on the outboard seat cushi on si de shi el d
onto the seat cushi on frame
the outboard seat cushi on si de shi el d to the seat
cushi on frame. Ti ghten the screws to 1.5 Nm (14 i n.
l bs.).
(6) I nstal l the recl i ner handl e and retai ni ng screw.
(7) Posi ti on the power seat swi tch knob onto the
swi tch control l evers and push fi rml y and evenl y
unti l i t snaps i nto pl ace.
Fig. 10 REMOVING SWITCH CONTROL KNOB -
TYPICAL
RIGHT POWER SEAT SWITCH (Continued)
POWER WINDOWS
TABLE OF CONTENTS
page page
POWER WINDOWS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
WINDOW MOTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WINDOW SWITCH
DIAGNOSIS AND TESTING - WINDOW
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
POWER WINDOWS
DESCRIPTION
The power wi ndow system al l ows each of the door
wi ndows to be rai sed and l owered el ectri cal l y by
actuati ng a swi tch on the center consol e. A master
swi tch on the front of the center consol e al l ows the
dri ver to rai se or l ower each of the passenger door
wi ndows and to l ock out the i ndi vi dual swi tches on
the rear of the center consol e from operati on. The
power wi ndow system recei ves battery feed through
fuse 13 i n the Power Di stri buti on Center (PDC), onl y
when the i gni ti on swi tch i s i n the RUN or ACCES-
SORY posi ti on.
OPERATION
WINDOW SWITCH
The power wi ndow swi tches control the battery
and ground feeds to the power wi ndow motors. Both
of the rear door power wi ndow swi tches recei ve thei r
battery and ground feeds through the ci rcui try of the
front wi ndow swi tch. When the power wi ndow l ock-
out swi tch i s i n the Lock posi ti on, the battery feed
for the rear door wi ndow swi tches i s i nterrupted.
WINDOW MOTOR
Front door wi ndow l i ft motors use permanent type
magnets. The B+ and ground appl i ed at the motor
termi nal pi ns wi l l cause the motor to rotate i n one
di recti on. Reversi ng current through the motor ter-
mi nal s wi l l cause the motor to rotate i n the opposi te
di recti on.
WINDOWS
WIRING VOLTAGE TEST
The fol l owi ng wi ri ng test determi nes whether or
not vol tage i s conti nuous through the body harness
to the front swi tch.
(1) Remove the power wi ndow swi tch and bezel
(Refer to 8 - ELECTRI CAL/POWER WI NDOWS/
POWER WI NDOW SWI TCH - REMOVAL).
(2) Di sconnect wi re connector from back of power
wi ndow swi tch.
(3) Swi tch i gni ti on to the ON posi ti on.
(4) Connect the cl i p end of a 12 vol t test l i ght to
Pi n 14 of the wi ndow swi tch harness connector.
Touch the test l i ght probe to Pi n 10.
I f the test l i ght i l l umi nates, the wi ri ng ci rcui t
between the battery and swi tch i s OK.
I f the l amp does not i l l umi nate, fi rst check fuse
13 i n the Power Di stri buti on Center (PDC). I f fuse 13
i s OK, then check for a broken wi re.
POWER WINDOW MOTOR TEST
I f the power wi ndow motor i s recei vi ng proper cur-
rent and ground and does not operate, proceed wi th
motor test. Refer to the appropri ate wi ri ng i nforma-
ti on. The wi ri ng i nformati on i ncl udes wi ri ng di a-
(1) Remove front door tri m panel as necessary to
gai n access to power wi ndow motor wi re connector
KJ POWER WINDOWS 8N - 21
(Refer to 23 - BODY/DOOR - FRONT/TRI M PANEL -
REMOVAL).
(2) Di sconnect power wi ndow motor wi re connector
from door harness.
(3) Usi ng two jumper wi res, connect one to a bat-
tery (+) source and the other to a good ground (-).
(4) Connect the Negati ve (-) jumper probe to one of
the motor connector termi nal s.
(5) Momentari l y touch the Posi ti ve (+) jumper
probe to the other motor connector termi nal .
When posi ti ve probe i s connected the motor shoul d
rotate i n one di recti on to ei ther move wi ndow up or
down. I f wi ndow i s al l the way up or down the motor
wi l l grunt and the i nner door panel wi l l fl ex when
actuated i n that one di recti on.
(6) Reverse jumper probes at the motor connector
termi nal s and wi ndow shoul d now move i n opposi te
di recti on. I f wi ndow does not move or grunt, repl ace
the motor.
I f wi ndow moved compl etel y up or down, reverse
the jumper probes and cycl e wi ndow to the opposi te
posi ti on to veri fy ful l operati on.
I f motor grunts and does not move, veri fy that reg-
ul ator i s not bi ndi ng.
WINDOW MOTOR
REMOVAL
The wi ndow motor i s i ncorporated i nto the wi ndow
regul ator assembl y. I f the wi ndow motor requi res
repl acement, the wi ndow regul ator must be repl aced.
(Refer to 23 - BODY/DOOR - FRONT/WI NDOW
REGULATOR - REMOVAL) or (Refer to 23 - BODY/
DOORS - REAR/WI NDOW REGULATOR - REMOV-
AL).
WINDOW SWITCH
DIAGNOSIS AND TESTING - WINDOW SWITCH
(1) Remove the swi tch to be tested (Refer to 8 -
ELECTRI CAL/POWER WI NDOWS/POWER WI N-
DOW SWI TCH - REMOVAL).
(2) Usi ng an ohmmeter, Test front swi tch for con-
ti nui ty (Fi g. 1).
POWER WINDOW FRONT SWITCH TEST
OFF 14 AND 4
14 AND 5
14 AND 6
14 AND 7
14 AND 9
14 AND 11
14 AND 12
14 AND 13
LEFT FRONT UP 10 AND 11
LEFT FRONT DOWN 10 AND 9
RIGHT FRONT UP 10 AND 12
RIGHT FRONT DOWN 10 AND 13
LEFT REAR UP 10 AND 5
LEFT REAR DOWN 10 AND 4
RIGHT REAR UP 10 AND 7
RIGHT REAR DOWN 10 AND 6
LOCKOUT (LOCKED) NO CONTINUITY
BETWEEN 10 AND 2
LOCKOUT (UNLOCKED) 10 AND 2
(3) I f the proper resul ts are not obtai ned, repl ace
the front wi ndow swi tch.
(4) Test rear swi tch for conti nui ty (Fi g. 2).
Fig. 1 FRONT WINDOW SWITCH
Fig. 2 REAR WINDOW SWITCH
8N - 22 POWER WINDOWS KJ
POWER WINDOWS (Continued)
POWER WINDOW REAR SWITCH TEST
OFF 1 AND 3
4 AND 2
7 AND 10
8 AND 9
LEFT UP 10 AND 6
LEFT DOWN 6 AND 8
RIGHT UP 5 AND 2
RIGHT DOWN 5 AND 3
(5) I f the proper resul ts are not obtai ned, repl ace
the rear wi ndow swi tch.
The power wi ndow master swi tch has a Auto-Down
feature on both front wi ndows. The swi tch i s
equi pped wi th two detent posi ti ons when actuati ng
the power wi ndow OPEN. The fi rst detent posi ti on
al l ows the wi ndow to rol l down and stop when the
swi tch i s rel eased. The second detent posi ti on actu-
ates an i ntegral express rol l down rel ay that rol l s the
wi ndow down after the swi tch i s rel eased. When the
express down ci rcui t senses stal l current (wi ndow
has reached end of down travel ), the swi tch wi l l turn
current off to the motor. The AUTO feature can be
cancel l ed by actuati ng the swi tch UP or DOWN whi l e
wi ndow i s i n moti on. I f the el ectroni c ci rcui t i n the
swi tch fai l s to detect a stal l current, the auto down
ci rcui t wi l l ti me out wi thi n 9 to 14 seconds.
REMOVAL
FRONT
cabl e.
(2) Usi ng a tri m sti ck, gentl y pry the swi tch from
the consol e (Fi g. 3).
(3) Di sconnect el ectri cal harness connector.
REAR
cabl e.
(2) Usi ng a tri m sti ck, gentl y pry the swi tch from
the consol e (Fi g. 4).
(3) Di sconnect el ectri cal harness connector.
INSTALLATION
FRONT
(1) Connect el ectri cal harness connector to swi tch.
Sl i de connector l ock i nto posi ti on.
(2) I nstal l swi tch i nto openi ng i n consol e and press
i nto pl ace.
REAR
(1) Connect el ectri cal harness connector to swi tch.
(2) I nstal l swi tch i nto openi ng i n consol e and press
i nto pl ace.
Fig. 3 FRONT WINDOW SWITCH
1 - FRONT WINDOW SWITCH
3 - CENTER CONSOLE
Fig. 4 REAR WINDOW SWITCH
1 - CENTER CONSOLE
3 - REAR WINDOW SWITCH
KJ POWER WINDOWS 8N - 23
WINDOW SWITCH (Continued)
RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WARNING - RESTRAINT SYSTEM . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - SERVICE
AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT. . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - VERIFICATION
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AIRBAG CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
CHILD TETHER ANCHOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CLOCKSPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE - CLOCKSPRING
CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
DRIVER AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
FRONT IMPACT SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
FRONT SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
FRONT SEAT BELT BUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
PASSENGER AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
PASSENGER AIRBAG DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
PASSENGER AIRBAG MOUNTING BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REAR CENTER SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
REAR OUTBOARD SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
REAR SEAT BELT BUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
SEAT BELT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SEAT BELT TENSIONER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SEAT BELT TURNING LOOP ADJUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
SIDE CURTAIN AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
SIDE IMPACT AIRBAG CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
KJ RESTRAINTS 8O - 1
RESTRAINTS
DESCRIPTION
Fig. 1 Supplemental Restraint System
1 - FRONT IMPACT SENSOR (2)
2 - AIRBAG CONTROL MODULE
3 - PASSENGER AIRBAG
4 - DRIVER AIRBAG
5 - SIDE CURTAIN AIRBAG (2)
6 - DRIVER SEAT BELT TENSIONER
7 - SIDE IMPACT AIRBAG CONTROL MODULE (2)
8O - 2 RESTRAINTS KJ
An occupant restrai nt system i s standard factory-
i nstal l ed safety equi pment on thi s model . Avai l abl e
occupant restrai nts for thi s model i ncl ude both acti ve
and passi ve types. Acti ve restrai nts are those whi ch
requi re the vehi cl e occupants to take some acti on to
empl oy, such as fasteni ng a seat bel t; whi l e passi ve
restrai nts requi re no acti on by the vehi cl e occupants
to be empl oyed (Fi g. 1).
ACTI VE RESTRAI NTS The acti ve restrai nts for
thi s model i ncl ude:
Front Seat Belts - Both front seati ng posi ti ons
are equi pped wi th three-poi nt seat bel t systems
empl oyi ng a l ower B-pi l l ar mounted i nerti a l atch-
type retractor, hei ght-adjustabl e upper B-pi l l ar
mounted turni ng l oops, a travel i ng l ower seat bel t
anchor secured to the outboard si de of the seat
frame, and a travel i ng end-rel ease seat bel t buckl e
secured to the i nboard si de of the seat frame. Both
front seat bel t buckl es i ncl ude an i ntegral Hal l -effect
seat bel t swi tch that detects whether i ts respecti ve
seat bel t has been fastened.
Rear Seat Belts - Al l three rear seati ng posi -
ti ons are equi pped wi th three-poi nt seat bel t sys-
tems. The outboard seati ng posi ti on bel ts empl oy a
l ower C-pi l l ar mounted i nerti a l atch-type retractor, a
fi xed posi ti on upper C-pi l l ar mounted turni ng l oop,
and a fi xed l ower seat bel t anchor secured to the
fl oor panel . The rear seat center seati ng posi ti on bel t
has an i nerti a l atch-type retractor that i s i ntegral to
the rear seat back panel , and a cabl e from the seat
back l atch l ocks the center bel t retractor spool unl ess
the seat back i s ful l y l atched. The rear seat center
seati ng posi ti on bel t l ower anchor i s secured to the
fl oor panel . Al l three rear seat bel ts have fi xed end-
rel ease seat bel t buckl es secured to the fl oor panel , a
si ngl e buckl e uni t on the ri ght si de and a doubl e
buckl e uni t on the l eft si de.
Child Seat Tether Anchors - Al l vehi cl es are
equi pped wi th three, fi xed-posi ti on, chi l d seat tether
anchors. Two anchors are i ntegral to the back of the
ri ght rear seat back panel , and one i s i ntegral to the
l eft rear seat back panel .
PASSI VE RESTRAI NTS The passi ve restrai nts
avai l abl e for thi s model i ncl ude the fol l owi ng:
Dual Front Airbags - Mul ti stage dri ver and
front passenger ai rbags are avai l abl e for thi s model .
Thi s ai rbag system i s a passi ve, i nfl atabl e, Suppl e-
mental Restrai nt System (SRS) and vehi cl es wi th
thi s equi pment can be readi l y i denti fi ed by the SRS
- AI RBAG l ogo mol ded i nto the dri ver ai rbag tri m
cover i n the center of the steeri ng wheel and al so
i nto the passenger ai rbag door on the i nstrument
panel above the gl ove box (Fi g. 2). Vehi cl es wi th the
ai rbag system can al so be i denti fi ed by the ai rbag
i ndi cator, whi ch wi l l i l l umi nate i n the i nstrument
cl uster for about seven seconds as a bul b test each
ti me the i gni ti on swi tch i s turned to the On posi ti on.
A pyrotechni c-type seat bel t tensi oner i s i ntegral to
the dri ver si de front seat bel t retractor mounted on
the l ower B-pi l l ar of al l model s equi pped wi th dual
front ai rbags.
Side Curtain Airbags - Opti onal si de curtai n
ai rbags are avai l abl e for thi s model when i t i s al so
equi pped wi th dual front ai rbags. Thi s ai rbag system
i s a passi ve, i nfl atabl e, Suppl emental Restrai nt Sys-
tem (SRS) and vehi cl es wi th thi s equi pment can be
readi l y i denti fi ed by a mol ded i denti fi cati on tri m but-
ton wi th the SRS - AI RBAG l ogo l ocated on the
headl i ner above each B-pi l l ar (Fi g. 2).
The suppl emental restrai nt system i ncl udes the
fol l owi ng major components, whi ch are descri bed i n
further detai l el sewhere i n thi s servi ce i nformati on:
Airbag Control Module - The Ai rbag Control
Modul e (ACM) i s al so someti mes referred to as the
Occupant Restrai nt Control l er (ORC). The ACM i s
l ocated on a mount on the fl oor panel transmi ssi on
tunnel , bel ow the center of the i nstrument panel .
Airbag Indicator - The ai rbag i ndi cator i s i nte-
gral to the El ectroMechani cal I nstrument Cl uster
(EMI C), whi ch i s l ocated on the i nstrument panel i n
front of the dri ver.
Clockspring - The cl ockspri ng i s l ocated near
the top of the steeri ng col umn, di rectl y beneath the
steeri ng wheel .
Driver Airbag - The dri ver ai rbag i s l ocated i n
the center of the steeri ng wheel , beneath the dri ver
ai rbag tri m cover.
Driver Knee Blocker - The dri ver knee bl ocker
i s a structural uni t secured to the back si de of and
i ntegral to the i nstrument panel steeri ng col umn
openi ng cover.
Front Impact Sensor - Two front i mpact sen-
sors are used on vehi cl es equi pped wi th dual front
ai rbags, one l eft si de and one ri ght si de. One sensor
Fig. 2 SRS Logo
RESTRAINTS (Continued)
i s l ocated on the back si de of each verti cal member of
the radi ator support.
Passenger Airbag - The passenger ai rbag i s
l ocated on the i nstrument panel , beneath the passen-
ger ai rbag door on the i nstrument panel above the
gl ove box on the passenger si de of the vehi cl e.
Passenger Knee Blocker - The passenger knee
bl ocker i s a structural rei nforcement that i s i ntegral
to and conceal ed wi thi n the gl ove box door.
Seat Belt Tensioner - The seat bel t tensi oner
i s i ntegral to the dri ver si de front seat bel t retractor
uni t on vehi cl es equi pped wi th dual front ai rbags.
Side Impact Airbag Control Module - Two
Si de I mpact Ai rbag Control Modul es (SI ACM) are
used on vehi cl es wi th the opti onal si de curtai n ai r-
bags, one l eft si de and one ri ght si de. One SI ACM i s
l ocated behi nd the B-pi l l ar tri m near the base of each
B-pi l l ar.
Side Curtain Airbag - I n vehi cl es equi pped
wi th thi s opti on, a si de curtai n ai rbag i s l ocated on
each i nsi de roof si de rai l above the headl i ner, and
extends from the A-pi l l ar to just beyond the C-pi l l ar.
The ACM, both SI ACMs, and the EMI C each con-
tai n a central processi ng uni t and programmi ng that
al l ow them to communi cate wi th each other usi ng
the Programmabl e Communi cati on I nterface (PCI )
data bus network. Thi s method of communi cati on i s
used by the ACM for control of the ai rbag i ndi cator
on al l model s equi pped wi th dual front ai rbags.
(Refer to 8 - ELECTRI CAL/ELECTRONI C CON-
TROL MODULES/COMMUNI CATI ON - DESCRI P-
TI ON).
Hard wi red ci rcui try connects the suppl emental
restrai nt system components to each other through
the el ectri cal system of the vehi cl e. These hard wi red
ci rcui ts are i ntegral to several wi re harnesses, whi ch
are routed throughout the vehi cl e and retai ned by
many di fferent methods. These ci rcui ts may be con-
nected to each other, to the vehi cl e el ectri cal system,
and to the suppl emental restrai nt system compo-
nents through the use of a combi nati on of sol dered
spl i ces, spl i ce bl ock connectors, and many di fferent
types of wi re harness termi nal connectors and i nsu-
l ators. Refer to the appropri ate wi ri ng i nformati on.
The wi ri ng i nformati on i ncl udes wi ri ng di agrams,
proper wi re and connector repai r procedures, further
detai l s on wi re harness routi ng and retenti on, as wel l
as pi n-out and l ocati on vi ews for the vari ous wi re
OPERATION
ACTI VE RESTRAI NTS The pri mary passenger
restrai nts i n thi s or any other vehi cl e are the stan-
dard equi pment factory-i nstal l ed seat bel ts. Seat
bel ts are referred to as an acti ve restrai nt because
the vehi cl e occupants are requi red to physi cal l y fas-
ten and properl y adjust these restrai nts i n order to
benefi t from them. See the owners manual i n the
vehi cl e gl ove box for more i nformati on on the fea-
tures, use and operati on of al l of the factory-i nstal l ed
acti ve restrai nts.
PASSI VE RESTRAI NTS The passi ve restrai nts
system i s referred to as a suppl emental restrai nt sys-
tem because they were desi gned and are i ntended to
enhance the protecti on for the vehi cl e occupants of
the vehi cl e only when used i n conjuncti on wi th the
seat bel ts. They are referred to as passi ve systems
because the vehi cl e occupants are not requi red to do
anythi ng to make them operate; however, the vehi cl e
occupants must be weari ng thei r seat bel ts i n order
to obtai n the maxi mum safety benefi t from the facto-
ry-i nstal l ed suppl emental restrai nt systems.
The suppl emental restrai nt system el ectri cal ci r-
cui ts are conti nuousl y moni tored and control l ed by a
mi croprocessor and software contai ned wi thi n the
Ai rbag Control Modul e (ACM) and, on vehi cl es
equi pped wi th the si de curtai n ai rbags, both Si de
I mpact Ai rbag Control Modul es (SI ACM). An ai rbag
i ndi cator i n the El ectroMechani cal I nstrument Cl us-
ter (EMI C) i l l umi nates for about seven seconds as a
bul b test each ti me the i gni ti on swi tch i s turned to
the On or Start posi ti ons. Fol l owi ng the bul b test,
the ai rbag i ndi cator i s turned on or off by the ACM
to i ndi cate the status of the suppl emental restrai nt
system. I f the ai rbag i ndi cator comes on at any ti me
other than duri ng the bul b test, i t i ndi cates that
there i s a probl em i n the suppl emental restrai nt sys-
tem el ectri cal ci rcui ts. Such a probl em may cause ai r-
bags not to depl oy when requi red, or to depl oy when
not requi red.
Depl oyment of the suppl emental restrai nts
depends upon the angl e and severi ty of an i mpact.
Depl oyment i s not based upon vehi cl e speed; rather,
depl oyment i s based upon the rate of decel erati on as
measured by the forces of gravi ty (G force) upon the
i mpact sensors. When an i mpact i s severe enough,
the mi croprocessor i n the ACM or the SI ACM si gnal s
the i nfl ator uni t of the ai rbag modul e to depl oy the
ai rbag. The seat bel t tensi oner i s provi ded wi th a
depl oyment si gnal by the ACM i n conjuncti on wi th
the dri ver ai rbag. Duri ng a frontal vehi cl e i mpact,
the knee bl ockers work i n concert wi th properl y fas-
tened and adjusted seat bel ts to restrai n both the
dri ver and the front seat passenger i n the proper
posi ti on for an ai rbag depl oyment. The knee bl ockers
al so absorb and di stri bute the crash energy from the
dri ver and the front seat passenger to the structure
of the i nstrument panel . The seat bel t tensi oner
removes the sl ack from the dri ver si de front seat bel t
to provi de further assurance that the dri ver i s prop-
erl y posi ti oned and restrai ned for an ai rbag depl oy-
ment.
Typi cal l y, the vehi cl e occupants recal l more about
the events precedi ng and fol l owi ng a col l i si on than
they have of an ai rbag depl oyment i tsel f. Thi s i s
because the ai rbag depl oyment and defl ati on occur so
rapi dl y. I n a typi cal 48 ki l ometer-per-hour (30 mi l e-
per-hour) barri er i mpact, from the moment of i mpact
unti l the ai rbags are ful l y i nfl ated takes about 40
mi l l i seconds. Wi thi n one to two seconds from the
moment of i mpact, the ai rbags are al most enti rel y
defl ated. The ti mes ci ted for these events are approx-
i mati ons, whi ch appl y onl y to a barri er i mpact at the
gi ven speed. Actual ti mes wi l l vary somewhat,
dependi ng upon the vehi cl e speed, i mpact angl e,
severi ty of the i mpact, and the type of col l i si on.
When the ACM moni tors a probl em i n any of the
dual front ai rbag system ci rcui ts or components,
i ncl udi ng the seat bel t tensi oner, i t stores a faul t
code or Di agnosti c Troubl e Code (DTC) i n i ts memory
ci rcui t and sends an el ectroni c message to the EMI C
to turn on the ai rbag i ndi cator. When the SI ACM
moni tors a probl em i n any of the si de curtai n ai rbag
system ci rcui ts or component, i t stores a faul t code or
Di agnosti c Troubl e Code (DTC) i n i ts memory ci rcui t
and sends an el ectroni c message to the ACM, and the
ACM sends an el ectroni c message to the EMI C to
turn on the ai rbag i ndi cator. Proper testi ng of the
ai rbag system components, the Programmabl e Com-
muni cati on I nterface (PCI ) data bus, the data bus
message i nputs to and outputs from the EMI C, the
SI ACM, or the ACM, as wel l as the retri eval or era-
sure of a DTC from the ACM, SI ACM, or EMI C
See the owners manual i n the vehi cl e gl ove box for
more i nformati on on the features, use and operati on
of al l of the factory-i nstal l ed passi ve restrai nts.
WARNING - RESTRAINT SYSTEM
WARNING: DURING AND FOLLOWING ANY SEAT
BELT SERVICE, CAREFULLY INSPECT ALL SEAT
BELTS, BUCKLES, MOUNTING HARDWARE, AND
RETRACTORS FOR PROPER INSTALLATION,
OPERATION, OR DAMAGE. REPLACE ANY BELT
THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN
ANY BELT THAT IS TWISTED. TIGHTEN ANY
LOOSE FASTENERS. REPLACE ANY BELT THAT
HAS A DAMAGED OR INOPERATIVE BUCKLE OR
RETRACTOR. REPLACE ANY BELT THAT HAS A
BENT OR DAMAGED LATCH PLATE OR ANCHOR
PLATE. NEVER ATTEMPT TO REPAIR A SEAT BELT
COMPONENT. ALWAYS REPLACE DAMAGED OR
FAULTY SEAT BELT COMPONENTS WITH THE COR-
RECT, NEW AND UNUSED REPLACEMENT PARTS
LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS
CATALOG.
FRONT IMPACT SENSOR, SIDE CURTAIN AIRBAG,
PERSONAL INJURY.
WARNING: AN AIRBAG INFLATOR UNIT MAY CON-
TAIN SODIUM AZIDE AND POTASSIUM NITRATE.
THESE MATERIALS ARE POISONOUS AND
EXTREMELY FLAMMABLE. CONTACT WITH ACID,
WATER, OR HEAVY METALS MAY PRODUCE HARM-
FUL AND IRRITATING GASES (SODIUM HYDROXIDE
IS FORMED IN THE PRESENCE OF MOISTURE) OR
COMBUSTIBLE COMPOUNDS. AN AIRBAG INFLA-
TOR UNIT MAY ALSO CONTAIN A GAS CANISTER
PRESSURIZED TO OVER 2500 PSI. DO NOT
ATTEMPT TO DISMANTLE AN AIRBAG UNIT OR
TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE,
INCINERATE, OR BRING INTO CONTACT WITH
ELECTRICITY. DO NOT STORE AT TEMPERATURES
EXCEEDING 93 C (200 F).
WARNING: WHEN HANDLING A SEAT BELT TEN-
SIONER RETRACTOR, PROPER CARE SHOULD BE
EXERCISED TO KEEP FINGERS OUT FROM UNDER
THE RETRACTOR COVER AND AWAY FROM THE
SEAT BELT WEBBING WHERE IT EXITS FROM THE
RETRACTOR COVER.
WARNING: REPLACE ALL RESTRAINT SYSTEM
COMPONENTS ONLY WITH PARTS SPECIFIED IN
THE DAIMLERCHRYSLER MOPAR PARTS CATA-
LOG. SUBSTITUTE PARTS MAY APPEAR INTER-
CHANGEABLE, BUT INTERNAL DIFFERENCES MAY
RESULT IN INFERIOR OCCUPANT PROTECTION.
WARNING: THE FASTENERS, SCREWS, AND
BOLTS ORIGINALLY USED FOR THE RESTRAINT
SYSTEM COMPONENTS HAVE SPECIAL COATINGS
AND ARE SPECIFICALLY DESIGNED FOR THE
RESTRAINT SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANY TIME A
NEW FASTENER IS NEEDED, REPLACE IT WITH
THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
WARNING: WHEN A STEERING COLUMN HAS AN
AIRBAG UNIT ATTACHED, NEVER PLACE THE COL-
UMN ON THE FLOOR OR ANY OTHER SURFACE
WITH THE STEERING WHEEL OR AIRBAG UNIT
FACE DOWN.
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM
Proper di agnosi s and testi ng of the suppl emental
restrai nt system components, the PCI data bus, the
data bus message i nputs to and outputs from the
El ectroMechani cal I nstrument Cl uster (EMI C), the
Ai rbag Control Modul e (ACM), or the Si de I mpact
Ai rbag Control Modul e (SI ACM) as wel l as the
retri eval or erasure of a Di agnosti c Troubl e Code
(DTC) from the ACM or SI ACM requi res the use of a
ti c i nformati on.
PERSONAL INJURY.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL RESTRAINTS
At no ti me shoul d any source of el ectri ci ty be per-
mi tted near the i nfl ator on the back of a non-de-
pl oyed ai rbag or seat bel t tensi oner. When carryi ng a
non-depl oyed ai rbag, the tri m cover or ai rbag cushi on
si de of the uni t shoul d be poi nted away from the
body to mi ni mi ze i njury i n the event of an acci dental
depl oyment. I f the ai rbag uni t i s pl aced on a bench or
any other surface, the tri m cover or ai rbag cushi on
si de of the uni t shoul d be face up to mi ni mi ze move-
ment i n the event of an acci dental depl oyment. When
handl i ng a non-depl oyed seat bel t tensi oner, take
proper care to keep fi ngers out from under the
retractor cover and away from the seat bel t webbi ng
where i t exi ts from the retractor cover. I n addi ti on,
the suppl emental restrai nt system shoul d be di s-
armed whenever any steeri ng wheel , steeri ng col -
umn, seat bel t tensi oner, dri ver ai rbag, passenger
ai rbag, front i mpact sensor, si de curtai n ai rbag, or
i nstrument panel components requi re di agnosi s or
servi ce. Fai l ure to observe thi s warni ng coul d resul t
i n acci dental ai rbag depl oyment and possi bl e per-
sonal i njury.
Al l damaged, faul ty or non-depl oyed ai rbags and
seat bel t tensi oners whi ch are repl aced on vehi cl es
are to be handl ed and di sposed of properl y. I f an ai r-
bag or seat bel t tensi oner uni t i s faul ty or damaged
and non-depl oyed, refer to the Hazardous Substance
Control System for proper di sposal . Di spose of al l
non-depl oyed and depl oyed ai rbags and seat bel t ten-
si oners i n a manner consi stent wi th state, provi nci al ,
l ocal and federal regul ati ons.
SUPPLEMENTAL RESTRAINT STORAGE
Ai rbags and seat bel t tensi oners must be stored i n
thei r ori gi nal , speci al contai ner unti l they are used
for servi ce. Al so, they must be stored i n a cl ean, dry
envi ronment; away from sources of extreme heat,
sparks, and hi gh el ectri cal energy. Al ways pl ace or
store any ai rbag on a surface wi th i ts tri m cover or
ai rbag cushi on si de faci ng up, to mi ni mi ze movement
i n case of an acci dental depl oyment.
STANDARD PROCEDURE - SERVICE AFTER A
SUPPLEMENTAL RESTRAINT DEPLOYMENT
Any vehi cl e whi ch i s to be returned to use fol l ow-
i ng a suppl emental restrai nt depl oyment, must have
the depl oyed restrai nts repl aced. I n addi ti on, i f the
dri ver ai rbag has been depl oyed, the cl ockspri ng
must be repl aced. I f the passenger ai rbag i s
depl oyed, the passenger ai rbag door and both passen-
ger ai rbag mounti ng brackets must be repl aced. I f a
si de curtai n ai rbag has been depl oyed, the compl ete
ai rbag uni t, the headl i ner, as wel l as the upper A, B,
and C-pi l l ar tri m must be repl aced. These compo-
nents are not i ntended for reuse and wi l l be damaged
or weakened as a resul t of a suppl emental restrai nt
depl oyment, whi ch may or may not be obvi ous duri ng
a vi sual i nspecti on.
On vehi cl es wi th an opti onal sunroof, the sunroof
drai n tubes and hoses must be cl osel y i nspected fol -
l owi ng a si de curtai n ai rbag depl oyment. I t i s al so
cri ti cal that the mounti ng surfaces and/or mounti ng
brackets for the Ai rbag Control Modul e (ACM), Si de
I mpact Ai rbag Control Modul e (SI ACM), and front
i mpact sensors be cl osel y i nspected and restored to
thei r ori gi nal condi ti ons fol l owi ng any vehi cl e i mpact
damage. Because the ACM, SI ACM, and each front
i mpact sensor are used by the suppl emental restrai nt
system to moni tor or confi rm the di recti on and sever-
i ty of a vehi cl e i mpact, i mproper ori entati on or i nse-
cure fasteni ng of these components may cause
ai rbags not to depl oy when requi red, or to depl oy
when not requi red. Al l other vehi cl e components
shoul d be cl osel y i nspected fol l owi ng any other sup-
pl emental restrai nt depl oyment, but are to be
repl aced onl y as requi red by the extent of the vi si bl e
damage i ncurred.
AIRBAG SQUIB STATUS
Mul ti stage ai rbags wi th mul ti pl e i ni ti ators (squi bs)
must be checked to determi ne that al l squi bs were
used duri ng the depl oyment event. The dri ver and
passenger ai rbags i n thi s model are depl oyed by el ec-
tri cal si gnal s generated by the Ai rbag Control Mod-
ul e (ACM) through the dri ver or passenger squi b 1
and squi b 2 ci rcui ts to the two i ni ti ators i n the ai r-
bag i nfl ators. Typi cal l y, both i ni ti ators are used and
al l potenti al l y hazardous chemi cal s are burned dur-
i ng an ai rbag depl oyment event. However, i t i s possi -
bl e for onl y one i ni ti ator to be used due to an ai rbag
system faul t; therefore, i t i s al ways necessary to con-
fi rm that both i ni ti ators have been used i n order to
avoi d the i mproper handl i ng or di sposal of poten-
ti al l y l i ve pyrotechni c or hazardous materi al s. The
fol l owi ng procedure shoul d be performed usi ng a
DRBI I I scan tool to veri fy the status of both ai rbag
squi bs before ei ther depl oyed ai rbag i s removed from
the vehi cl e for di sposal .
CAUTION: Deployed front airbags having two initia-
tors (squibs) in the airbag inflator may or may not
have live pyrotechnic material within the inflator. Do
not dispose of these airbags unless you are sure of
complete deployment. Refer to the Hazardous Sub-
stance Control System for proper disposal proce-
dures. Dispose of all non-deployed and deployed
airbags in a manner consistent with state, provin-
cial, local, and federal regulations.
(1) Be certai n that the DRBI I I scan tool contai ns
the l atest versi on of the proper DRBI I I software.
Connect the DRBI I I to the 16-way Data Li nk Con-
nector (DLC). The DLC i s l ocated on the dri ver si de
l ower edge of the i nstrument panel , outboard of the
steeri ng col umn.
(3) Usi ng the DRBI I I , read and record the acti ve
(current) Di agnosti c Troubl e Code (DTC) data.
Usi ng the acti ve DTC i nformati on, refer to the Air-
bag Squib Status tabl e to determi ne the status of
both dri ver and/or passenger ai rbag squi bs.
AIRBAG SQUIB STATUS
IF the Active DTC is: Conditions Squib Status
Driver or Passenger Squib 1 open AND the stored DTC mi nutes for both
Dri ver or Passenger squi bs are wi thi n 15
mi nutes of each other
Both Squib 1 and 2
were used.
Driver or Passenger Squib 2 open
Driver or Passenger Squib 1 open AND the stored DTC mi nutes for Dri ver or
Passenger Squi b 2 open i s GREATER than
the stored DTC mi nutes for Dri ver or
Passenger Squi b 1 by 15 mi nutes or more
Squib 1 was used;
Squib 2 is live.
Driver or Passenger Squib 1 open AND the stored DTC mi nutes for Dri ver or
Passenger Squi b 1 open i s GREATER than
the stored DTC mi nutes for Dri ver or
Passenger Squi b 2 by 15 mi nutes or more
Squib 1 is live; Squib
2 was used.
Driver or Passenger Squib 1 open AND Dri ver or Passenger Squi b 2 open i s
NOT an acti ve code
Squib 1 was used;
Squib 2 is live.
Driver or Passenger Squib 2 open AND Dri ver or Passenger Squi b 1 open i s
NOT an acti ve code
Squib 1 is live; Squib
2 was used.
If none of the Dri ver or Passenger Squi b 1 or 2
open are acti ve codes, the status of the ai rbag squi bs
i s unknown. I n thi s case the ai rbag shoul d be han-
dl ed and di sposed of as i f the squi bs were both l i ve.
CLEANUP PROCEDURE
Fol l owi ng a suppl emental restrai nt depl oyment,
the vehi cl e i nteri or wi l l contai n a powdery resi due.
Thi s resi due consi sts pri mari l y of harml ess parti cu-
l ate by-products of the smal l pyrotechni c charge that
i ni ti ates the propel l ant used to depl oy a suppl emen-
tal restrai nt. However, thi s resi due may al so contai n
traces of sodi um hydroxi de powder, a chemi cal
by-product of the propel l ant materi al that i s used to
generate the i nert gas that i nfl ates the ai rbag. Si nce
sodi um hydroxi de powder can i rri tate the ski n, eyes,
nose, or throat, be sure to wear safety gl asses, rubber
gl oves, and a l ong-sl eeved shi rt duri ng cl eanup (Fi g.
3).
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE IRRITA-
TION OF THE NOSE OR THROAT, EXIT THE VEHICLE
FOR FRESH AIR UNTIL THE IRRITATION CEASES. IF
IRRITATION CONTINUES, SEE A PHYSICIAN.
(1) Begi n the cl eanup by usi ng a vacuum cl eaner
to remove any resi dual powder from the vehi cl e i nte-
ri or. Cl ean from outsi de the vehi cl e and work your
way i nsi de, so that you avoi d kneel i ng or si tti ng on a
non-cl eaned area.
(2) Be certai n to vacuum the heater and ai r condi -
ti oni ng outl ets as wel l (Fi g. 4). Run the heater and
ai r condi ti oner bl ower on the l owest speed setti ng
and vacuum any powder expel l ed from the outl ets.
CAUTION: Deployed front airbags having two initiators
(squibs) in the airbag inflator may or may not have live
pyrotechnic material within the inflator. Do not dispose
of these airbags unless you are sure of complete
deployment. Refer to AIRBAG SQUIB STATUS . Refer
to the Hazardous Substance Control System for
proper disposal procedures. Dispose of all non-de-
ployed and deployed airbags in a manner consistent
with state, provincial, local, and federal regulations.
(3) Next, remove the depl oyed suppl emental
restrai nts from the vehi cl e. Refer to the appropri ate
servi ce removal procedures.
(4) You may need to vacuum the i nteri or of the
vehi cl e a second ti me to recover al l of the powder.
STANDARD PROCEDURE - VERIFICATION TEST
The fol l owi ng procedure shoul d be performed usi ng
a DRBI I I scan tool to veri fy proper suppl emental
restrai nt system operati on fol l owi ng the servi ce or
repl acement of any suppl emental restrai nt system
component.
PERSONAL INJURY.
Fig. 3 Wear Safety Glasses and Rubber Gloves -
Typical
Fig. 4 Vacuum Heater and A/C Outlets - Typical
(1) Duri ng the fol l owi ng test, the battery negati ve
cabl e remai ns di sconnected and i sol ated, as i t was
duri ng the ai rbag component removal and i nstal l a-
ti on procedures.
(2) Be certai n that the DRBI I I scan tool contai ns
the l atest versi on of the proper DRBI I I software.
Connect the DRBI I I to the 16-way Data Li nk Con-
nector (DLC). The DLC i s l ocated on the dri ver si de
l ower edge of the i nstrument panel , outboard of the
steeri ng col umn (Fi g. 5).
(3) Turn the i gni ti on swi tch to the On posi ti on and
exi t the vehi cl e wi th the DRBI I I scan tool .
(4) Check to be certai n that nobody i s i n the vehi -
cl e, then reconnect the battery negati ve cabl e.
(5) Usi ng the DRBI I I , read and record the acti ve
(current) Di agnosti c Troubl e Code (DTC) data.
(6) Next, use the DRBI I I to read and record any
stored (hi stori cal ) DTC data.
(7) I f any DTC i s found i n Step 5 or Step 6, refer
(8) Use the DRBI I I to erase the stored DTC data.
I f any probl ems remai n, the stored DTC data wi l l not
erase. Refer to the appropri ate di agnosti c i nforma-
ti on to di agnose any stored DTC that wi l l not erase.
I f the stored DTC i nformati on i s successful l y erased,
go to Step 9.
(9) Turn the i gni ti on swi tch to the Off posi ti on for
about fi fteen seconds, and then back to the On posi -
ti on. Observe the ai rbag i ndi cator i n the i nstrument
cl uster. I t shoul d i l l umi nate for si x to ei ght seconds,
and then go out. Thi s i ndi cates that the suppl emen-
tal restrai nt system i s functi oni ng normal l y and that
the repai rs are compl ete. I f the ai rbag i ndi cator fai l s
to l i ght, or l i ghts and stays on, there i s sti l l an acti ve
suppl emental restrai nt system faul t or mal functi on.
Refer to the appropri ate di agnosti c i nformati on to
di agnose the probl em.
AIRBAG CONTROL MODULE
DESCRIPTION
The Ai rbag Control Modul e (ACM) i s al so some-
ti mes referred to as the Occupant Restrai nt Control -
l er (ORC) (Fi g. 6). The ACM i s secured wi th two l ong
screws wi thi n a tray-l i ke stamped steel mounti ng
bracket wel ded onto the top of the fl oor panel trans-
mi ssi on tunnel forward of the i nstrument panel cen-
ter support bracket and bel ow the i nstrument panel
center stack i n the passenger compartment of the
vehi cl e.
Conceal ed wi thi n a hol l ow i n the center of the di e
cast al umi num ACM housi ng i s the el ectroni c ci r-
cui try of the ACM whi ch i ncl udes a mi croprocessor,
an el ectroni c i mpact sensor, an el ectromechani cal saf-
i ng sensor, and an energy storage capaci tor. A
stamped metal cover pl ate i s secured to the bottom of
the ACM housi ng wi th four screws to encl ose and
protect the i nternal el ectroni c ci rcui try and compo-
nents. An arrow cast i nto the top of the ACM housi ng
near the front provi des a vi sual veri fi cati on of the
proper ori entati on of the uni t, and shoul d al ways be
poi nted toward the front of the vehi cl e.
Fig. 5 16-Way Data Link Connector - Typical
1 - 16WAY DATA LINK CONNECTOR
2 - BOTTOM OF INSTRUMENT PANEL
Fig. 6 Airbag Control Module
2 - ORIENTATION ARROW
3 - CONNECTOR RECEPTACLES
4 - MOUNTING HOLES
5 - GROUND LUG
The ACM housi ng al so has an i ntegral ground l ug
wi th a tapped hol e that protrudes from the l ower l eft
rear corner of the uni t. Thi s l ug provi des a case
ground to the ACM when a ground screw i s i nstal l ed
through the l eft si de of the mounti ng bracket. Two
mol ded pl asti c el ectri cal connector receptacl es exi t
the ri ght si de of the ACM housi ng. The smal l er of the
two receptacl es contai ns twel ve termi nal pi ns, whi l e
the l arger one contai ns twenty-three. These termi nal
pi ns connect the ACM to the vehi cl e el ectri cal system
through two dedi cated take outs and connectors of
the i nstrument panel wi re harness.
A mol ded rubber protecti ve cover i s i nstal l ed
l oosel y over the ACM to protect the uni t from con-
densati on or cool ant l eaki ng from a damaged or
faul ty heater-ai r condi ti oner uni t housi ng. An i nte-
gral fl ange on the l eft si de of the cover i s secured to
the fl oor panel transmi ssi on tunnel wi th a short
pi ece of doubl e-faced tape as an assembl y ai d duri ng
the manufacturi ng process, but thi s tape does not
requi re repl acement fol l owi ng servi ce removal .
The i mpact sensor and safi ng sensor i nternal to
the ACM are cal i brated for the speci fi c vehi cl e, and
are onl y servi ced as a uni t wi th the ACM. The ACM
cannot be repai red or adjusted and, i f damaged or
faul ty, i t must be repl aced. The ACM cover i s avai l -
abl e for separate servi ce repl acement.
OPERATION
The mi croprocessor i n the Ai rbag Control Modul e
(ACM) contai ns the front suppl emental restrai nt sys-
tem l ogi c ci rcui ts and control s al l of the front suppl e-
mental restrai nt system components. The ACM uses
On-Board Di agnosti cs (OBD) and can communi cate
wi th other el ectroni c modul es i n the vehi cl e as wel l
as wi th the DRBI I I scan tool usi ng the Programma-
work. Thi s method of communi cati on i s used for
control of the ai rbag i ndi cator i n the El ectroMechani -
cal I nstrument Cl uster (EMI C) and for suppl emental
restrai nt system di agnosi s and testi ng through the
16-way data l i nk connector l ocated on the dri ver si de
l ower edge of the i nstrument panel . (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER/AI RBAG
I NDI CATOR - OPERATI ON).
The ACM mi croprocessor conti nuousl y moni tors al l
of the front suppl emental restrai nt system el ectri cal
ci rcui ts to determi ne the system readi ness. I f the
ACM detects a moni tored system faul t, i t sets an
acti ve and stored Di agnosti c Troubl e Code (DTC) and
sends el ectroni c messages to the EMI C over the PCI
data bus to turn on the ai rbag i ndi cator. An acti ve
faul t onl y remai ns for the durati on of the faul t or i n
some cases the durati on of the current i gni ti on
swi tch cycl e, whi l e a stored faul t causes a DTC to be
stored i n memory by the ACM. For some DTCs, i f a
faul t does not recur for a number of i gni ti on cycl es,
the ACM wi l l automati cal l y erase the stored DTC.
For other i nternal faul ts, the stored DTC i s l atched
forever.
On model s equi pped wi th opti onal si de curtai n ai r-
bags, the ACM communi cates wi th both the l eft and
ri ght Si de I mpact Ai rbag Control Modul es (SI ACM)
over the PCI data bus. The SI ACM noti fi es the ACM
when i t has detected a moni tored system faul t and
stored a DTC i n memory for i ts respecti ve si de cur-
tai n ai rbag system, and the ACM sets a DTC and
control s the ai rbag i ndi cator operati on accordi ngl y.
The ACM al so moni tors a Hal l effect-type seat bel t
swi tch l ocated i n the buckl e of each front seat bel t to
determi ne whether the seatbel ts are buckl ed, and
provi des an i nput to the EMI C over the PCI data bus
to control the seatbel t i ndi cator operati on based upon
the status of the dri ver si de front seat bel t swi tch.
The ACM recei ves battery current through two ci r-
cui ts; a fused i gni ti on swi tch output (run) ci rcui t
through a fuse i n the Juncti on Bl ock (JB), and a
through a second fuse i n the JB. The ACM has a case
ground through a l ug on the bottom of the ACM
housi ng that i s secured wi th a ground screw to the
l eft si de of the ACM mounti ng bracket. The ACM
al so recei ves a power ground through a ground ci r-
cui t and take out of the i nstrument panel wi re har-
ness. Thi s take out has a si ngl e eyel et termi nal
connector that i s secured by a second ground screw
to the l eft si de of the ACM mounti ng bracket. These
connecti ons al l ow the ACM to be operati onal when-
ever the i gni ti on swi tch i s i n the Start or On posi -
ti ons. The ACM al so contai ns an energy-storage
capaci tor. When the i gni ti on swi tch i s i n the Start or
On posi ti ons, thi s capaci tor i s conti nual l y bei ng
charged wi th enough el ectri cal energy to depl oy the
ai rbags for up to one second fol l owi ng a battery di s-
connect or fai l ure. The purpose of the capaci tor i s to
provi de backup suppl emental restrai nt system pro-
tecti on i n case there i s a l oss of battery current sup-
pl y to the ACM duri ng an i mpact.
Two sensors are contai ned wi thi n the ACM, an
el ectroni c i mpact sensor and a safi ng sensor. The
ACM al so moni tors i nputs from two remote front
i mpact sensors l ocated on the back of the ri ght and
l eft verti cal members of the radi ator support near
the front of the vehi cl e. The el ectroni c i mpact sensors
are accel erometers that sense the rate of vehi cl e
decel erati on, whi ch provi des veri fi cati on of the di rec-
ti on and severi ty of an i mpact. The safi ng sensor i s
an el ectromechani cal sensor wi thi n the ACM that
provi des an addi ti onal l ogi c i nput to the ACM mi cro-
processor. The safi ng sensor i s a normal l y open
swi tch that i s used to veri fy the need for an ai rbag
depl oyment by detecti ng i mpact energy of a l esser
AIRBAG CONTROL MODULE (Continued)
magni tude than that of the el ectroni c i mpact sensors,
and must be cl osed i n order for the ai rbags/seat bel t
tensi oner to depl oy. A pre-programmed deci si on al go-
ri thm i n the ACM mi croprocessor determi nes when
the decel erati on rate as si gnal ed by the i mpact sen-
sors and the safi ng sensor i ndi cate an i mpact that i s
severe enough to requi re front suppl emental
restrai nt system protecti on and, based upon the sta-
tus of the seatbel t swi tch i nputs and the severi ty of
the moni tored i mpact, determi nes what combi nati on
of dri ver seat bel t tensi oner and/or front ai rbag
depl oyment i s requi red for each front seati ng posi -
ti on. When the programmed condi ti ons are met, the
ACM sends the proper el ectri cal si gnal s to depl oy the
dri ver seat bel t tensi oner and/or the mul ti stage dual
front ai rbags at the programmed force l evel s.
The hard wi red i nputs and outputs for the ACM
ti onal di agnosti c methods wi l l not prove concl usi ve i n
the di agnosi s of the ACM, the PCI data bus network,
or the el ectroni c message i nputs to and outputs from
the ACM. The most rel i abl e, effi ci ent, and accurate
means to di agnose the ACM, the PCI data bus net-
work, and the el ectroni c message i nputs to and out-
puts from the ACM requi res the use of a DRBI I I
mati on.
REMOVAL
PERSONAL INJURY.
WARNING: THE AIRBAG CONTROL MODULE CON-
TAINS THE IMPACT SENSOR, WHICH ENABLES
THE SYSTEM TO DEPLOY THE FRONT SUPPLE-
MENTAL RESTRAINTS. NEVER STRIKE OR DROP
THE AIRBAG CONTROL MODULE, AS IT CAN DAM-
AGE THE IMPACT SENSOR OR AFFECT ITS CALI-
BRATION. IF AN AIRBAG CONTROL MODULE IS
ACCIDENTALLY DROPPED DURING SERVICE, THE
MODULE MUST BE SCRAPPED AND REPLACED
WITH A NEW UNIT. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN ACCIDENTAL,
INCOMPLETE, OR IMPROPER FRONT SUPPLEMEN-
TAL RESTRAINT DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.
cabl e. Wai t two mi nutes for the system capaci tor to
di scharge before further servi ce.
(2) Remove the center consol e from the top of the
fl oor panel transmi ssi on tunnel . (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - REMOVAL).
(3) From the l eft si de of the fl oor panel transmi s-
si on tunnel , remove the Ai rbag Control Modul e
(ACM) cover from the ACM (Fi g. 7). The cover fl ange
i s secured to the si l encer pad on the fl oor panel
transmi ssi on tunnel wi th doubl e-faced tape.
(4) Remove the ground screw that secures the
ground l ug on the l eft rear corner of the ACM hous-
i ng to the ACM bracket on the fl oor panel transmi s-
si on tunnel .
Fig. 7 ACM Cover Remove/Install
1 - FLANGE
2 - COVER
3 - TAPE
4 - SCREW
5 - BRACKET
7 - FLOOR PANEL TRANSMISSION TUNNEL
(5) Remove the two screws that secure the ACM to
the ACM bracket that i s wel ded onto the top of the
fl oor panel transmi ssi on tunnel (Fi g. 8).
(6) Li ft the ACM from the ACM bracket on the top
of the fl oor panel transmi ssi on tunnel and move the
uni t to the l eft far enough to access the ACM wi re
harness connectors.
ness connectors for the ACM from the ACM connector
receptacl es on the ri ght si de of the modul e. To di scon-
nect the l arge i nstrument panel wi re harness connec-
tor from the ACM:
(a) Sl i de the red Connector Posi ti on Assurance
(CPA) l ock on the top of the connector toward the
si de of the connector.
(b) Depress the connector l atch tab and pul l the
connector strai ght away from the ACM connector
receptacl e.
(8) Remove the ACM from the l eft si de of the fl oor
panel transmi ssi on tunnel .
INSTALLATION
PERSONAL INJURY.
WARNING: THE AIRBAG CONTROL MODULE CON-
TAINS THE IMPACT SENSOR, WHICH ENABLES
THE AIRBAG CONTROL MODULE, AS IT CAN DAM-
AGE THE IMPACT SENSOR OR AFFECT ITS CALI-
BRATION. IF AN AIRBAG CONTROL MODULE IS
ACCIDENTALLY DROPPED DURING SERVICE, THE
MODULE MUST BE SCRAPPED AND REPLACED
WITH A NEW UNIT. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN ACCIDENTAL,
INCOMPLETE, OR IMPROPER FRONT SUPPLEMEN-
TAL RESTRAINT DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.
(1) Posi ti on the Ai rbag Control Modul e (ACM) to
the l eft si de of the fl oor panel transmi ssi on tunnel
near the ACM bracket (Fi g. 8).
connectors for the ACM to the ACM connector recep-
tacl es on the ri ght si de of the modul e. Be certai n that
the l atches on both connectors and the red Connector
Posi ti on Assurance (CPA) l ock on the l arge connector
are each ful l y engaged.
(3) Careful l y posi ti on the ACM i nto the ACM
bracket on the top of the fl oor panel transmi ssi on
tunnel . When the ACM i s correctl y posi ti oned, the
arrow on the ACM housi ng wi l l be poi nted forward i n
the vehi cl e.
the ACM to the ACM bracket that i s wel ded onto the
fl oor panel transmi ssi on tunnel . Ti ghten the screws
to 36 Nm (26 ft. l bs.).
(5) I nstal l and ti ghten the ground screw that
secures the ground l ug on the l eft rear corner of the
ACM housi ng to the ACM bracket on the fl oor panel
transmi ssi on tunnel (Fi g. 7). Ti ghten the screw to 12
Nm (105 i n. l bs.).
(6) From the l eft si de of the fl oor panel transmi s-
si on tunnel , careful l y posi ti on the ACM cover back
over the top of the ACM.
Fig. 8 Airbag Control Module Remove/Install
3 - BRACKET
4 - SCREW (2)
NOTE: The integral flange on the left side of the
ACM cover is secured to the floor panel transmis-
sion tunnel with a short piece of double-faced tape
as an assembly aid during the manufacturing pro-
cess, but this tape does not require replacement
following service removal.
(7) Rei nstal l the center consol e onto the top of the
fl oor panel transmi ssi on tunnel . (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - I NSTALLATI ON).
(8) Do not reconnect the battery negati ve cabl e at
thi s ti me. The ai rbag system veri fi cati on test proce-
dure shoul d be performed fol l owi ng servi ce of any
suppl emental restrai nt system component. (Refer to
8 - ELECTRI CAL/RESTRAI NTS - STANDARD PRO-
CEDURE - VERI FI CATI ON TEST).
CHILD TETHER ANCHOR
DESCRIPTION
Al l vehi cl es are equi pped wi th three, fi xed-posi ti on,
chi l d seat tether anchors (Fi g. 9). Two anchors are
i ntegral to the back of the ri ght rear seat back panel ,
and one i s i ntegral to the l eft rear seat back panel .
The chi l d seat tether anchors cannot be adjusted or
repai red and, i f faul ty or damaged, they must be
repl aced as a uni t wi th the rear seat back panel .
OPERATION
more i nformati on on the proper use of the factory-i n-
stal l ed chi l d seat tether anchors.
CLOCKSPRING
DESCRIPTION
The cl ockspri ng assembl y i s secured wi th two i nte-
gral pl asti c l atches onto the upper steeri ng col umn
housi ng near the top of the steeri ng col umn behi nd
the steeri ng wheel (Fi g. 10). The cl ockspri ng consi sts
of a fl at, round mol ded pl asti c case wi th a stubby tai l
that hangs bel ow the steeri ng col umn and contai ns
two connector receptacl es that face toward the
i nstrument panel (Fi g. 11). Wi thi n the pl asti c hous-
i ng i s a spool -l i ke mol ded pl asti c rotor wi th a l arge
exposed hub and several pl asti c rol l ers. The upper
surface of the rotor hub has a l arge center hol e, a
rel ease button, a cl ear pl asti c i nspecti on wi ndow, two
short pi gtai l wi res wi th connectors, and a connector
receptacl e that faces toward the steeri ng wheel . Two
versi ons of the cl ockspri ng are used on thi s model ,
one i s a seven ci rcui t uni t for vehi cl es not equi pped
wi th opti onal remote radi o swi tches on the steeri ng
wheel and can be vi sual l y i denti fi ed by the use of yel -
l ow heat-shri nk tubi ng on the pi gtai l wi res, whi l e the
other i s a ni ne ci rcui t uni t for vehi cl es wi th remote
radi o swi tches and can be vi sual l y i denti fi ed by the
use of bl ack heat-shri nk tubi ng on the pi gtai l wi res.
A rubber bumper bl ock i s l ocated on each si de of
the tower formati on that contai ns the connector
receptacl e and pi gtai l wi res on the upper surface of
the rotor hub. The l ower surface of the rotor hub has
Fig. 9 Child Tether Anchors
1 - REAR SEAT BACK (LEFT)
2 - REAR SEAT BACK (RIGHT)
3 - CHILD TETHER ANCHOR (3)
Fig. 10 Clockspring
1 - PIGTAIL WIRE (2)
2 - UPPER CONNECTOR RECEPTACLE
3 - BUMPER (2)
4 - BRACKET (2)
5 - LABEL
6 - SHIELD
7 - CASE
8 - WINDOW
9 - ROTOR
a mol ded pl asti c turn si gnal cancel cam wi th a si ngl e
l obe that i s i ntegral to the rotor. Wi thi n the pl asti c
case and wound around the rotor spool i s a l ong ri b-
bon-l i ke tape that consi sts of several thi n copper wi re
l eads sandwi ched between two thi n pl asti c mem-
branes. The outer end of the tape termi nates at the
connector receptacl es that face the i nstrument panel ,
whi l e the i nner end of the tape termi nates at the pi g-
tai l wi res and connector receptacl e on the hub of the
cl ockspri ng rotor that face the steeri ng wheel .
Servi ce repl acement cl ockspri ngs are shi pped pre-
centered and wi th a mol ded pl asti c shi el d that snaps
onto the rotor over the rel ease button. The rel ease
button secures the centered cl ockspri ng rotor to the
cl ockspri ng case and the shi el d prevents the rel ease
button from bei ng i nadvertentl y depressed duri ng
shi pment and handl i ng, but the shi el d must be
removed from the cl ockspri ng after i t i s i nstal l ed on
the steeri ng col umn. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - STANDARD PROCE-
DURE - CLOCKSPRI NG CENTERI NG).
The cl ockspri ng cannot be repai red. I f the cl ock-
spri ng i s faul ty, damaged, or i f the dri ver ai rbag has
been depl oyed, the cl ockspri ng must be repl aced.
OPERATION
The cl ockspri ng i s a mechani cal el ectri cal ci rcui t
component that i s used to provi de conti nuous el ectri -
cal conti nui ty between the fi xed i nstrument panel
wi re harness and the el ectri cal components mounted
on or i n the rotati ng steeri ng wheel . On thi s model
the rotati ng el ectri cal components i ncl ude the dri ver
ai rbag, the horn swi tch, the speed control swi tches,
and the remote radi o swi tches, i f the vehi cl e i s so
equi pped. The cl ockspri ng case i s posi ti oned and
secured to the upper steeri ng col umn housi ng near
the top of the steeri ng col umn. The connector recep-
tacl es on the tai l of the fi xed cl ockspri ng case connect
the cl ockspri ng to the vehi cl e el ectri cal system
through two take outs wi th connectors from the
i nstrument panel wi re harness. The cl ockspri ng rotor
i s movabl e and i s keyed by the tower formati on that
i s mol ded onto the upper surface of the rotor hub to
an openi ng that i s cast i nto the steeri ng wheel arma-
ture. Rubber bumper bl ocks on ei ther si de of the
cl ockspri ng tower formati on el i mi nate contact noi se
between the cl ockspri ng tower and the steeri ng
wheel . The l obe of the turn si gnal cancel cam on the
l ower surface of the cl ockspri ng rotor hub contacts a
turn si gnal cancel actuator of the mul ti -functi on
swi tch to provi de automati c turn si gnal cancel l ati on.
The yel l ow-sl eeved pi gtai l wi res on the upper surface
of the cl ockspri ng rotor connect the cl ockspri ng to the
dri ver ai rbag, whi l e a steeri ng wheel wi re harness
connects the connector receptacl e on the upper sur-
face of the cl ockspri ng rotor to the horn swi tch and,
i f the vehi cl e i s so equi pped, to the opti onal speed
control swi tches and remote radi o swi tches on the
steeri ng wheel .
Li ke the cl ockspri ng i n a ti mepi ece, the cl ockspri ng
tape has travel l i mi ts and can be damaged by bei ng
wound too ti ghtl y duri ng ful l stop-to-stop steeri ng
wheel rotati on. To prevent thi s from occurri ng, the
cl ockspri ng i s centered when i t i s i nstal l ed on the
steeri ng col umn. Centeri ng the cl ockspri ng i ndexes
the cl ockspri ng tape to the movabl e steeri ng compo-
nents so that the tape can operate wi thi n i ts
desi gned travel l i mi ts. However, i f the cl ockspri ng i s
removed from the steeri ng col umn or i f the steeri ng
shaft i s di sconnected from the steeri ng gear, the
cl ockspri ng spool can change posi ti on rel ati ve to the
movabl e steeri ng components and must be re-cen-
tered fol l owi ng compl eti on of the servi ce or the tape
may be damaged. Servi ce repl acement cl ockspri ngs
are shi pped pre-centered and wi th a pl asti c shi el d
i nstal l ed over the cl ockspri ng rel ease button. Thi s
shi el d shoul d not be removed and the rel ease button
shoul d not be depressed unti l the cl ockspri ng has
been i nstal l ed on the steeri ng col umn. I f the rel ease
button i s depressed before the cl ockspri ng i s i nstal l ed
on a steeri ng col umn, the cl ockspri ng centeri ng pro-
cedure must be performed. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/CLOCKSPRI NG - STANDARD
PROCEDURE - CLOCKSPRI NG CENTERI NG).
STANDARD PROCEDURE - CLOCKSPRING
CENTERING
The cl ockspri ng i s desi gned to wi nd and unwi nd
when the steeri ng wheel i s rotated, but i s onl y
Fig. 11 Clockspring Latches
1 - CASE
2 - LATCH (2)
3 - ROTOR
4 - CANCEL CAM
5 - LOWER CONNECTOR RECEPTACLE (2)
CLOCKSPRING (Continued)
desi gned to rotate the same number of turns (about
fi ve compl ete rotati ons) as the steeri ng wheel can be
turned from stop to stop. Centeri ng the cl ockspri ng
i ndexes the cl ockspri ng tape to other steeri ng compo-
nents so that i t can operate wi thi n i ts desi gned
travel l i mi ts. The rotor of a centered cl ockspri ng can
be rotated two and one-hal f turns i n ei ther di recti on
from the centered posi ti on, wi thout damagi ng the
cl ockspri ng tape.
However, i f the cl ockspri ng i s removed for servi ce
or i f the steeri ng col umn i s di sconnected from the
steeri ng gear, the cl ockspri ng tape can change posi -
ti on rel ati ve to the other steeri ng components. The
cl ockspri ng must then be re-centered fol l owi ng com-
pl eti on of such servi ce or the cl ockspri ng tape may be
damaged. Servi ce repl acement cl ockspri ngs are
shi pped pre-centered, wi th the rel ease button
engaged (rai sed) and a mol ded pl asti c shi el d i nstal l ed
over the rel ease button. Thi s rel ease button shoul d
not be di sengaged and the shi el d shoul d not be
removed unti l the cl ockspri ng has been i nstal l ed on
the steeri ng col umn. I f the rel ease button i s di sen-
gaged before the cl ockspri ng i s i nstal l ed on a steeri ng
col umn, the cl ockspri ng centeri ng procedure must be
performed.
PERSONAL INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) Pl ace the front wheel s i n the strai ght-ahead
posi ti on.
(2) Remove the cl ockspri ng from the steeri ng col -
umn. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
CLOCKSPRI NG - REMOVAL).
(3) Depress the rel ease button (Fi g. 12).
(4) Keepi ng the rel ease button depressed, rotate
the cl ockspri ng rotor cl ockwi se to the end of i ts
travel . Do not apply excessive torque.
(5) From the end of the cl ockwi se travel , rotate the
rotor about two and one-hal f turns countercl ockwi se,
then rel ease the rel ease button. The cl ockspri ng
tower formati on wi th the pi gtai l wi res for the dri ver
ai rbag and the connector receptacl e for the steeri ng
wheel wi re harness shoul d end up at the top, the
bl ue rol l er shoul d be vi si bl e through the i nspecti on
wi ndow, and the pri nted arrow on the l abel of the
cl ockspri ng rotor shoul d be al i gned wi th the arrow
mol ded i nto the cl ockspri ng case. The cl ockspri ng i s
now centered.
(6) The front wheel s shoul d sti l l be i n the strai ght-
ahead posi ti on. Rei nstal l the cl ockspri ng onto the
steeri ng col umn. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - I NSTALLATI ON).
REMOVAL
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver ai rbag
has been depl oyed.
Fig. 12 Clockspring Centering
1 - ROTOR LABEL
2 - RELEASE BUTTON
3 - ALIGNMENT ARROWS
4 - INSPECTION WINDOW
PERSONAL INJURY.
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on.
(2) Remove the dri ver ai rbag from the steeri ng
wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - REMOVAL).
(3) Di sconnect the steeri ng wheel wi re harness
connector from the upper cl ockspri ng connector
receptacl e.
(4) Remove the steeri ng wheel from the steeri ng
col umn. (Refer to 19 - STEERI NG/COLUMN/STEER-
I NG WHEEL - REMOVAL).
shroud (Fi g. 13).
other.
ness connectors for the cl ockspri ng from the two con-
nector receptacl es bel ow the steeri ng col umn on the
back of the cl ockspri ng housi ng.
(10) Usi ng a smal l thi n-bl aded screwdri ver, rel ease
the two i ntegral pl asti c l atches that secure the back
of the cl ockspri ng housi ng to the steeri ng col umn
l ock housi ng.
(11) Remove the cl ockspri ng from the steeri ng col -
umn l ock housi ng. The cl ockspri ng cannot be
repai red. I t must be repl aced i f faul ty or damaged, or
i f the dri ver ai rbag has been depl oyed.
(12) I f the removed cl ockspri ng i s to be reused, be
certai n that the rel ease button on the cl ockspri ng
rotor i s rai sed and l atched to secure the rotor to the
cl ockspri ng case to mai ntai n cl ockspri ng centeri ng
unti l i t i s rei nstal l ed on the steeri ng col umn. I f cl ock-
spri ng centeri ng i s not mai ntai ned, the cl ockspri ng
must be centered agai n before i t i s rei nstal l ed. (Refer
to 8 - ELECTRI CAL/RESTRAI NTS/CLOCKSPRI NG -
STANDARD PROCEDURE - CLOCKSPRI NG CEN-
TERI NG).
INSTALLATION
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver ai rbag
has been depl oyed.
I f the cl ockspri ng i s not properl y centered i n rel a-
ti on to the steeri ng wheel , steeri ng shaft and steer-
i ng gear, i t may be damaged. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/CLOCKSPRI NG -
STANDARD PROCEDURE - CLOCKSPRI NG CEN-
Fig. 13 Clockspring Remove/Install
1 - UPPER SHROUD
2 - CLOCKSPRING
3 - LATCH (2)
4 - SCREW (2)
5 - LOWER SHROUD
8 - STEERING COLUMN
TERI NG). Servi ce repl acement cl ockspri ngs are
shi pped pre-centered, wi th the rel ease button
engaged (rai sed) and a mol ded pl asti c shi el d i nstal l ed
over the rel ease button. Thi s rel ease button shoul d
not be di sengaged and the shi el d shoul d not be
removed unti l the cl ockspri ng has been i nstal l ed on
the steeri ng col umn. I f the rel ease button i s di sen-
gaged before the cl ockspri ng i s i nstal l ed on a steeri ng
col umn, the cl ockspri ng centeri ng procedure must be
performed.
PERSONAL INJURY.
(1) Careful l y sl i de the centered cl ockspri ng down
over the steeri ng col umn upper shaft unti l the two
i ntegral pl asti c l atches on the back of the cl ockspri ng
housi ng are ful l y engaged through thei r openi ngs i n
the steeri ng col umn l ock housi ng (Fi g. 13).
ness connectors for the cl ockspri ng to the two connec-
tor receptacl es bel ow the steeri ng col umn on the back
of the cl ockspri ng housi ng.
steeri ng col umn.
i n. l bs.).
l ever back to the l ocked (up) posi ti on.
(7) Rei nstal l the steeri ng wheel onto the steeri ng
col umn. (Refer to 19 - STEERI NG/COLUMN/STEER-
I NG WHEEL - I NSTALLATI ON).
NOTE: Be certain that the steering wheel mounting
screw is tightened to the proper torque specifica-
tion to ensure proper clockspring operation.
(8) Reconnect the steeri ng wheel wi re harness con-
nector to the upper cl ockspri ng connector receptacl e.
(9) Rei nstal l the dri ver ai rbag onto the steeri ng
wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - I NSTALLATI ON).
DRIVER AIRBAG
DESCRIPTION
The bl ack, i njecti on mol ded, thermopl asti c dri ver
ai rbag protecti ve tri m cover i s the most vi si bl e part
of the dri ver ai rbag (Fi g. 14). The dri ver ai rbag i s
l ocated i n the center of the steeri ng wheel , where i t
i s secured wi th two screws to the two hori zontal
spokes of the four-spoke steeri ng wheel armature.
Base model s have a Jeep l ogo embossed i n the cen-
ter of the tri m cover, whi l e premi um model s feature a
stamped, sati n pol i shed embl em wi th the Jeep l ogo
appl i ed to the center of the tri m cover. Conceal ed
beneath the dri ver ai rbag tri m cover are the horn
swi tch, the fol ded ai rbag cushi on, the ai rbag retai ner
or housi ng, the ai rbag i nfl ator, and the retai ners that
secure the i nfl ator to the ai rbag housi ng. The ai rbag
cushi on, housi ng, and i nfl ator are secured wi thi n an
i ntegral receptacl e mol ded i nto the back of the tri m
cover.
Fig. 14 Driver Airbag Trim Cover
1 - STEERING WHEEL
2 - TRIM COVER
The resi sti ve membrane-type horn swi tch i s
secured wi th heat stakes to the i nsi de surface of the
dri ver ai rbag tri m cover, between the tri m cover and
the fol ded ai rbag cushi on. The horn swi tch ground
pi gtai l wi re has a femal e spade termi nal connector
that recei ves a path to ground through a mal e spade
termi nal that i s i ntegral to the dri ver ai rbag housi ng
stampi ng and i s l ocated near the upper ri ght corner
on the back of the housi ng (Fi g. 15). The horn swi tch
feed pi gtai l wi re has a whi te, mol ded pl asti c i nsul a-
tor that i s secured by an i ntegral retai ner to a
mounti ng hol e l ocated near the l ower l eft corner on
the back of the housi ng, and i s connected to the vehi -
cl e el ectri cal system through a take out and connec-
tor of the steeri ng wheel wi re harness.
The ai rbag used i n thi s model i s a mul ti stage, Next
Generati on-type that compl i es wi th revi sed federal
ai rbag standards to depl oy wi th l ess force than those
used i n some pri or model s. A 67 centi meter (26.5
i nch) di ameter, radi al depl oyi ng fabri c cushi on wi th
tethers i s used. The ai rbag i nfl ator i s a dual -i ni ti ator,
non-azi de, pyrotechni c-type uni t wi th four mounti ng
studs and i s secured to the stamped metal ai rbag
housi ng usi ng four hex nuts wi th washers. Two
keyed and col or-coded connector receptacl es on the
dri ver ai rbag i nfl ator connect the two i nfl ator i ni ti a-
tors to the vehi cl e el ectri cal system through two yel -
l ow-jacketed, two-wi re pi gtai l harnesses of the
cl ockspri ng. The dri ver ai rbag and horn swi tch uni t
cannot be repai red, and must be repl aced i f depl oyed
or i n any way damaged.
OPERATION
The mul ti stage dri ver ai rbag i s depl oyed by el ectri -
cal si gnal s generated by the Ai rbag Control Modul e
(ACM) through the dri ver ai rbag squi b 1 and squi b 2
ci rcui ts to the two i ni ti ators i n the ai rbag i nfl ator. By
usi ng two i ni ti ators, the ai rbag can be depl oyed at
mul ti pl e l evel s of force. The force l evel i s control l ed
by the ACM to sui t the moni tored i mpact condi ti ons
by provi di ng one of three del ay i nterval s between the
el ectri cal si gnal s provi ded to the two i ni ti ators. The
l onger the del ay between these si gnal s, the l ess force-
ful l y the ai rbag wi l l depl oy. When the ACM sends the
proper el ectri cal si gnal s to each i ni ti ator, the el ectri -
cal energy generates enough heat to i ni ti ate a smal l
pyrotechni c charge whi ch, i n turn i gni tes chemi cal
pel l ets wi thi n the i nfl ator. Once i gni ted, these chem-
i cal pel l ets burn rapi dl y and produce a l arge quanti ty
of ni trogen gas. The i nfl ator i s seal ed to the back of
the ai rbag housi ng and a di ffuser i n the i nfl ator
di rects al l of the ni trogen gas i nto the ai rbag cush-
i on, causi ng the cushi on to i nfl ate. As the cushi on
i nfl ates, the dri ver ai rbag tri m cover wi l l spl i t at pre-
determi ned breakout l i nes, then fol d back out of the
way al ong wi th the horn swi tch uni t. Fol l owi ng an
ai rbag depl oyment, the ai rbag cushi on qui ckl y
defl ates by venti ng the ni trogen gas towards the
i nstrument panel through vent hol es wi thi n the fab-
ri c used to construct the back (steeri ng wheel si de)
panel of the ai rbag cushi on.
Some of the chemi cal s used to create the ni trogen
gas may be consi dered hazardous whi l e i n thei r sol i d
state before they are burned, but they are securel y
seal ed wi thi n the ai rbag i nfl ator. Typi cal l y, both i ni -
ti ators are used and al l potenti al l y hazardous chem-
i cal s are burned duri ng an ai rbag depl oyment event.
However, i t i s possi bl e for onl y one i ni ti ator to be
used duri ng a depl oyment due to an ai rbag system
faul t; therefore, i t i s necessary to al ways confi rm
that both i ni ti ators have been used i n order to avoi d
the i mproper di sposal of potenti al l y l i ve pyrotechni c
or hazardous materi al s. (Refer to 8 - ELECTRI CAL/
RESTRAI NTS - STANDARD PROCEDURE - SER-
VI CE AFTER A SUPPLEMENTAL RESTRAI NT
DEPLOYMENT). The ni trogen gas that i s produced
when the chemi cal s are burned i s harml ess. How-
ever, a smal l amount of resi due from the burned
chemi cal s may cause some temporary di scomfort i f i t
contacts the ski n, eyes, or breathi ng passages. I f ski n
or eye i rri tati on i s noted, ri nse the affected area wi th
pl enty of cool , cl ean water. I f breathi ng passages are
i rri tated, move to another area where there i s pl enty
of cl ean, fresh ai r to breath. I f the i rri tati on i s not
al l evi ated by these acti ons, contact a physi ci an.
Fig. 15 Driver Airbag Housing
1 - HOUSING
2 - HORN SWITCH GROUND WIRE
3 - HORN SWITCH FEED WIRE
4 - INFLATOR
5 - TRIM COVER
DRIVER AIRBAG (Continued)
REMOVAL
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged dri ver ai rbag. I f the dri ver ai rbag
has been depl oyed, revi ew the recommended proce-
dures for servi ce after a passi ve restrai nt depl oyment
before removi ng the ai rbag from the vehi cl e. (Refer to
CEDURE - SERVI CE AFTER A SUPPLEMENTAL
RESTRAI NT DEPLOYMENT).
PERSONAL INJURY.
WARNING: WHEN REMOVING A DEPLOYED AIR-
BAG, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG CUSHION AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
(2) From the undersi de of the steeri ng wheel ,
remove the two screws that secure the dri ver ai rbag
to the steeri ng wheel armature (Fi g. 16).
(3) Pul l the dri ver ai rbag away from the steeri ng
wheel far enough to access the three el ectri cal con-
necti ons on the back of the ai rbag housi ng.
Fig. 16 Driver Airbag Remove/Install
1 - DRIVER AIRBAG
2 - HORN SWITCH FEED WIRE CONNECTOR
4 - STEERING WHEEL
5 - TO CLOCKSPRING
7 - STEERING COLUMN
8 - CLOCKSPRING PIGTAIL WIRE CONNECTOR (2)
9 - SCREW (2)
(4) Di sconnect the steeri ng wheel wi re harness
connector for the horn swi tch from the horn swi tch
feed pi gtai l wi re connector, whi ch i s l ocated on the
back of the dri ver ai rbag housi ng.
CAUTION: Do not pull on the clockspring pigtail
wires or pry on the connector insulator to disen-
gage the connector from the driver airbag inflator
connector receptacle. Improper removal of these
pigtail wires and their connector insulators can
result in damage to the airbag circuits or connector
insulators.
(5) The cl ockspri ng dri ver ai rbag pi gtai l wi re con-
nectors are secured by i ntegral l atches to the ai rbag
i nfl ator connector receptacl es, whi ch are l ocated on
the back of the dri ver ai rbag housi ng. Depress the
l atches on each si de of each connector i nsul ator and
pul l the i nsul ators strai ght out from the ai rbag i nfl a-
tor to di sconnect them from the connector recepta-
cl es.
(6) Remove the dri ver ai rbag from the steeri ng
wheel .
(7) I f the dri ver ai rbag has been depl oyed, the
cl ockspri ng must be repl aced. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/CLOCKSPRI NG - REMOVAL).
INSTALLATION
faul ty or damaged dri ver ai rbag. I f the dri ver ai rbag
has been depl oyed, the cl ockspri ng must al so be
repl aced. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
CLOCKSPRI NG - I NSTALLATI ON).
PERSONAL INJURY.
WARNING: USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
WARNING: THE DRIVER AIRBAG TRIM COVER
MUST NEVER BE PAINTED. REPLACEMENT AIR-
BAGS ARE SERVICED IN THE ORIGINAL COLORS.
PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) Posi ti on the dri ver ai rbag cl ose enough to the
steeri ng wheel to reconnect al l three el ectri cal con-
necti ons on the back of the ai rbag housi ng.
(2) When i nstal l i ng the dri ver ai rbag, reconnect
the two cl ockspri ng dri ver ai rbag pi gtai l wi re connec-
tors to the ai rbag i nfl ator connector receptacl es by
pressi ng strai ght i n on the connectors (Fi g. 16). Be
certai n to engage each keyed and col or-coded connec-
tor to the matchi ng connector receptacl e. You can be
certai n that each connector i s ful l y engaged i n i ts
receptacl e by l i steni ng careful l y for a di sti nct, audi -
bl e cl i ck as the connector l atches snap i nto pl ace.
(3) Reconnect the steeri ng wheel wi re harness con-
nector for the horn swi tch to the horn swi tch feed
pi gtai l wi re connector, whi ch i s l ocated at the back of
the dri ver ai rbag housi ng.
(4) Careful l y posi ti on the dri ver ai rbag i n the
steeri ng wheel . Be certai n that the cl ockspri ng pi g-
tai l wi res and steeri ng wheel wi re harness i n the
steeri ng wheel hub area are not pi nched between the
dri ver ai rbag and the steeri ng wheel armature.
(5) From the undersi de of the steeri ng wheel ,
i nstal l and ti ghten the two screws that secure the
dri ver ai rbag to the steeri ng wheel armature.
FRONT IMPACT SENSOR
DESCRIPTION
Two front i mpact sensors are used on thi s model ,
one each for the l eft and ri ght si des of the vehi cl e
(Fi g. 17). These sensors are mounted remotel y from
the i mpact sensor that i s i nternal to the Ai rbag Con-
trol Modul e (ACM). Each front sensor i s secured wi th
two screws to the backs of the ri ght and l eft verti cal
members of the radi ator support wi thi n the engi ne
compartment. The sensor housi ng has an i ntegral
connector receptacl e and two i ntegral mounti ng
poi nts each wi th a metal sl eeve to provi de crush pro-
tecti on.
The ri ght and l eft front i mpact sensors are i denti -
cal i n constructi on and cal i brati on wi th two excep-
ti ons:
On model s equi pped wi th an opti onal 2.4L gaso-
l i ne engi ne, the l eft front i mpact sensor i ncl udes a
shi m that moves the sensor three mi l l i meters toward
the rear of the vehi cl e on the l eft verti cal member of
the radi ator support for addi ti onal cl earance that i s
requi red for that appl i cati on.
On model s equi pped wi th an opti onal di esel
engi ne, the l eft front i mpact sensor i ncl udes a
stamped metal mounti ng bracket that rotates the
connector receptacl e end of the sensor toward the
outboard si de of the vehi cl e for addi ti onal cl earance
that i s requi red for that appl i cati on.
A cavi ty i n the center of the mol ded bl ack pl asti c
i mpact sensor housi ng contai ns the el ectroni c ci r-
cui try of the sensor whi ch i ncl udes an el ectroni c com-
muni cati on chi p and an el ectroni c i mpact sensor.
Potti ng materi al fi l l s the cavi ty to seal and protect
the i nternal el ectroni c ci rcui try and components. The
front i mpact sensors are each connected to the vehi -
cl e el ectri cal system through a dedi cated take out
and connector of the headl amp and dash wi re har-
ness.
The i mpact sensors cannot be repai red or adjusted
and, i f damaged or faul ty, they must be repl aced. The
mounti ng bracket for the l eft front i mpact sensor on
model s wi th a di esel engi ne i s servi ced as a uni t wi th
that sensor.
OPERATION
The front i mpact sensors are el ectroni c accel erom-
eters that sense the rate of vehi cl e decel erati on,
whi ch provi des veri fi cati on of the di recti on and sever-
i ty of an i mpact. Each sensor al so contai ns an el ec-
troni c communi cati on chi p that al l ows the uni t to
communi cate the sensor status as wel l as sensor
faul t i nformati on to the mi croprocessor i n the Ai rbag
Control Modul e (ACM). The ACM mi croprocessor con-
ti nuousl y moni tors al l of the front passi ve restrai nt
system el ectri cal ci rcui ts to determi ne the system
readi ness. I f the ACM detects a moni tored system
faul t, i t sets a Di agnosti c Troubl e Code (DTC) and
control s the ai rbag i ndi cator operati on accordi ngl y.
The i mpact sensors each recei ve battery current and
ground through dedi cated l eft and ri ght sensor pl us and
mi nus ci rcui ts from the ACM. The i mpact sensors and
the ACM communi cate by modul ati ng the vol tage i n the
sensor pl us ci rcui t. The hard wi red ci rcui ts between the
front i mpact sensors and the ACM may be di agnosed
and tested usi ng conventi onal di agnosti c tool s and pro-
cedures. However, conventi onal di agnosti c methods wi l l
not prove concl usi ve i n the di agnosi s of the ACM or the
i mpact sensors. The most rel i abl e, effi ci ent, and accu-
rate means to di agnose the i mpact sensors, the ACM,
and the el ectroni c message communi cati on between the
sensors and the ACM requi res the use of a DRBI I I
scan tool . Refer to the appropri ate di agnosti c i nforma-
ti on.
Fig. 17 Front Impact Sensor
1 - SENSOR
REMOVAL
PERSONAL INJURY.
WARNING: THE FRONT IMPACT SENSOR ENABLES
THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE
THE IMPACT SENSOR OR AFFECT ITS CALIBRA-
TION. IF AN IMPACT SENSOR IS ACCIDENTALLY
DROPPED DURING SERVICE, THE SENSOR MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER FRONT SUPPLEMENTAL RESTRAINT
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(2) Remove the two screws that secure the ri ght or
l eft front i mpact sensor, l eft i mpact sensor and shi m
(2.4L engi ne onl y), or l eft i mpact sensor and bracket
uni t (di esel engi ne onl y) to the back of the ri ght or
l eft radi ator support verti cal member (Fi g. 18).
(3) Di sconnect the headl amp and dash wi re har-
ness connector for the front i mpact sensor from the
sensor connector receptacl e.
(4) Remove the ri ght or l eft front i mpact sensor,
l eft i mpact sensor and shi m (2.4L engi ne onl y), or l eft
i mpact sensor and bracket uni t (di esel engi ne onl y)
from the engi ne compartment.
INSTALLATION
PERSONAL INJURY.
WARNING: THE FRONT IMPACT SENSOR ENABLES
THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE
THE IMPACT SENSOR OR AFFECT ITS CALIBRA-
TION. IF AN IMPACT SENSOR IS ACCIDENTALLY
DROPPED DURING SERVICE, THE SENSOR MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER FRONT SUPPLEMENTAL RESTRAINT
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Posi ti on the ri ght or l eft front i mpact sensor,
Fig. 18 Front Impact Sensor Remove/Install
1 - RADIATOR SUPPORT
2 - IMPACT SENSOR OR LEFT IMPACT SENSOR & SHIM (2.4L
ENGINE ONLY)
3 - SCREW (4)
5 - LEFT IMPACT SENSOR & BRACKET (DIESEL ENGINE ONLY)
FRONT IMPACT SENSOR (Continued)
i nto the engi ne compartment (Fi g. 18).
(2) Reconnect the headl amp and dash wi re harness
connector for the front i mpact sensor to the sensor
(3) Posi ti on the ri ght or l eft front i mpact sensor,
onto the back of the ri ght or l eft radi ator support
verti cal member.
(4) Loosel y i nstal l the upper screw that secures
the ri ght or l eft front i mpact sensor, l eft i mpact sen-
sor and shi m (2.4L engi ne onl y), or l eft i mpact sensor
and bracket uni t (di esel engi ne onl y) to the back of
the ri ght or l eft radi ator support verti cal member.
(5) I nstal l and ti ghten the l ower screw that secures
the ri ght or l eft front i mpact sensor, l eft i mpact sensor
and shi m (2.4L engi ne onl y), or l eft i mpact sensor and
bracket uni t (di esel engi ne onl y) to the back of the ri ght
or l eft radi ator support verti cal member. Ti ghten the
(6) Ti ghten the upper screw that secures the ri ght
or l eft front i mpact sensor, l eft i mpact sensor and
shi m (2.4L engi ne onl y), or l eft i mpact sensor and
bracket uni t (di esel engi ne onl y) to the back of the
ri ght or l eft radi ator support verti cal member.
Ti ghten the screw to 7 Nm (65 i n. l bs.).
ai rbag system component. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS - STANDARD PROCEDURE -
VERI FI CATI ON TEST).
FRONT SEAT BELT &
RETRACTOR
REMOVAL
PERSONAL INJURY.
LISTED IN THE MOPAR PARTS CATALOG.
(1) Adjust the front seat to i ts most forward posi -
ti on for easi est access to the front seat bel t l ower
anchor and the B-pi l l ar tri m.
fl at-bl aded tool , gentl y pry the pl ug that covers the
front seat bel t l ower anchor screw to remove i t from
the rear of the outboard seat si de shi el d (Fi g. 19).
Fig. 19 Front Seat Belt Lower Anchor Remove/
Install
1 - FRONT SEAT
2 - LOWER ANCHOR
3 - SCREW
4 - PLUG
FRONT IMPACT SENSOR (Continued)
(4) Remove the screw that secures the l ower
anchor to the bracket on the outboard si de of the
front seat cushi on frame.
(5) Unsnap and l i ft the tri m cover to access the
nut that secures the front seat bel t turni ng l oop to
the hei ght adjuster on the upper B-pi l l ar (Fi g. 20).
(6) Remove the nut that secures the seat bel t turn-
i ng l oop to the hei ght adjuster stud on the upper
B-pi l l ar.
(7) Remove the seat bel t turni ng l oop from the
hei ght adjuster stud.
(8) Remove the upper and l ower tri m from the
i nsi de of the B-pi l l ar. (Refer to 23 - BODY/I NTERI -
OR/B-PI LLAR UPPER TRI M - REMOVAL) and
(Refer to 23 - BODY/I NTERI OR/B-PI LLAR LOWER
TRI M - REMOVAL).
(9) On the dri ver si de onl y, di sconnect the seat bel t
tensi oner pi gtai l wi re connector from the body wi re
harness connector.
(10) Remove the screw that secures the l ower
retractor bracket to the l ower B-pi l l ar.
(11) Di sengage the engagement tab on the upper
retractor bracket/seat bel t web gui de from the
engagement sl ot i n the l ower B-pi l l ar.
(12) Remove the front seat bel t and retractor from
the B-pi l l ar as a uni t.
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the front seat bel t and retractor to the
B-pi l l ar as a uni t (Fi g. 20). Be certai n to engage the
engagement tab on the upper retractor bracket/seat
bel t web gui de i nto the engagement sl ot i n the l ower
B-pi l l ar.
l ower retractor bracket to the l ower B-pi l l ar. Ti ghten
the screw to 43 Nm (32 ft. l bs.).
(3) On the dri ver si de onl y, reconnect the seat bel t
tensi oner pi gtai l wi re connector to the body wi re har-
ness connector.
(4) Rei nstal l the upper and l ower tri m onto the
i nsi de of the B-pi l l ar. (Refer to 23 - BODY/I NTERI -
OR/B-PI LLAR UPPER TRI M - I NSTALLATI ON) and
(Refer to 23 - BODY/I NTERI OR/B-PI LLAR LOWER
TRI M - I NSTALLATI ON).
(5) Posi ti on the seat bel t turni ng l oop onto the
hei ght adjuster stud on the upper B-pi l l ar.
Fig. 20 Front Seat Belt Retractor Remove/Install
1 - ADJUSTER
2 - B-PILLAR
3 - RETRACTOR
4 - B-PILLAR TRIM
5 - CONNECTOR (DRIVER SIDE ONLY)
6 - LOWER ANCHOR
7 - NUT
8 - TURNING LOOP
9 - COVER
FRONT SEAT BELT & RETRACTOR (Continued)
(6) I nstal l and ti ghten the nut that secures the
seat bel t turni ng l oop to the hei ght adjuster stud.
Ti ghten the nut to 34 Nm (25 ft. l bs.).
(7) Fol d and snap the tri m cover back i nto pl ace to
conceal the nut that secures the front seat bel t turn-
i ng l oop to the hei ght adjuster on the upper B-pi l l ar.
(8) Posi ti on the front seat bel t l ower anchor to the
bracket on the outboard si de of the front seat cushi on
frame (Fi g. 19).
l ower anchor to the bracket on the outboard si de of
the front seat cushi on frame. Ti ghten the screw to 43
Nm (32 ft. l bs.).
(10) Al i gn the pl ug that covers the front seat bel t
l ower anchor screw wi th the hol e near the rear of the
outboard seat si de shi el d. Usi ng hand pressure, press
fi rml y and evenl y on the pl ug unti l i t snaps i nto
pl ace.
FRONT SEAT BELT BUCKLE
REMOVAL
PERSONAL INJURY.
(2) Remove the front seat and seat track from the
fl oor panel as a uni t. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - REMOVAL).
(3) Di sconnect the seat bel t swi tch pi gtai l wi re
connector from the seat wi re harness connector on
the seat cushi on frame bracket l ocated under the
rear edge of the seat cushi on near the i nboard si de of
the seat (Fi g. 21).
Fig. 21 Seat Belt Switch Connector
1 - PIGTAIL WIRE
2 - SEAT WIRE HARNESS
3 - SEAT CUSHION FRAME BRACKET
4 - BODY WIRE HARNESS
5 - INBOARD SEAT TRACK
FRONT SEAT BELT & RETRACTOR (Continued)
(4) Remove the screw that secures the front seat
bel t buckl e anchor to the bracket near the rear of the
i nboard seat track (Fi g. 22).
(5) Remove the two screws that secure the i nboard
seat cushi on si de shi el d to the seat cushi on frame.
seat track to the rear i nboard corner of the seat cush-
i on frame.
(7) Di sconnect the seat bel t swi tch pi gtai l wi re
routi ng cl i p from the l ocati ng hol e i n the seat cushi on
frame.
(8) Remove the seat bel t swi tch pi gtai l wi re from
between the seat cushi on frame and the seat track by
gentl y pryi ng the i nboard seat track away from the
i nboard rear corner of the seat cushi on frame far
enough to sl i de the pi gtai l wi re from between them.
(9) Remove the front seat bel t buckl e from the
i nboard seat cushi on si de shi el d.
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the front seat bel t buckl e to the
i nboard seat cushi on si de shi el d (Fi g. 22).
(2) Posi ti on the seat bel t swi tch pi gtai l wi re between
the seat cushi on frame and the seat track by gentl y pry-
i ng the i nboard seat track away from the i nboard rear
corner of the seat cushi on frame far enough to sl i de the
pi gtai l wi re i nto posi ti on between them.
(3) Engage the seat bel t swi tch pi gtai l wi re routi ng
cl i p i nto the l ocati ng hol e i n the seat cushi on frame.
the i nboard seat track to the rear i nboard corner of
the seat cushi on frame. Ti ghten the screws to 28 Nm
(21 ft. l bs.).
(5) Posi ti on the i nboard seat cushi on si de shi el d to
the seat cushi on frame.
the i nboard seat cushi on si de shi el d to the seat cush-
i on frame. Ti ghten the screws to 1 Nm (9 i n. l bs.).
(7) Posi ti on the front seat bel t buckl e anchor to
the bracket on the i nboard si de of the seat track.
front seat bel t buckl e anchor to the bracket on the
i nboard si de of the seat track. Ti ghten the screw to
43 Nm (32 ft. l bs.).
(9) Reconnect the seat bel t swi tch pi gtai l wi re connec-
tor to the seat wi re harness connector on the seat cush-
i on frame bracket l ocated under the rear edge of the seat
cushi on near the i nboard si de of the seat (Fi g. 21).
(10) Rei nstal l the front seat and seat track to the
fl oor panel as a uni t. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - I NSTALLATI ON).
Fig. 22 Front Seat Belt Buckle Remove/Install
1 - FRONT SEAT BELT BUCKLE
2 - INBOARD SIDE SHIELD
3 - SCREW
4 - PIGTAIL WIRE
FRONT SEAT BELT BUCKLE (Continued)
PASSENGER AIRBAG
DESCRIPTION
The rearward faci ng surface of the i njecti on
mol ded, thermopl asti c passenger ai rbag door i s the
most vi si bl e part of the passenger ai rbag (Fi g. 23).
The passenger ai rbag door i s l ocated above the gl ove
box openi ng i n front of the front seat passenger seat-
i ng posi ti on on the i nstrument panel . The i ntegral
upper mounti ng fl ange i s secured wi th fi ve screws
and the l ower mounti ng fl ange wi th si x screws to the
i nstrument panel structural support. The passenger
ai rbag door i ncl udes an i ntegral ai r condi ti oni ng
panel outl et housi ng and an i ntegral si de wi ndow
demi ster outl et. An i ntegral stamped metal bracket
that rei nforces the upper ai rbag door mounti ng
fl ange i s secured to the back of the door uni t wi th
heat stakes. The upper ai rbag door fasteners and
mounti ng fl ange are conceal ed beneath the i nstru-
ment panel top cover, whi l e the l ower fasteners and
mounti ng fl ange are conceal ed beneath a bezel on the
i nstrument panel above the gl ove box openi ng.
Located behi nd the passenger ai rbag door wi thi n
the i nstrument panel i s the passenger ai rbag uni t
(Fi g. 24). The passenger ai rbag uni t used i n thi s
model i s a mul ti stage, Next Generati on-type that
compl i es wi th revi sed federal ai rbag standards to
depl oy wi th l ess force than those used i n some pri or
model s. The passenger ai rbag uni t consi sts of a
mol ded, gl ass-fi l l ed nyl on pl asti c housi ng, a mol ded
pl asti c i nner ai rbag cushi on cover, the ai rbag cush-
i on, and the ai rbag i nfl ator. The ai rbag housi ng con-
tai ns the ai rbag i nfl ator, whi l e the i nner cover
contai ns the fol ded ai rbag cushi on. The i nner cover
compl etel y encl oses the ai rbag cushi on and i s perma-
nentl y retai ned to the housi ng. The passenger ai rbag
uni t i s secured by two screws on each si de to two
stamped metal mounti ng brackets that are fastened
wi th screws to the i nstrument panel structural sup-
port. The ai rbag cushi on i s constructed of a coated
nyl on fabri c. The ai rbag i nfl ator i s a dual -i ni ti ator,
hybri d-type uni t that i s secured to and seal ed wi thi n
the ai rbag housi ng. A short four-wi re pi gtai l harness
wi th a keyed, yel l ow connector i nsul ator connects the
two i nfl ator i ni ti ators to the vehi cl e el ectri cal system
through a dedi cated take out and connector of the
i nstrument panel wi re harness.
The passenger ai rbag cannot be repai red, and must
be repl aced i f depl oyed, faul ty, or i n any way dam-
aged. The passenger ai rbag door and the passenger
ai rbag mounti ng brackets are avai l abl e for separate
servi ce repl acement.
OPERATION
The mul ti stage passenger ai rbag i s depl oyed by
el ectri cal si gnal s generated by the Ai rbag Control
Modul e (ACM) through the passenger ai rbag squi b 1
and squi b 2 ci rcui ts to the two i ni ti ators i n the ai r-
bag i nfl ator. By usi ng two i ni ti ators, the ai rbag can
be depl oyed at mul ti pl e l evel s of force. The force l evel
i s control l ed by the ACM to sui t the moni tored
i mpact condi ti ons by provi di ng one of three del ay
i nterval s between the el ectri cal si gnal s provi ded to
the two i ni ti ators. The l onger the del ay between
these si gnal s, the l ess forceful l y the ai rbag wi l l
depl oy.
Fig. 23 Passenger Airbag Door
1 - PASSENGER AIRBAG DOOR
2 - DEMISTER OUTLET
3 - PANEL OUTLET
4 - BEZEL
5 - GLOVE BOX
Fig. 24 Passenger Airbag Unit
1 - PIGTAIL WIRE CONNECTOR
2 - RETAINER
3 - HOUSING
4 - INNER COVER
The hybri d-type i nfl ator assembl y i ncl udes a smal l
cani ster of hi ghl y compressed gas. When the ACM
sends the proper el ectri cal si gnal to the ai rbag i nfl a-
tor, the i ni ti ator converts the el ectri cal energy i nto
chemi cal energy. Thi s chemi cal energy opens up a
burst di sk to al l ow the i nert gas to fl ow i nto the ai r-
bag cushi on. The i nfl ator i s seal ed to the ai rbag
cushi on so that al l of the rel eased i nert gas i s
di rected i nto the ai rbag cushi on, causi ng the cushi on
to i nfl ate. As the cushi on i nfl ates, the passenger ai r-
bag door wi l l spl i t at predetermi ned tear seam l i nes
on the i nsi de surface of the door and the door wi l l
pi vot downwards out of the way. Fol l owi ng a passen-
ger ai rbag depl oyment, the ai rbag cushi on qui ckl y
defl ates by venti ng the i nert gas through vent hol es
wi thi n the fabri c used to construct the si des of the
ai rbag cushi on.
Typi cal l y, both i ni ti ators are used duri ng an ai rbag
depl oyment event. However, i t i s possi bl e for onl y one
i ni ti ator to be used duri ng a depl oyment due to an
ai rbag system faul t; therefore, i t i s necessary to
al ways confi rm that both i ni ti ators have been used i n
order to avoi d the i mproper di sposal of potenti al l y
l i ve pyrotechni c materi al s. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS - STANDARD PROCEDURE -
SERVI CE AFTER A SUPPLEMENTAL RESTRAI NT
DEPLOYMENT).
REMOVAL
faul ty or damaged passenger ai rbag. I f the passenger
ai rbag has been depl oyed, revi ew the recommended
procedures for servi ce after a suppl emental restrai nt
depl oyment before removi ng the ai rbag from the
vehi cl e. (Refer to 8 - ELECTRI CAL/RESTRAI NTS -
STANDARD PROCEDURE - SERVI CE AFTER A
SUPPLEMENTAL RESTRAI NT DEPLOYMENT).
PERSONAL INJURY.
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
SKIN AND EYES.
(2) Remove the passenger ai rbag door from the
i nstrument panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG DOOR - REMOV-
AL).
(3) Remove the two screws on each si de of the pas-
senger ai rbag that secure the passenger ai rbag to the
metal brackets on the i nstrument panel support
structure (Fi g. 25).
(4) Di sengage the passenger ai rbag wi re harness
connector from the retai ner securi ng the connector to
the metal bracket on the i nstrument panel support
structure above the ai rbag by sl i di ng both hal ves of
the connector to the l eft.
(5) Di sconnect the passenger ai rbag pi gtai l wi re
connector from the i nstrument panel wi re harness
connector for the ai rbag. To di sconnect the connector:
(a) Sl i de the red Connector Posi ti on Assurance
(CPA) l ock on the top of the connector toward the
si de of the connector.
(b) Depress the connector l atch tab and pul l the
two hal ves of the connector strai ght away from
each other.
Fig. 25 Passenger Airbag Remove/Install
1 - PASSENGER AIRBAG
3 - SCREW (4)
4 - GLOVE BOX LATCH STRIKER
PASSENGER AIRBAG (Continued)
(6) Remove the passenger ai rbag from the i nstru-
ment panel as a uni t.
(7) I f the passenger ai rbag has been depl oyed, both
passenger ai rbag mounti ng brackets on the i nstru-
ment panel must be repl aced. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/PASSENGER AI RBAG
MOUNTI NG BRACKET - REMOVAL).
INSTALLATION
faul ty or damaged passenger ai rbag. I f the passenger
ai rbag has been depl oyed, both passenger ai rbag
mounti ng brackets on the i nstrument panel must
al so be repl aced. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG MOUNTI NG
BRACKET - I NSTALLATI ON).
PERSONAL INJURY.
SKIN AND EYES.
FOREIGN MATERIAL FROM ENTERING THE PAS-
SENGER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Posi ti on the passenger ai rbag uni t i nto the
(2) Reconnect the passenger ai rbag pi gtai l wi re
connector to the i nstrument panel wi re harness con-
nector for the ai rbag. Be certai n that the l atch on the
connector and the red Connector Posi ti on Assurance
(CPA) l ock are each ful l y engaged.
(3) Engage the passenger ai rbag wi re harness con-
nector onto the retai ner that secures the connector to
the metal bracket on the i nstrument panel support
structure above the ai rbag by al i gni ng the ri ght end
of the connector sl ot wi th the l eft end of the retai ner
and sl i di ng both hal ves of the connector to the ri ght.
(4) Careful l y posi ti on the passenger ai rbag uni t
onto the two metal brackets on the i nstrument panel
support structure, bei ng certai n that the al i gnment
pi n features on each si de of the ai rbag are engaged
i n the al i gnment hol es i n the metal brackets.
(5) I nstal l and ti ghten the two screws on each si de
of the passenger ai rbag that secure the passenger
ai rbag to the metal brackets on the i nstrument panel
support structure. Ti ghten the screws to 6 Nm (55
i n. l bs.).
(6) Rei nstal l the passenger ai rbag door onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG DOOR - I NSTAL-
LATI ON).
PASSENGER AIRBAG DOOR
REMOVAL
PERSONAL INJURY.
PASSENGER AIRBAG (Continued)
SKIN AND EYES.
(2) Remove the top cover from the i nstrument
I NSTRUMENT PANEL TOP COVER - REMOVAL).
(3) Remove the passenger si de bezel from the
upper gl ove box openi ng of the i nstrument panel .
(Refer to 23 - BODY/I NSTRUMENT PANEL/I P PAS-
SENGER SI DE BEZEL - REMOVAL).
(4) Remove the three smal l screws that secure the
passenger ai rbag door to the gl ove box openi ng upper
rei nforcement (Fi g. 26).
(5) Remove the three l arge screws that secure the
passenger ai rbag door to the gl ove box openi ng upper
rei nforcement.
(6) Remove the one smal l screw that secures the
passenger ai rbag door to the top of the i nstrument
panel .
(7) Remove the four l arge screws that secure the
passenger ai rbag door to the top of the i nstrument
panel .
(8) Remove the passenger ai rbag door from the
i nstrument panel .
INSTALLATION
PERSONAL INJURY.
WARNING: THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAG DOORS ARE SERVICED IN THE ORIGINAL
COLORS. PAINT MAY CHANGE THE WAY IN WHICH
THE MATERIAL OF THE AIRBAG DOOR RESPONDS
TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT INJU-
RIES UPON AIRBAG DEPLOYMENT.
(1) Posi ti on the passenger ai rbag door onto the
(2) I nstal l and ti ghten the four l arge screws that
secure the passenger ai rbag door to the top of the
i nstrument panel . Ti ghten the screws to 4 Nm (35
i n. l bs.).
(3) I nstal l and ti ghten the one smal l screw that
secures the passenger ai rbag door to the top of the
i nstrument panel . Ti ghten the screw to 2 Nm (20 i n.
l bs.).
(4) I nstal l and ti ghten the three l arge screws that
secure the passenger ai rbag door to the gl ove box
openi ng upper rei nforcement. Ti ghten the screws to 4
Nm (35 i n. l bs.).
(5) I nstal l and ti ghten the three smal l screws that
secure the passenger ai rbag door to the gl ove box
openi ng upper rei nforcement. Ti ghten the screws to 2
Nm (20 i n. l bs.).
(6) Rei nstal l the passenger si de bezel onto the
upper gl ove box openi ng of the i nstrument panel .
(Refer to 23 - BODY/I NSTRUMENT PANEL/I P PAS-
SENGER SI DE BEZEL - I NSTALLATI ON).
(7) Rei nstal l the top cover onto the i nstrument
I NSTRUMENT PANEL TOP COVER - I NSTALLA-
TI ON).
Fig. 26 Passenger Airbag Door Remove/Install
1 - PASSENGER AIRBAG DOOR
2 - LARGE SCREW (7)
3 - SMALL SCREW (4)
PASSENGER AIRBAG DOOR (Continued)
PASSENGER AIRBAG
MOUNTING BRACKET
REMOVAL
The passenger ai rbag mounti ng brackets cannot be
repai red. They must be repl aced i f faul ty or dam-
aged, or i f the passenger ai rbag has been depl oyed.
PERSONAL INJURY.
(1) Remove the passenger ai rbag from the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG - REMOVAL).
and/or outboard passenger ai rbag mounti ng brack-
et(s) to the i nstrument panel support structure (Fi g.
27).
(3) Remove the i nboard and/or outboard passenger
ai rbag mounti ng bracket(s) from the i nstrument
panel support structure.
INSTALLATION
The passenger ai rbag mounti ng brackets cannot be
repai red. They must be repl aced i f faul ty or dam-
aged, or i f the passenger ai rbag has been depl oyed.
PERSONAL INJURY.
(1) Posi ti on the i nboard and/or outboard passenger
ai rbag mounti ng bracket(s) to the i nstrument panel
support structure (Fi g. 27).
the i nboard and/or outboard passenger ai rbag mount-
i ng bracket(s) to the i nstrument panel support struc-
ture. Ti ghten the screws to 2 Nm (20 i n. l bs.).
(3) Rei nstal l the passenger ai rbag to the i nstru-
ment panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/PASSENGER AI RBAG -
I NSTALLATI ON).
Fig. 27 Passenger Airbag Mounting Brackets
Remove/Install
1 - INBOARD BRACKET
2 - I/P SUPPORT STRUCTURE
3 - OUTBOARD BRACKET
4 - SCREW (2)
5 - SCREW (2)
RETRACTOR
REMOVAL
(1) Remove the ri ght center seat bel t buckl e uni t
from the fl oor panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/REAR SEAT BELT BUCKLE - REMOV-
AL).
(2) Unl atch and fol d the ri ght rear seat back for-
ward and separate the cargo area carpet from the
base of the seat back panel .
(3) Reach between the base of the ri ght rear seat
back and the forward edge of the rear cargo fl oor to
access and remove the screw that secures the rear
center seat bel t l ower anchor to the fl oor panel (Fi g.
28).
(4) Li ft the rear center seat bel t l ower anchor off of
the stud on the rear fl oor panel .
(5) Remove the two screws that secure the bel t
web gui de to the top of the ri ght rear seat back
panel .
(6) Remove the ri ght rear seat back panel from the
vehi cl e. (Refer to 23 - BODY/SEATS/SEAT BACK -
REAR - REMOVAL).
(7) Remove the two screws that secure the bel t
web gui de to the top of the ri ght rear seat back
panel .
(8) Remove the tri m from the ri ght rear seat back.
(Refer to 23 - BODY/SEATS/SEAT BACK COVER -
REAR - REMOVAL).
(9) Route the rear seat bel t l ower anchor and bel t
web gui de through the top of the seat back panel .
(10) Di sengage the seat back l atch cabl e fi tti ng
from the cabl e support on the retractor, whi ch i s a
l i ght snap fi t (Fi g. 29).
Fig. 28 Rear Center Seat Belt Anchor Plate
Remove/Install
1 - SCREW (2)
2 - BUCKLE UNIT
3 - REAR SEAT BACK
4 - REAR FLOOR PANEL
5 - STUD (1)
6 - ANCHOR PLATE
Fig. 29 Seat Back Latch Cable Disengage/Engage
1 - LEVER
2 - PLUNGER
3 - LATCH CABLE FITTING
4 - REAR CENTER RETRACTOR
5 - SUPPORT
(11) Remove the screw that secures the retractor
to the rear seat back panel (Fi g. 30).
(12) Remove the rear center seat bel t and retractor
uni t from the seat back panel .
INSTALLATION
(1) Posi ti on the rear center seat bel t and retractor
uni t onto the seat back panel .
retractor to the rear seat back panel (Fi g. 30).
Ti ghten the screw to 27 Nm (20 ft. l bs.).
(3) Posi ti on the seat back l atch cabl e pl unger
agai nst the retractor l atch l ever, then engage the
cabl e fi tti ng i nto the cabl e support on the retractor,
whi ch i s a l i ght snap fi t (Fi g. 29).
(4) Route the rear seat bel t l ower anchor and bel t
web gui de through the top of the seat back panel .
(5) Rei nstal l the tri m onto the ri ght rear seat
back. (Refer to 23 - BODY/SEATS/SEAT BACK
COVER - REAR - I NSTALLATI ON).
the bel t web gui de to the top of the ri ght rear seat
back panel . Ti ghten the screws to 2 Nm (20 i n. l bs.).
(7) Rei nstal l the ri ght rear seat back panel i nto
the vehi cl e. (Refer to 23 - BODY/SEATS/SEAT BACK
- REAR - I NSTALLATI ON).
(8) Posi ti on the rear center seat bel t l ower anchor
off of the stud on the rear fl oor panel (Fi g. 28).
(9) Reach between the base of the ri ght rear seat
back and the forward edge of the rear cargo fl oor to
i nstal l and ti ghten the screw that secures the rear
center seat bel t l ower anchor to the fl oor panel .
(10) Restore the cargo area carpet to the base of
the seat back panel and unfol d the ri ght rear seat
back to i ts upri ght posi ti on.
(11) Rei nstal l the ri ght center seat bel t buckl e uni t
onto the fl oor panel . (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/SEAT BELT BUCKLE - I NSTALLA-
TI ON).
REAR OUTBOARD SEAT BELT
& RETRACTOR
REMOVAL
screw that secures the rear outboard seat bel t turn-
i ng l oop to the upper C-pi l l ar (Fi g. 31).
(2) Remove the screw that secures the seat bel t
turni ng l oop to the upper C-pi l l ar.
(3) Remove the screw that secures the l ower seat
bel t anchor to the bracket on the outboard si de of the
rear seat cushi on frame.
Fig. 30 Rear Center Retractor Remove/Install
1 - REAR SEAT BACK PANEL
2 - SCREW (1)
REAR CENTER SEAT BELT & RETRACTOR (Continued)
(4) Remove the quarter tri m panel from the C-pi l -
l ar. (Refer to 23 - BODY/I NTERI OR/QUARTER
(5) Route the seat bel t l ower anchor and turni ng
l oop through the access hol e i n the quarter tri m
panel .
(6) Remove the screw that secures the retractor
bracket to the l ower C-pi l l ar.
(7) Li ft the retractor upward far enough to di sen-
gage the retractor tab from the engagement hol e i n
the l ower C-pi l l ar.
(8) Remove the rear outboard seat bel t and retrac-
tor from the C-pi l l ar as a uni t.
INSTALLATION
(1) Posi ti on the rear outboard seat bel t and retrac-
tor to the C-pi l l ar as a uni t (Fi g. 31).
(2) Engage the retractor tab i nto the engagement
hol e i n the l ower C-pi l l ar.
retractor bracket to the l ower C-pi l l ar. Ti ghten the
screw to 43 Nm (32 ft. l bs.).
(4) Route the seat bel t l ower anchor and turni ng
l oop through the access hol e i n the quarter tri m
panel .
(5) Rei nstal l the quarter tri m panel onto the C-pi l -
l ar. (Refer to 23 - BODY/I NTERI OR/QUARTER
TRI M PANEL - I NSTALLATI ON).
(6) Posi ti on the l ower seat bel t anchor to the
bracket on the outboard si de of the rear seat cushi on
frame. Be certai n that the anti -rotati on tab on the
anchor i s engaged i n the sl ot i n the seat bracket.
l ower seat bel t anchor to the bracket on the outboard
si de of the rear seat cushi on frame. Ti ghten the
screw to 43 Nm (32 ft. l bs.).
(8) Posi ti on the seat bel t turni ng l oop to the upper
C-pi l l ar.
seat bel t turni ng l oop to the upper C-pi l l ar. Ti ghten
the screw to 43 Nm (32 ft. l bs.).
(10) Fol d and snap the tri m cover back i nto pl ace
to conceal the screw that secures the rear outboard
seat bel t turni ng l oop to the upper C-pi l l ar.
REAR SEAT BELT BUCKLE
REMOVAL
Fig. 31 Rear Outboard Seat Belt & Retractor
Remove/Install
1 - C-PILLAR
2 - QUARTER TRIM PANEL
3 - COVER
4 - SEAT BELT & RETRACTOR
5 - SCREW (1)
6 - LOWER ANCHOR
7 - SCREW (1)
8 - ACCESS COVER
9 - SCREW (1)
REAR OUTBOARD SEAT BELT & RETRACTOR (Continued)
(1) Unl atch the rear seat back and fol d i t forward
far enough to access the screw that secures the rear
seat bel t buckl e anchor to the rear fl oor panel
between the rear seat back and the rear seat cush-
i on.
(2) Remove the screw that secures the rear seat
bel t buckl e anchor to the rear fl oor panel (Fi g. 32).
(3) Li ft the rear seat bel t buckl e anchor off of the
stud on the rear fl oor panel .
(4) Remove the rear seat bel t buckl e and anchor
from between the rear seat back and the rear seat
cushi on as a uni t.
INSTALLATION
(1) Unl atch the rear seat back and fol d i t forward
far enough to access the mounti ng l ocati on for the
rear seat bel t buckl e anchor to the rear fl oor panel
between the rear seat back and the rear seat cush-
i on.
(2) Posi ti on the rear seat bel t buckl e and anchor
between the rear seat back and the rear seat cushi on
as a uni t (Fi g. 32).
(3) Lower the rear seat bel t buckl e anchor over the
stud on the rear fl oor panel .
rear seat bel t buckl e anchor to the rear fl oor panel .
SEAT BELT SWITCH
DESCRIPTION
The seat bel t swi tch for thi s model i s actual l y a
Hal l Effect-type sensor. Thi s sensor consi sts of a
fi xed-posi ti on, Hal l Effect I ntegrated Ci rcui t (I C) chi p
and a smal l , movabl e, permanent magnet that are
i ntegral to each front seat bel t buckl e. The front seat
bel t buckl es are each l ocated on a stamped steel
stanchi on secured wi th a screw to the i nboard si de of
each front seat cushi on frame between the seat and
the fl oor panel transmi ssi on tunnel (Fi g. 33). The
seat bel t swi tches are connected to the vehi cl e el ec-
tri cal system through a two-l ead pi gtai l wi re and
connector on the seat bel t buckl e-hal f, whi ch i s con-
nected to a wi re harness connector and take out of
the seat wi re harness beneath the rear edge of the
seat cushi on frame. A di agnosti c resi stor i s connected
Fig. 32 Rear Seat Belt Buckle Remove/Install
1 - SCREW (1)
2 - BUCKLE (SINGLE)
3 - REAR SEAT
4 - BUCKLE (DOUBLE)
5 - SCREW (1)
6- REAR FLOOR PANEL
Fig. 33 Front Seat Belt Buckle
1 - FRONT SEAT BELT BUCKLE
2 - INBOARD SIDE SHIELD
3 - SCREW
4 - PIGTAIL WIRE
REAR SEAT BELT BUCKLE (Continued)
i n paral l el wi th the I C where the two pi gtai l wi re
l eads connect to the I C pi ns.
The seat bel t swi tch cannot be adjusted or repai red
and, i f faul ty or damaged, the enti re seat bel t buckl e-
hal f uni t must be repl aced.
OPERATION
The seat bel t swi tches are desi gned to provi de a
status si gnal to the seat bel t swi tch sense i nputs of
the Ai rbag Control Modul e (ACM) i ndi cati ng whether
the front seat bel ts are fastened. The ACM uses the
seat bel t swi tch i nputs as a factor i n determi ni ng
what l evel of force wi th whi ch i t shoul d depl oy the
mul ti stage dri ver and passenger ai rbags. I n addi ti on,
the ACM sends el ectroni c messages to the El ectroMe-
chani cal I nstrument Cl uster (EMI C) to control the
seat bel t i ndi cator based upon the status of the
dri ver si de front seat bel t swi tch. A spri ng-l oaded
pl asti c sl i de wi th a smal l , encl osed permanent mag-
net i s i ntegral to the buckl e l atch mechani sm. When
a seat bel t ti p-hal f i s i nserted and l atched i nto the
seat bel t buckl e, the sl i de i s pushed downward and
i nto cl ose proxi mi ty of the Hal l Effect I ntegrated Ci r-
cui t (I C) chi p wi thi n the buckl e, whi ch i nduces a cur-
rent wi thi n the chi p. The chi p provi des thi s i nduced
current as an output to the ACM, whi ch moni tors the
current to determi ne the status of the front seat
bel ts. When the seat bel t i s unbuckl ed, the spri ng-
l oaded sl i de and permanent magnet move upward
and away from the I C, causi ng the output current
from the seat bel t swi tch to be reduced.
The seat bel t swi tch recei ves a suppl y current from
the ACM, and the ACM senses the status of the front
seat bel ts through i ts pi gtai l wi re connecti on to the
seat wi re harness. The ACM al so moni tors the condi -
ti on of the seat bel t swi tch ci rcui ts through ci rcui t
resi stance created by the di agnosti c resi stor. The
ACM wi l l i l l umi nate the ai rbag i ndi cator i n the
EMI C and store a Di agnosti c Troubl e Code (DTC) for
any faul t that i s detected i n ei ther seat bel t swi tch
ci rcui t. For proper di agnosi s of the seat bel t swi tches,
a DRBI I I scan tool i s requi red. Refer to the appro-
pri ate di agnosti c i nformati on.
SEAT BELT TENSIONER
DESCRIPTION
A dri ver si de seat bel t tensi oner suppl ements the
dri ver ai rbag system for al l versi ons of thi s model
(Fi g. 34). The seat bel t tensi oner i s i ntegral to the
dri ver si de front seat bel t and retractor uni t, whi ch i s
secured to the B-pi l l ar on the l eft si de of the vehi cl e.
The retractor i s conceal ed beneath the mol ded pl asti c
B-pi l l ar tri m. The seat bel t tensi oner consi sts pri ma-
ri l y of a mol ded pl asti c tensi oner housi ng, a tubul ar
metal pi ston housi ng, a pi ston, a short rack gear, a
set of pi ni on gears, a pyrotechni cal l y acti vated gas
generator, and a short pi gtai l wi re. Al l of these com-
ponents are l ocated on one si de of the retractor spool
on the outsi de of the retractor housi ng. The seat bel t
tensi oner i s control l ed by the Ai rbag Control Modul e
(ACM) and i s connected to the vehi cl e el ectri cal sys-
tem through a dedi cated take out of the body wi re
harness by a keyed and l atchi ng mol ded pl asti c con-
nector i nsul ator to ensure a secure connecti on.
The seat bel t tensi oner cannot be repai red and, i f
faul ty or damaged, the enti re dri ver si de front seat
bel t and retractor uni t must be repl aced. The seat
bel t tensi oner i s not i ntended for reuse and must be
repl aced fol l owi ng a depl oyment. A l ocked retractor
that wi l l not al l ow the seat bel t webbi ng to be
retracted or extracted i s a sure i ndi cati on that the
seat bel t tensi oner has been depl oyed and requi res
repl acement. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/FRONT SEAT BELT & RETRACTOR -
REMOVAL).
OPERATION
The seat bel t tensi oner i s depl oyed by a si gnal gen-
erated by the Ai rbag Control Modul e (ACM) through
the dri ver seat bel t tensi oner l i ne 1 and l i ne 2 (or
squi b) ci rcui ts. When the ACM sends the proper el ec-
tri cal si gnal to the tensi oner, the el ectri cal energy
generates enough heat to i ni ti ate a smal l pyrotechni c
gas generator. The gas generator i s i nstal l ed i n one
end of the tubul ar metal pi ston housi ng, whi ch con-
tai ns a pi ston and a smal l rack gear. As the gas
expands, i t pushes the pi ston and the rack gear
Fig. 34 Seat Belt Tensioner
1 - RETRACTOR
2 - TENSIONER HOUSING
3 - PISTON HOUSING
4 - PIGTAIL WIRE
5 - GAS GENERATOR
SEAT BELT SWITCH (Continued)
through the tube. The rack gear engages a pi ni on
gear that dri ves a gear set i n the tensi oner housi ng,
whi ch dri ves the seat bel t retractor spool causi ng the
sl ack to be removed from the dri ver si de front seat
bel t. Removi ng excess sl ack from the dri ver si de front
seat bel t not onl y keeps the occupant properl y posi -
ti oned for an ai rbag depl oyment fol l owi ng a frontal
i mpact of the vehi cl e, but al so hel ps to reduce i nju-
ri es that the occupant of the dri ver si de front seat
mi ght experi ence i n these si tuati ons as a resul t of a
harmful contact wi th the steeri ng wheel and/or steer-
i ng col umn. Al so, the seat bel t tensi oner has a tor-
si on bar mechani sm that i s desi gned to deform i n
order to control the l oadi ng bei ng appl i ed to the occu-
pant of the dri ver si de front seat by the seat bel t dur-
i ng a frontal i mpact, further reduci ng the potenti al
for occupant i njuri es.
The ACM moni tors the condi ti on of the seat bel t
tensi oner through ci rcui t resi stance, and wi l l i l l umi -
nate the ai rbag i ndi cator i n the El ectroMechani cal
I nstrument Cl uster (EMI C) and store a Di agnosti c
Troubl e Code (DTC) for any faul t that i s detected.
For proper di agnosi s of the seat bel t tensi oner, a
SEAT BELT TURNING LOOP
ADJ USTER
REMOVAL
PERSONAL INJURY.
nut that secures the front seat bel t turni ng l oop to
the hei ght adjuster on the upper B-pi l l ar.
(3) Remove the nut that secures the seat bel t turn-
i ng l oop to the hei ght adjuster stud on the upper
B-pi l l ar.
(4) Remove the seat bel t turni ng l oop from the
hei ght adjuster stud.
(5) Remove the upper tri m from the i nsi de of the
B-pi l l ar. (Refer to 23 - BODY/I NTERI OR/B-PI LLAR
UPPER TRI M - REMOVAL).
(6) Remove the screw that secures the seat bel t
turni ng l oop adjuster to the upper B-pi l l ar (Fi g. 35).
(7) Pul l the upper end of the turni ng l oop adjuster
away from the B-pi l l ar far enough to di sengage the
hooks on the l ower end of the adjuster from the sl ots
i n the B-pi l l ar.
(8) Remove the seat bel t turni ng l oop adjuster
from the B-pi l l ar.
Fig. 35 Seat Belt Turning Loop Adjuster Remove/
Install
1 - SCREW
2 - B-PILLAR
3 - ADJUSTER
SEAT BELT TENSIONER (Continued)
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the seat bel t turni ng l oop adjuster to
the B-pi l l ar (Fi g. 35).
(2) Engage the hooks on the l ower end of the
adjuster i nto the sl ots i n the B-pi l l ar.
(3) Ti l t the upper end of the turni ng l oop adjuster
up i nto posi ti on agai nst the B-pi l l ar.
seat bel t turni ng l oop adjuster to the upper B-pi l l ar.
(5) Rei nstal l the upper tri m onto the i nsi de of the
UPPER TRI M - I NSTALLATI ON).
(6) Posi ti on the seat bel t turni ng l oop onto the
hei ght adjuster stud on the upper B-pi l l ar.
seat bel t turni ng l oop to the hei ght adjuster stud.
(8) Fol d and snap the tri m cover back i nto pl ace to
conceal the nut that secures the front seat bel t turn-
i ng l oop to the hei ght adjuster on the upper B-pi l l ar.
SIDE CURTAIN AIRBAG
DESCRIPTION
Opti onal si de curtai n ai rbags are avai l abl e for thi s
model when i t i s al so equi pped wi th dual front ai r-
bags. These ai rbags are passi ve, i nfl atabl e, Suppl e-
mental Restrai nt System (SRS) components, and
vehi cl es wi th thi s equi pment can be readi l y i denti fi ed
by a mol ded i denti fi cati on tri m button wi th the SRS
- AI RBAG l ogo l ocated on the headl i ner above each
B-pi l l ar (Fi g. 36). Thi s system i s desi gned to reduce
i njuri es to the vehi cl e occupants i n the event of a
si de i mpact col l i si on.
Vehi cl es equi pped wi th si de curtai n ai rbags have
two i ndi vi dual l y control l ed curtai n ai rbag uni ts.
These ai rbag uni ts are conceal ed and mounted above
the headl i ner where they are each secured to one of
the roof si de rai l s (Fi g. 37). Each fol ded ai rbag cush-
i on i s contai ned wi thi n a l ong extruded pl asti c chan-
nel that extends al ong the roof rai l from the A-pi l l ar
at the front of the vehi cl e to just behi nd the C-pi l l ar
at the rear of the vehi cl e. The channel i s secured
wi th pl asti c push-i n fasteners to the roof rai l . A
tether extends down the A-pi l l ar from the front of the
ai rbag cushi on, where i t i s retai ned to the pi l l ar wi th
pl asti c push-i n routi ng cl i ps and i t i s secured to the
base of the A-pi l l ar near the bel t l i ne wi th a screw.
The hybri d-type i nfl ator for each ai rbag i s secured
to the roof rai l at the rear of the ai rbag uni t between
the C-pi l l ar and the D-pi l l ar, and i s connected to the
ai rbag cushi on by a l ong tubul ar mani fol d. The
bracket hol di ng the i nfl ator and three other brackets
hol di ng the mani fol d are secured to the roof rai l wi th
Fig. 36 SRS Logo
SEAT BELT TURNING LOOP ADJ USTER (Continued)
screws. A two-wi re pi gtai l harness i s routed forward
from the ai rbag i nfl ator through a trough al ong the
top of the pl asti c ai rbag channel on the roof rai l and
down the B-pi l l ar, where i t i s retai ned by three rout-
i ng cl i ps. The pi gtai l harness i s connected to a take
out and connector of the body wi re harness on the
B-pi l l ar, whi ch connects to the respecti ve ri ght or l eft
Si de I mpact Ai rbag Control Modul e (SI ACM) on the
si l l panel at the base of the B-pi l l ar.
The si de curtai n ai rbag uni t cannot be adjusted or
repai red and must be repl aced i f depl oyed, faul ty, or
i n any way damaged. Once a si de curtai n ai rbag has
been depl oyed, the compl ete ai rbag uni t, the head-
l i ner, the upper A, B, and C-pi l l ar tri m, and al l other
vi si bl y damaged components must be repl aced.
OPERATION
Each si de curtai n ai rbag i s depl oyed i ndi vi dual l y by
an el ectri cal si gnal generated by the l eft or ri ght Si de
I mpact Ai rbag Control Modul e (SI ACM) to whi ch i t i s
connected through l eft or ri ght curtai n ai rbag l i ne 1 and
l i ne 2 (or squi b) ci rcui ts. The hybri d-type i nfl ator
assembl y for each ai rbag contai ns a smal l cani ster of
hi ghl y compressed hel i um gas. When the SI ACM sends
the proper el ectri cal si gnal to the ai rbag i nfl ator, the
el ectri cal energy creates enough heat to i gni te chemi cal
pel l ets wi thi n the i nfl ator. Once i gni ted, these chemi cal s
burn rapi dl y and produce the pressure necessary to rup-
ture a contai nment di sk i n the hel i um gas cani ster. The
i nfl ator and hel i um gas cani ster are seal ed and con-
nected to a tubul ar mani fol d so that al l of the rel eased
gas i s di rected i nto the fol ded curtai n ai rbag cushi on,
causi ng the cushi on to i nfl ate.
As the ai rbag cushi on i nfl ates i t wi l l drop down
from the roof rai l between the edge of the headl i ner
and the si de gl ass/body pi l l ars to form a curtai n-l i ke
cushi on to protect the vehi cl e occupants duri ng a si de
i mpact col l i si on. The front tether keeps the front por-
ti on of the bag taut, thus ensuri ng that the bag wi l l
depl oy i n the proper posi ti on. Fol l owi ng the ai rbag
depl oyment, the ai rbag cushi on qui ckl y defl ates by
venti ng the hel i um gas through the l oose weave of
the cushi on fabri c, and the defl ated cushi on hangs
down l oosel y from the roof rai l .
Fig. 37 Side Curtain Airbag
1 - INFLATOR
2 - MANIFOLD
3 - CHANNEL
4 - TETHER
5 - PIGTAIL WIRE RETAINER (3)
6 - PUSH-IN FASTENER (4)
7 - BRACKET (3)
SIDE CURTAIN AIRBAG (Continued)
REMOVAL
faul ty or damaged si de curtai n ai rbag. I f the si de
curtai n ai rbag has been depl oyed, revi ew the recom-
mended procedures for servi ce after a suppl emental
restrai nt depl oyment before removi ng the ai rbag
from the vehi cl e. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS - STANDARD PROCEDURE - SERVI CE
AFTER A SUPPLEMENTAL RESTRAI NT DEPLOY-
MENT).
PERSONAL INJURY.
SKIN AND EYES.
FOREIGN MATERIAL FROM ENTERING THE SIDE
CURTAIN AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE SIDE CURTAIN AIRBAG CUSHION
AND THE HEADLINER. FAILURE TO OBSERVE THIS
(2) Remove the l ower tri m from the i nsi de of the
LOWER TRI M - REMOVAL).
(3) Remove the headl i ner from the vehi cl e. (Refer
to 23 - BODY/I NTERI OR/HEADLI NER - REMOV-
AL).
(4) Remove the screw that secures the si de curtai n
ai rbag tether retai ner to the base of the A-pi l l ar near
the bel t l i ne (Fi g. 38).
Fig. 38 Side Curtain Airbag Tether Remove/Install
1 - A-PILLAR
2 - CLIP (2)
3 - TETHER
4 - RETAINER (1)
5 - SCREW (1)
(5) Di sengage the two si de curtai n ai rbag tether
pl asti c retai ner cl i ps from the A-pi l l ar.
(6) Di sconnect the si de curtai n ai rbag pi gtai l wi re
connector from the body wi re harness connector near
the base of the B-pi l l ar (Fi g. 39).
(7) Di sengage the three si de curtai n ai rbag pi gtai l
wi re retai ner cl i ps from the B-pi l l ar.
(8) Remove the three screws that secure the si de
curtai n ai rbag mani fol d tube brackets to the U-nuts
i n the roof rai l (Fi g. 40) and (Fi g. 41).
(9) Remove the two screws that secure the si de
curtai n ai rbag i nfl ator bracket to the U-nuts i n the
roof rai l (Fi g. 42).
(10) Grasp the extruded pl asti c si de curtai n ai rbag
channel fi rml y and pul l i t strai ght away from the
roof rai l far enough to di sengage al l four pl asti c
push-i n fasteners that secure i t.
(11) Remove the si de curtai n ai rbag from the vehi -
cl e as a uni t.
INSTALLATION
PERSONAL INJURY.
SKIN AND EYES.
Fig. 39 Side Curtain Airbag Pigtail Wire Remove/
Install
1 - RETAINER (3)
2 - B-PILLAR
4 - PIGTAIL WIRE
Fig. 40 Side Curtain Airbag (Front) Remove/Install
1 - ROOF PANEL
2 - PIGTAIL WIRE
3 - B-PILLAR
5 - RETAINER
6 - CHANNEL
7 - A-PILLAR
8 - TETHER
9 - SCREW (3)
10 - U-NUT (5)
FOREIGN MATERIAL FROM ENTERING THE SIDE
CURTAIN AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE SIDE CURTAIN AIRBAG CUSHION
AND THE HEADLINER. FAILURE TO OBSERVE THIS
(1) Posi ti on the si de curtai n ai rbag i nto the vehi cl e
as a uni t.
(2) Al i gn al l four pl asti c push-i n fasteners that
secure the extruded pl asti c si de curtai n ai rbag chan-
nel wi th thei r hol es i n the roof si de rai l and push
them strai ght i nto the roof rai l unti l they are ful l y
seated (Fi g. 40) and (Fi g. 41).
(3) I nstal l and ti ghten the upper screw that
secures the si de curtai n ai rbag i nfl ator bracket to the
U-nut i n the roof rai l , fol l owed by the l ower screw
(Fi g. 42). Ti ghten the screws to 12 Nm (105 i n. l bs.).
(4) Worki ng from the rear of the vehi cl e to the
front, i nstal l and ti ghten each of the three screws
that secure the si de curtai n ai rbag mani fol d tube
brackets to the U-nuts i n the roof rai l . Ti ghten the
screws to 12 Nm (105 i n. l bs.).
(5) Route the si de curtai n ai rbag pi gtai l wi re
through the trough al ong the top of the extruded
pl asti c ai rbag channel on the roof si de rai l , then
between the channel and the body down the B-pi l l ar.
NOTE: Be certain that the side curtain airbag pigtail
wire is routed behind the airbag channel, between
the channel and the body above the B-pillar.
(6) Engage the three si de curtai n ai rbag pi gtai l
wi re retai ner cl i ps i nto the B-pi l l ar (Fi g. 39).
(7) Reconnect the si de curtai n ai rbag pi gtai l wi re
connector to the body wi re harness connector near
the base of the B-pi l l ar.
(8) Engage the two si de curtai n ai rbag tether pl as-
ti c retai ner cl i ps i nto the A-pi l l ar (Fi g. 38).
si de curtai n ai rbag tether retai ner to the base of the
A-pi l l ar near the bel t l i ne. Ti ghten the screw to 14
Nm (120 i n. l bs.).
Fig. 41 Side Curtain Airbag (Rear) Remove/Install
1 - ROOF PANEL
2 - SCREW (3)
3 - U-NUT (5)
4 - PIGTAIL WIRE
5 - MANIFOLD
6 - C-PILLAR
8 - CHANNEL
Fig. 42 Side Curtain Airbag Inflator Remove/Install
1 - U-NUT (5)
2 - ROOF PANEL
3 - INFLATOR
4 - C-PILLAR
5 - SCREW (2)
6 - MANIFOLD
7 - PIGTAIL WIRE
8 - BRACKET
(10) Rei nstal l the headl i ner i nto the vehi cl e. (Refer
to 23 - BODY/I NTERI OR/HEADLI NER - I NSTALLA-
TI ON).
(11) Rei nstal l the l ower tri m onto the i nsi de of the
LOWER TRI M - I NSTALLATI ON).
SIDE IMPACT AIRBAG
CONTROL MODULE
DESCRIPTION
On vehi cl es equi pped wi th the opti onal si de curtai n
ai rbags, a Si de I mpact Ai rbag Control Modul e
(SI ACM) and i ts mounti ng bracket are secured wi th
four screws to the si l l panel at the base of each B-pi l -
l ar behi nd the l ower B-pi l l ar tri m (Fi g. 43). Con-
ceal ed wi thi n a hol l ow i n the center of the di e cast
al umi num SI ACM housi ng i s the el ectroni c ci rcui try
of the SI ACM whi ch i ncl udes a mi croprocessor and
an el ectroni c i mpact sensor. The SI ACM housi ng i s
secured to a stamped steel mounti ng bracket, whi ch
i s uni que for the ri ght or l eft si de appl i cati on of thi s
component. The SI ACM shoul d never be removed
from i ts mounti ng bracket. The housi ng al so recei ves
a case ground through thi s mounti ng bracket when i t
i s secured to the vehi cl e. A mol ded pl asti c el ectri cal
connector receptacl e that exi ts the top of the SI ACM
housi ng connects the uni t to the vehi cl e el ectri cal
the body wi re harness. Both the SI ACM housi ng and
i ts el ectri cal connecti on are seal ed to protect the
i nternal el ectroni c ci rcui try and components agai nst
moi sture i ntrusi on.
The i mpact sensor i nternal to the SI ACM i s cal i -
brated for the speci fi c vehi cl e, and i s onl y servi ced as
a uni t wi th the SI ACM. The SI ACM cannot be
repai red or adjusted and, i f damaged or faul ty, i t
must be repl aced.
OPERATION
The mi croprocessor i n the Si de I mpact Ai rbag Con-
trol Modul e (SI ACM) contai ns the si de curtai n ai rbag
system l ogi c ci rcui ts and control s al l of the features
of onl y the si de curtai n ai rbag mounted on the same
si de of the vehi cl e as the SI ACM. The SI ACM uses
On-Board Di agnosti cs (OBD) and can communi cate
wi th other el ectroni c modul es i n the vehi cl e as wel l
as wi th the DRBI I I scan tool usi ng the Programma-
work. Thi s method of communi cati on i s used by the
SI ACM to communi cate wi th the Ai rbag Control
Modul e (ACM) and for suppl emental restrai nts sys-
tem di agnosi s and testi ng through the 16-way data
l i nk connector l ocated on the dri ver si de l ower edge
of the i nstrument panel . The ACM communi cates
wi th both the l eft and ri ght SI ACM over the PCI
data bus.
The SI ACM mi croprocessor conti nuousl y moni tors
al l of the si de curtai n ai rbag el ectri cal ci rcui ts to
determi ne the system readi ness. I f the SI ACM
detects a moni tored system faul t, i t sets an acti ve
and stored Di agnosti c Troubl e Code (DTC) and sends
el ectroni c messages to the ACM over the PCI data
bus. The ACM wi l l respond by sendi ng an el ectroni c
message to the EMI C to turn on the ai rbag i ndi cator,
and by stori ng a DTC that wi l l i ndi cate whether the
l eft or the ri ght SI ACM has stored the DTC that i ni -
ti ated the ai rbag i ndi cator i l l umi nati on. An acti ve
faul t onl y remai ns for the current i gni ti on swi tch
cycl e, whi l e a stored faul t causes a DTC to be stored
i n memory by the SI ACM. For some DTCs, i f a faul t
does not recur for a number of i gni ti on cycl es, the
SI ACM wi l l automati cal l y erase the stored DTC. For
other i nternal faul ts, the stored DTC i s l atched for-
ever.
The SI ACM recei ves battery current on a fused
i gni ti on swi tch output (run-start) ci rcui t through a
fuse i n the Juncti on Bl ock (JB). The SI ACM has a
case ground through i ts mounti ng bracket and al so
recei ves a power ground through a ground ci rcui t
and take out of the body wi re harness. Thi s take out
has a si ngl e eyel et termi nal connector that i s secured
by a ground screw to the front seat front crossmem-
Fig. 43 Side Impact Airbag Control Module
1 - BRACKET (RIGHT SHOWN)
3 - SIACM
ber beneath the respecti ve ri ght or l eft front seat.
These connecti ons al l ow the SI ACM to be operati onal
whenever the i gni ti on swi tch i s i n the Start or On
posi ti ons. An el ectroni c i mpact sensor i s contai ned
wi thi n the SI ACM. The el ectroni c i mpact sensor i s
an accel erometer that senses the rate of vehi cl e
decel erati on, whi ch provi des veri fi cati on of the di rec-
ti on and severi ty of an i mpact. A pre-programmed
deci si on al gori thm i n the SI ACM mi croprocessor
determi nes when the decel erati on rate as si gnal ed by
the i mpact sensor i ndi cates a si de i mpact that i s
severe enough to requi re si de curtai n ai rbag protec-
ti on. When the programmed condi ti ons are met, the
SI ACM sends the proper el ectri cal si gnal s to depl oy
the si de curtai n ai rbag.
The hard wi red i nputs and outputs for the SI ACM
ti onal di agnosti c methods wi l l not prove concl usi ve i n
the di agnosi s of the SI ACM, the PCI data bus net-
work, or the el ectroni c message i nputs to and outputs
from the SI ACM. The most rel i abl e, effi ci ent, and
accurate means to di agnose the SI ACM, the PCI data
bus network, and the el ectroni c message i nputs to
and outputs from the SI ACM requi res the use of a
ti c i nformati on.
REMOVAL
PERSONAL INJURY.
WARNING: THE SIDE IMPACT AIRBAG CONTROL
MODULE CONTAINS THE IMPACT SENSOR, WHICH
ENABLES THE SYSTEM TO DEPLOY THE SIDE
CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE
SIDE IMPACT AIRBAG CONTROL MODULE, AS IT
CAN DAMAGE THE IMPACT SENSOR OR AFFECT
ITS CALIBRATION. IF A SIDE IMPACT AIRBAG CON-
TROL MODULE IS ACCIDENTALLY DROPPED DUR-
ING SERVICE, THE MODULE MUST BE SCRAPPED
AND REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER SIDE CUR-
TAIN AIRBAG DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.
(1) Adjust the front seat to i ts most forward posi -
ti on for easi est access to the l ower B-pi l l ar tri m.
(3) Remove the l ower tri m from the i nsi de of the
LOWER TRI M - REMOVAL).
(4) Di sconnect the body wi re harness connector for
the Si de I mpact Ai rbag Control Modul e (SI ACM)
from the modul e connector receptacl e (Fi g. 44).
(5) Di sengage the body wi re harness retai ner from
the tab on the SI ACM mounti ng bracket.
(6) Remove the four screws that secure the SI ACM
mounti ng bracket to the si l l panel at the base of the
B-pi l l ar.
(7) Remove the SI ACM and i ts mounti ng bracket
from the si l l panel as a uni t.
Fig. 44 Side Impact Airbag Control Module
Remove/Install
1 - B-PILLAR
3 - SIACM
4 - SCREW (4)
SIDE IMPACT AIRBAG CONTROL MODULE (Continued)
INSTALLATION
PERSONAL INJURY.
WARNING: THE SIDE IMPACT AIRBAG CONTROL
MODULE CONTAINS THE IMPACT SENSOR, WHICH
ENABLES THE SYSTEM TO DEPLOY THE SIDE
CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE
SIDE IMPACT AIRBAG CONTROL MODULE, AS IT
CAN DAMAGE THE IMPACT SENSOR OR AFFECT
ITS CALIBRATION. IF A SIDE IMPACT AIRBAG CON-
TROL MODULE IS ACCIDENTALLY DROPPED DUR-
ING SERVICE, THE MODULE MUST BE SCRAPPED
AND REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER SIDE CUR-
TAIN AIRBAG DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.
(1) Posi ti on the Si de I mpact Ai rbag Control Mod-
ul e (SI ACM) and i ts mounti ng bracket to the si l l
panel as a uni t (Fi g. 44).
(2) Loosel y i nstal l the four screws that secure the
SI ACM mounti ng bracket to the si l l panel at the
base of the B-pi l l ar.
(3) Ti ghten the four screws that secure the SI ACM
mounti ng bracket to the si l l panel i n the fol l owi ng
sequence: upper front, upper rear, l ower front, l ower
rear. Ti ghten the screws to 12 Nm (105 i n. l bs.).
(4) Engage the body wi re harness retai ner to the
tab on the SI ACM mounti ng bracket.
(5) Reconnect the body wi re harness connector for
the SI ACM to the modul e connector receptacl e.
(6) Rei nstal l the l ower tri m onto the i nsi de of the
LOWER TRI M - I NSTALLATI ON).
SIDE IMPACT AIRBAG CONTROL MODULE (Continued)
SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - ROAD TEST . . . . . 2
SPECIFICATIONS
TORQUE - SPEED CONTROL . . . . . . . . . . . . . 2
CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL - 3.7L . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION - 3.7L . . . . . . . . . . . . . . . . . . . . . 4
SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VACUUM RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - VACUUM
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPEED CONTROL
DESCRIPTION
The speed control system i s el ectroni cal l y con-
trol l ed and vacuum operated. El ectroni c control of
the speed control system i s i ntegrated i nto the Pow-
ertrai n Control Modul e (PCM). The control s consi st
of two steeri ng wheel mounted swi tches. The
swi tches are l abel ed: ON/OFF, RES/ACCEL, SET,
COAST, and CANCEL.
The system i s desi gned to operate at speeds above
30 mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
OPERATION
When speed control i s sel ected by depressi ng the
ON swi tch, the PCM al l ows a set speed to be stored
i n PCM RAM for speed control . To store a set speed,
depress the SET swi tch whi l e the vehi cl e i s movi ng
at a speed between 35 and 85 mph. I n order for the
speed control to engage, the brakes cannot be
appl i ed, nor can the gear sel ector be i ndi cati ng the
transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
Steppi ng on the brake pedal
Depressi ng the OFF swi tch
Depressi ng the CANCEL swi tch.
Depressi ng the cl utch pedal (i f equi pped).
NOTE: Depressing the OFF switch or turning off the
ignition switch will erase the set speed stored in
the PCM.
For added safety, the speed control system i s pro-
grammed to di sengage for any of the fol l owi ng condi -
ti ons:
An i ndi cati on of Park or Neutral
A rapi d i ncrease rpm (i ndi cates that the cl utch
has been di sengaged)
Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
The speed si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the coeffi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
The speed si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
Once the speed control has been di sengaged,
depressi ng the RES/ACCEL swi tch (when speed i s
greater than 30 mph) restores the vehi cl e to the tar-
get speed that was stored i n the PCM.
Whi l e the speed control i s engaged, the dri ver can
i ncrease the vehi cl e speed by depressi ng the RES/AC-
CEL swi tch. The new target speed i s stored i n the
PCM when the RES/ACCEL i s rel eased. The PCM
al so has a tap-up feature i n whi ch vehi cl e speed
i ncreases at a rate of approxi matel y 2 mph for each
momentary swi tch acti vati on of the RES/ACCEL
swi tch.
KJ SPEED CONTROL 8P - 1
A tap down feature i s used to decel erate wi thout
di sengagi ng the speed control system. To decel erate
from an exi sti ng recorded target speed, momentari l y
depress the COAST swi tch. For each swi tch acti va-
ti on, speed wi l l be l owered approxi matel y 1 mph.
OVERSHOOT/UNDERSHOOT
I f the vehi cl e operator repeatedl y presses and
rel eases the SET button wi th thei r foot off of the
accel erator (referred to as a l i ft foot set), the vehi cl e
may accel erate and exceed the desi red set speed by
up to 5 mph (8 km/h). I t may al so decel erate to l ess
than the desi red set speed, before fi nal l y achi evi ng
the desi red set speed.
The Speed Control System has an adapti ve strat-
egy that compensates for vehi cl e-to-vehi cl e vari ati ons
i n speed control cabl e l engths. When the speed con-
trol i s set wi th the vehi cl e operators foot off of the
accel erator pedal , the speed control thi nks there i s
excessi ve speed control cabl e sl ack and adapts
accordi ngl y. I f the l i ft foot sets are conti nual l y used,
a speed control overshoot/undershoot condi ti on wi l l
devel op.
To unl earn the overshoot/undershoot condi ti on,
the vehi cl e operator has to press and rel ease the set
button whi l e mai ntai ni ng the desi red set speed usi ng
the accel erator pedal (not decel erati ng or accel erat-
i ng), and then turni ng the crui se control swi tch to
the OFF posi ti on (or press the CANCEL button i f
equi pped) after wai ti ng 10 seconds. Thi s procedure
must be performed approxi matel y 1015 ti mes to
compl etel y unl earn the overshoot/undershoot condi -
ti on.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehi cl e road test to veri fy reports of
speed control system mal functi on. The road test
shoul d i ncl ude attenti on to the speedometer. Speed-
ometer operati on shoul d be smooth and wi thout fl ut-
ter at al l speeds.
Fl utter i n the speedometer i ndi cates a probl em
whi ch mi ght cause surgi ng i n the speed control sys-
tem. The cause of any speedometer probl ems shoul d
be corrected before proceedi ng. Refer to Group 8J,
I nstrument Cl uster for speedometer di agnosi s.
I f a road test veri fi es a system probl em and the
speedometer operates properl y, check for:
A Di agnosti c Troubl e Code (DTC). I f a DTC
exi sts, conduct tests per the Powertrai n Di agnosti c
Procedures servi ce manual .
A mi sadjusted brake (stop) l amp swi tch. Thi s
coul d al so cause an i ntermi ttent probl em.
Loose, damaged or corroded el ectri cal connec-
ti ons at the servo. Corrosi on shoul d be removed from
el ectri cal termi nal s and a l i ght coati ng of Mopar
Mul ti Purpose Grease, or equi val ent, appl i ed.
Leaki ng vacuum reservoi r.
Loose or l eaki ng vacuum hoses or connecti ons.
Defecti ve one-way vacuum check val ve.
Secure attachment of both ends of the speed con-
trol servo cabl e.
Smooth operati on of throttl e l i nkage and throttl e
body ai r val ve.
Fai l ed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS
TORQUE - SPEED CONTROL
Servo Mounting Bracket-to-Servo Nuts 9 - 75
Servo Mounting Bracket-to-Body Bolts 12 - 105
Speed Control Switch Mounting Screws 1.5 - 14
Vacuum Reservoir Mounting Screws 3 - 20
8P - 2 SPEED CONTROL KJ
SPEED CONTROL (Continued)
CABLE
DESCRIPTION
The speed control servo cabl e i s connected between
the speed control vacuum servo di aphragm and the
throttl e body control l i nkage.
OPERATION
Thi s cabl e causes the throttl e control l i nkage to
open or cl ose the throttl e val ve i n response to move-
ment of the vacuum servo di aphragm.
REMOVAL - 3. 7L
(2) Remove ai r fi l ter resonator at throttl e body.
The accel erator cabl e must be parti al l y removed to
gai n access to speed control cabl e.
(3) Hol d throttl e i n wi de open posi ti on. Whi l e hel d
i n thi s posi ti on, sl i de throttl e cabl e pi n (Fi g. 1) from
throttl e body bel l crank.
(4) Usi ng a pi ck or smal l screwdri ver, press rel ease
tab (Fi g. 2) to rel ease pl asti c cabl e mount from
bracket. Press on tab only enough to release
cable from bracket. If tab is pressed too much,
it will be broken. Sl i de pl asti c mount (Fi g. 2)
towards ri ght si de of vehi cl e to remove throttl e cabl e
from throttl e body bracket.
(5) Usi ng fi nger pressure onl y, di sconnect servo
cabl e connector (Fi g. 3) at throttl e body bel l crank pi n
by pushi ng connector off bel l crank pi n towards front
of vehi cl e. DO NOT try to pull connector off per-
pendicular to the bellcrank pin. Connector will
be broken.
Fig. 1 THROTTLE CABLE PIN
1 - THROTTLE CABLE PIN
2 - THROTTLE BODY BELLCRANK
3 - PUSH UP HERE
Fig. 2 THROTTLE CABLE RELEASE TAB
1 - THROTTLE CABLE
2 - RELEASE TAB
3 - PICK OR SCREWDRIVER
4 - PLASTIC CABLE MOUNT
Fig. 3 SPEED CONTROL CABLE AT BELLCRANK
2 - SPEED CONTROL CABLE CONNECTOR
(6) Sl i de speed control cabl e pl asti c mount towards
ri ght of vehi cl e to remove cabl e from throttl e body
bracket (Fi g. 4).
(7) Remove servo cabl e from servo. Refer to Servo
INSTALLATION - 3. 7L
(1) I nstal l end of cabl e to speed control servo.
Refer to Servo Removal /I nstal l ati on.
(2) Sl i de speed control cabl e pl asti c mount i nto
throttl e body bracket.
(3) I nstal l speed control cabl e connector onto throt-
tl e body bel l crank pi n (push rearward to snap i nto
l ocati on).
(4) Sl i de throttl e (accel erator) cabl e pl asti c mount
i nto throttl e body bracket. Conti nue sl i di ng unti l
cabl e rel ease tab i s al i gned to hol e i n throttl e body
mounti ng bracket.
(5) Whi l e hol di ng throttl e to wi de open posi ti on,
pl ace throttl e cabl e pi n i nto throttl e body bel l crank.
(6) I nstal l ai r fi l ter resonator box to throttl e body.
(7) Connect negati ve battery cabl e at battery.
(8) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
SERVO
DESCRIPTION
The servo uni t consi sts of a sol enoi d val ve body,
and a vacuum chamber. The sol enoi d val ve body con-
tai ns three sol enoi ds:
Vacuum
Vent
Dump
The vacuum chamber contai ns a di aphragm wi th a
cabl e attached to control the throttl e l i nkage.
OPERATION
The Powertrai n Control Modul e (PCM) control s the
sol enoi d val ve body. The sol enoi d val ve body control s
the appl i cati on and rel ease of vacuum to the di a-
phragm of the vacuum servo. The servo uni t cannot
be repai red and i s servi ced onl y as a compl ete assem-
bl y.
Power i s suppl i ed to the servos by the PCM
through the brake swi tch. The PCM control s the
ground path for the vacuum and vent sol enoi ds.
The dump sol enoi d i s energi zed anyti me i t recei ves
power. I f power to the dump sol enoi d i s i nterrupted,
the sol enoi d dumps vacuum i n the servo. Thi s pro-
vi des a safety backup to the vent and vacuum sol e-
noi ds.
The vacuum and vent sol enoi ds must be grounded
at the PCM to operate. When the PCM grounds the
vacuum servo sol enoi d, the sol enoi d al l ows vacuum
to enter the servo and pul l open the throttl e pl ate
usi ng the cabl e. When the PCM breaks the ground,
the sol enoi d cl oses and no more vacuum i s al l owed to
enter the servo. The PCM al so operates the vent sol e-
noi d vi a ground. The vent sol enoi d opens and cl oses a
passage to bl eed or hol d vacuum i n the servo as
requi red.
The PCM duty cycl es the vacuum and vent sol e-
noi ds to mai ntai n the set speed, or to accel erate and
decel erate the vehi cl e. To i ncrease throttl e openi ng,
the PCM grounds the vacuum and vent sol enoi ds. To
decrease throttl e openi ng, the PCM removes the
grounds from the vacuum and vent sol enoi ds. When
the brake i s rel eased, i f vehi cl e speed exceeds 30
mph to resume, 35 mph to set, and the RES/ACCEL
swi tch has been depressed, ground for the vent and
vacuum ci rcui ts i s restored.
REMOVAL
(2) Di sconnect vacuum l i ne at servo (Fi g. 5).
(3) Di sconnect el ectri cal connector at servo (Fi g. 5).
(4) Remove cool ant bottl e nuts/bol ts. Posi ti on bot-
tl e forward a few i nches.
(5) Di sconnect servo cabl e at throttl e body. Refer to
servo Cabl e Removal /I nstal l ati on.
(6) Remove servo bracket mounti ng nuts (Fi g. 5).
(7) Remove 2 mounti ng nuts hol di ng servo cabl e
sl eeve to bracket (Fi g. 6).
(8) Pul l speed control cabl e sl eeve and servo away
from servo mounti ng bracket to expose cabl e retai n-
i ng cl i p (Fi g. 6) and remove cl i p. Note: The servo
Fig. 4 SPEED CONTROL CABLE AT BRACKET
1 - THROTTLE CABLE BRACKET
3 - SPEED CONTROL CABLE
CABLE (Continued)
mounti ng bracket di spl ayed i n (Fi g. 6) i s a typi cal
bracket and may/may not be appl i cabl e to thi s model
vehi cl e.
(9) Remove servo from mounti ng bracket. Whi l e
removi ng, note ori entati on of servo to bracket.
INSTALLATION
(1) Posi ti on servo to mounti ng bracket.
(2) Al i gn hol e i n cabl e connector wi th hol e i n servo
pi n. I nstal l cabl e-to-servo retai ni ng cl i p.
(3) I nsert servo mounti ng studs through hol es i n
servo mounti ng bracket.
(4) I nstal l servo-to-mounti ng bracket nuts and
ti ghten. Refer to torque speci fi cati ons.
(5) I nstal l servo mounti ng bracket-to-body nuts
and ti ghten. Refer to torque speci fi cati ons.
(6) Connect vacuum l i ne at servo.
(7) Connect el ectri cal connector at servo.
(8) Connect servo cabl e to throttl e body. Refer to
servo Cabl e Removal /I nstal l ati on.
(9) I nstal l cool ant bottl e.
SWITCH
DESCRIPTION
There are two separate swi tch pods that operate
the speed control system. The steeri ng-wheel -
mounted swi tches use mul ti pl exed ci rcui ts to provi de
i nputs to the PCM for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer to
the owners manual for more i nformati on on speed
control swi tch functi ons and setti ng procedures.
The i ndi vi dual swi tches cannot be repai red. I f one
swi tch fai l s, the enti re swi tch modul e must be
repl aced.
OPERATION
When speed control i s sel ected by depressi ng the
ON, OFF swi tch, the PCM al l ows a set speed to be
stored i n i ts RAM for speed control . To store a set
speed, depress the SET swi tch whi l e the vehi cl e i s
movi ng at a speed between approxi matel y 35 and 85
mph. I n order for the speed control to engage, the
brakes cannot be appl i ed, nor can the gear sel ector
be i ndi cati ng the transmi ssi on i s i n Park or Neutral .
The speed control can be di sengaged manual l y by:
Steppi ng on the brake pedal
Depressi ng the OFF swi tch
Depressi ng the CANCEL swi tch.
The speed control can be di sengaged al so by any of
the fol l owi ng condi ti ons:
An i ndi cati on of Park or Neutral
The VSS si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the co-effi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
Depressi ng the cl utch pedal .
Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
Fig. 5 SPEED CONTROL SERVO
1 - T FITTING
2 - VACUUM LINE
3 - SERVO BRACKET MOUNTING NUTS
4 - SERVO MOUNTING BRACKET
5 - SERVO
6 - SERVO ELECTRICAL CONNECTOR
Fig. 6 SERVO CABLE CLIP REMOVE/INSTALL
TYPICAL
1 - SERVO MOUNTING NUTS (2)
2 - SERVO
3 - CABLE RETAINING CLIP
4 - SERVO CABLE AND SLEEVE
SERVO (Continued)
The VSS si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
I f the actual speed i s not wi thi n 20 mph of the
set speed
The previ ous di sengagement condi ti ons are pro-
grammed for added safety.
Once the speed control has been di sengaged,
depressi ng the ACCEL swi tch restores the vehi cl e to
the target speed that was stored i n the PCMs RAM.
NOTE: Depressing the OFF switch will erase the set
speed stored in the PCMs RAM.
I f, whi l e the speed control i s engaged, the dri ver
wi shes to i ncrease vehi cl e speed, the PCM i s pro-
grammed for an accel erati on feature. Wi th the
ACCEL swi tch hel d cl osed, the vehi cl e accel erates
sl owl y to the desi red speed. The new target speed i s
stored i n the PCMs RAM when the ACCEL swi tch i s
rel eased. The PCM al so has a tap-up feature i n
whi ch vehi cl e speed i ncreases at a rate of approxi -
matel y 2 mph for each momentary swi tch acti vati on
of the ACCEL swi tch.
The PCM al so provi des a means to decel erate wi th-
out di sengagi ng speed control . To decel erate from an
exi sti ng recorded target speed, depress and hol d the
COAST swi tch unti l the desi red speed i s reached.
Then rel ease the swi tch. The ON, OFF swi tch oper-
ates two components: the PCMs ON, OFF i nput, and
the battery vol tage to the brake swi tch, whi ch powers
the speed control servo.
Multiplexing
The PCM sends out 5 vol ts through a fi xed resi stor
and moni tors the vol tage change between the fi xed
resi stor and the swi tches. I f none of the swi tches are
depressed, the PCM wi l l measure 5 vol ts at the sen-
sor poi nt (open ci rcui t). I f a swi tch wi th no resi stor i s
cl osed, the PCM wi l l measure 0 vol ts (grounded ci r-
cui t). Now, i f a resi stor i s added to a swi tch, then the
PCM wi l l measure some vol tage proporti onal to the
si ze of the resi stor. By addi ng a di fferent resi stor to
each swi tch, the PCM wi l l see a di fferent vol tage
dependi ng on whi ch swi tch i s pushed.
Another resi stor has been added to the at rest ci r-
cui t causi ng the PCM to never see 5 vol ts. Thi s was
done for di agnosti c purposes. I f the swi tch ci rcui t
shoul d open (bad connecti on), then the PCM wi l l see
the 5 vol ts and know the ci rcui t i s bad. The PCM wi l l
then set an open ci rcui t faul t.
REMOVAL
WARNING: BEFORE ATTEMPTING TO DIAGNOSE,
REMOVE OR INSTALL ANY AIRBAG SYSTEM OR
RELATED STEERING WHEEL AND STEERING COL-
UMN COMPONENTS YOU MUST FIRST DISCON-
NECT AND ISOLATE THE NEGATIVE (GROUND)
BATTERY CABLE. WAIT 2 MINUTES FOR SYSTEM
CAPACITOR TO DISCHARGE BEFORE FURTHER
SYSTEM SERVICE. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.
(1) Di sconnect and i sol ate negati ve battery cabl e
from battery.
(2) Remove ai rbag modul e. Refer to Restrai nt Sys-
tems.
(3) Unpl ug el ectri cal connector (Fi g. 7).
(4) Remove speed control swi tch mounti ng screw
(Fi g. 7) and remove swi tch from steeri ng wheel .
INSTALLATION
(1) Posi ti on swi tch to steeri ng wheel .
(2) I nstal l swi tch mounti ng screw and ti ghten.
Refer to torque speci fi cati ons.
(3) Pl ug el ectri cal connector i nto swi tch.
(4) I nstal l ai rbag modul e. Refer to Restrai nt Sys-
tems.
Fig. 7 SPEED CONTROL SWITCH
1 - SWITCH
2 - SCREW
SWITCH (Continued)
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoi r i s a pl asti c storage tank con-
nected to an engi ne vacuum source by vacuum l i nes.
OPERATION
The vacuum reservoi r i s used to suppl y the vac-
uum needed to mai ntai n proper speed control opera-
ti on when engi ne vacuum drops, such as i n cl i mbi ng
a grade whi l e dri vi ng. A one-way check val ve i s used
i n the vacuum l i ne between the reservoi r and the
vacuum source. Thi s check val ve i s used to trap
engi ne vacuum i n the reservoi r. On certai n vehi cl e
appl i cati ons, thi s reservoi r i s shared wi th the heat-
i ng/ai r-condi ti oni ng system. The vacuum reservoi r
cannot be repai red and must be repl aced i f faul ty.
RESERVOIR
(1) Di sconnect vacuum hose at speed control servo
and i nstal l a vacuum gauge i nto the di sconnected
hose.
(2) Start engi ne and observe gauge at i dl e. Vac-
uum gauge shoul d read at l east ten i nches of mer-
cury.
(3) I f vacuum i s l ess than ten i nches of mercury,
determi ne source of l eak. Check vacuum l i ne to
engi ne for l eaks. Al so check actual engi ne i ntake
mani fol d vacuum. I f mani fol d vacuum does not meet
thi s requi rement, check for poor engi ne performance
and repai r as necessary.
(4) I f vacuum l i ne to engi ne i s not l eaki ng, check
for l eak at vacuum reservoi r. To l ocate and gai n
access to reservoi r, refer to Vacuum Reservoi r Remov-
al /I nstal l ati on i n thi s group. Di sconnect vacuum l i ne
at reservoi r and connect a hand-operated vacuum
pump to reservoi r fi tti ng. Appl y vacuum. Reservoi r
vacuum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace reservoi r.
(5) Veri fy operati on of one-way check val ve and
check i t for l eaks. Certain models may be
equipped with 2 check-valves.
(a) Locate one-way check val ve. The val ve i s
l ocated i n vacuum l i ne between vacuum reservoi r
and engi ne vacuum source. Di sconnect vacuum
hoses (l i nes) at each end of val ve.
(b) Connect a hand-operated vacuum pump to
reservoi r end of check val ve. Appl y vacuum. Vac-
uum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace one-way check val ve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check val ve. Appl y vacuum.
Vacuum shoul d fl ow through val ve. I f vacuum i s
not fl owi ng, repl ace one-way check val ve. Seal the
fi tti ng at opposi te end of val ve wi th a fi nger and
appl y vacuum. I f vacuum wi l l not hol d, di aphragm
wi thi n check val ve has ruptured. Repl ace val ve.
REMOVAL
The vacuum reservoi r i s l ocated behi nd, and at the
outer end of the i nstrument panel (Fi g. 8). To gai n
access for testi ng or removal , remove gl ovebox assem-
bl y. Al so remove fuse box access cover panel at end of
i nstrument panel . On vehi cl es equi pped wi th LHD
(Left Hand Dri ve), thi s fuse access panel i s l ocated at
ri ght end of i nstrument panel . On vehi cl es equi pped
wi th RHD (Ri ght Hand Dri ve), thi s access panel i s
l ocated at l eft end of i nstrument panel .
(1) Remove gl ovebox assembl y. Access to reservoi r
vacuum l i ne and fi tti ng can now be made.
(2) Remove vacuum l i ne at reservoi r.
(3) Remove fuse access cover panel at end of
i nstrument panel .
(4) Through fuse access openi ng, remove 2 hori zon-
tal l y mounted screws (Fi g. 8).
(5) From bottom of i nstrument panel , remove 1
verti cal l y mounted screw (Fi g. 9).
(6) Remove reservoi r from i nstrument panel .
Fig. 8 VACUUM RESERVOIR LOCATION
1 - VACUUM RESERVOIR
2 - HORIZONTAL MOUNTING SCREWS
3 - OUTBOARD END OF I.P.
INSTALLATION
The vacuum reservoi r i s l ocated behi nd, and at the
outer end of the i nstrument panel . To gai n access for
testi ng or removal , remove gl ovebox assembl y. Al so
remove fuse box access cover panel at end of i nstru-
ment panel . On vehi cl es equi pped wi th LHD (Left
Hand Dri ve), thi s fuse access panel i s l ocated at ri ght
end of i nstrument panel . On vehi cl es equi pped wi th
RHD (Ri ght Hand Dri ve), thi s access panel i s l ocated
at l eft end of i nstrument panel .
(1) Posi ti on reservoi r to i nstrument panel .
(2) I nstal l 3 mounti ng screws and ti ghten. Refer to
(3) Connect vacuum l i ne to reservoi r fi tti ng.
(4) I nstal l gl ovebox assembl y.
(5) I nstal l fuse box access cover panel .
Fig. 9 VACUUM RESERVOIR REMOVE/INSTALL
1 - VACUUM RESERVOIR
2 - HORIZONTAL MOUNTING SCREWS (2)
3 - VERTICAL MOUNTING SCREW (1)
VACUUM RESERVOIR (Continued)
VEHICLE THEFT SECURITY
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - VEHICLE THEFT
SECURITY SYSTEM . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE
STANDARD PROCEDURE - SKIS
INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - SENTRY KEY
TRANSPONDER PROGRAMMING. . . . . . . . . . 8
DOOR CYLINDER LOCK SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - DOOR
CYLINDER LOCK SWITCH . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
HOOD AJAR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - HOOD AJAR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
HOOD AJAR SWITCH BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
HOOD AJAR SWITCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
INTRUSION TRANSCEIVER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
SIREN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
TRANSPONDER KEY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DESCRIPTION
The Vehi cl e Theft Securi ty System (VTSS) i s an
avai l abl e factory-i nstal l ed opti on on thi s model (Fi g.
1). The VTSS i s compri sed of two pri mary sub-
systems: Vehi cl e Theft Al arm (VTA) and Sentry Key
I mmobi l i zer System (SKI S). The VTA i s an acti ve
system that provi des vi sual and audi bl e responses as
deterrents to and warni ngs of unauthori zed vehi cl e
tamperi ng. The SKI S i s a passi ve system that effec-
ti vel y i mmobi l i zes the vehi cl e agai nst unauthori zed
operati on. Fol l owi ng are paragraphs whi ch descri be
the vari ous components that are i ncl uded i n each of
these subsystems of the VTSS.
Hard wi red ci rcui try connects many of the VTSS
components to each other through the el ectri cal sys-
tem of the vehi cl e. These hard wi red ci rcui ts are
i ntegral to several wi re harnesses, whi ch are routed
throughout the vehi cl e and retai ned by many di ffer-
ent methods. These ci rcui ts may be connected to each
other, to the vehi cl e el ectri cal system and to the
VTSS components through the use of a combi nati on
VEHI CLE THEFT ALARM The VTA i s avai l abl e i n
two di fferent confi gurati ons for thi s vehi cl e: One con-
fi gurati on i s desi gned for vehi cl es manufactured for
sal e i n North Ameri ca; whi l e, the other confi gurati on
i s desi gned for vehi cl es manufactured for sal e i n
markets outsi de of North Ameri ca, al so referred to as
Rest-Of-Worl d or ROW. I n addi ti on, the VTA for
ROW i s avai l abl e i n two versi ons: base and premi um.
Al l vehi cl es equi pped wi th VTA are al so equi pped
wi th the Remote Keyl ess Entry (RKE) system and
the Sentry Key I mmobi l i zer System (SKI S), regard-
l ess of thei r market desti nati on. The North Ameri can
and ROW base versi on of the VTA provi des peri meter
vehi cl e protecti on by moni tori ng the vehi cl e doors,
the tai l gate, the rear fl i p-up gl ass and, for vehi cl es
bui l t for certai n markets where i t i s requi red equi p-
ment, the hood. I f unauthori zed vehi cl e use or tam-
peri ng i s detected, these systems respond by pul si ng
the horn and fl ashi ng certai n exteri or l amps. The
ROW premi um versi on of the VTA i s onl y avai l abl e
KJ VEHICLE THEFT SECURITY 8Q - 1
i n vehi cl es manufactured for sal e i n certai n markets
where i t i s requi red equi pment. The ROW premi um
versi on of the VTA provi des the same peri meter pro-
tecti on features as the base versi on, but adds i nteri or
vehi cl e i ntrusi on protecti on. The ROW premi um VTA
al so repl aces the pul si ng horn feature of the base
versi on wi th an al arm si ren as the audi bl e deterrent,
whi l e retai ni ng the fl ashi ng exteri or l amps vi sual
deterrent.
The VTA i ncl udes the fol l owi ng major components,
whi ch are descri bed i n further detai l el sewhere i n
thi s servi ce i nformati on:
- DESCRI PTI ON).
Fig. 1 Vehicle Theft Security System
1 - SIREN MODULE
3 - SENTRY KEY IMMOBILIZER MODULE
4 - DOOR CYLINDER LOCK SWITCH (2)
5 - INTRUSION TRANSCEIVER MODULE
8Q - 2 VEHICLE THEFT SECURITY KJ
VEHICLE THEFT SECURITY (Continued)
ti on fl asher i s i ntegral to the hazard swi tch l ocated
i n the center of the i nstrument panel above the
radi o. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR/COMBI NATI ON FLASHER -
DESCRI PTI ON).
Door Ajar Switch - A door ajar swi tch i s i nte-
gral to the l atch of each door i n the vehi cl e. (Refer to
8 - ELECTRI CAL/LAMPS/LI GHTI NG - I NTERI OR/
DOOR AJAR SWI TCH - DESCRI PTI ON).
Door Cylinder Lock Switch - For North
Ameri can vehi cl es onl y, a door cyl i nder l ock swi tch i s
l ocated on the back of the l ock cyl i nder of each front
door. (Refer to 8 - ELECTRI CAL/VEHI CLE THEFT
SECURI TY/DOOR CYLI NDER LOCK SWI TCH -
DESCRI PTI ON).
Flip-Up Glass Ajar Switch - A fl i p-up gl ass
ajar swi tch i s i ntegral to the rear fl i p-up gl ass l atch,
l ocated on the top of the tai l gate near the center.
I NTERI OR/FLI P-UP GLASS AJAR SWI TCH -
DESCRI PTI ON).
Hood Ajar Switch - A hood ajar swi tch i s
l ocated beneath the hood panel on the ri ght i nner
fender si de shi el d of vehi cl es bui l t for sal e i n certai n
markets where i t i s requi red equi pment. (Refer to 8 -
ELECTRI CAL/VEHI CLE THEFT SECURI TY/HOOD
AJAR SWI TCH - DESCRI PTI ON).
Horn Relay - A horn rel ay i s l ocated on the
end of the i nstrument panel . (Refer to 8 - ELECTRI -
CAL/HORN/HORN RELAY - DESCRI PTI ON).
Intrusion Transceiver Module - An I ntrusi on
Transcei ver Modul e (I TM) i s l ocated near the center
of the headl i ner i n the passenger compartment of
vehi cl es bui l t for sal e i n certai n markets where i t i s
requi red equi pment. (Refer to 8 - ELECTRI CAL/VE-
HI CLE THEFT SECURI TY/UK SECURI TY SYSTEM
MODULE - DESCRI PTI ON).
Security Indicator - A securi ty i ndi cator i s
l ocated i n the El ectroMechani cal I nstrument Cl uster
(EMI C) on the i nstrument panel i n front of the dri ver
si de front seat. (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER/SECURI TY I NDI CATOR -
DESCRI PTI ON).
Siren - An al arm si ren i s l ocated on the front
extensi on of the ri ght front wheel house panel i n the
engi ne compartment of vehi cl es bui l t for sal e i n cer-
tai n markets where i t i s requi red equi pment. (Refer
to 8 - ELECTRI CAL/VEHI CLE THEFT SECURI TY/
SI REN - DESCRI PTI ON).
TailgateAjar Switch - A tai l gate ajar swi tch i s
i ntegral to the l atch for the tai l gate i n the vehi cl e.
I NTERI OR/TAI LGATE AJAR SWI TCH - DESCRI P-
TI ON).
SENTRY KEY I MMOBI LI ZER SYSTEM The Sen-
try Key I mmobi l i zer System (SKI S) i s avai l abl e as a
factory-i nstal l ed opti on on thi s model . Vehi cl es
equi pped wi th the Vehi cl e Theft Al arm (VTA) are al so
equi pped wi th SKI S. The SKI S provi des passi ve vehi -
cl e protecti on by preventi ng the engi ne from operat-
i ng unl ess a val i d el ectroni cal l y encoded key i s
detected i n the i gni ti on l ock cyl i nder. The SKI S
i ncl udes the fol l owi ng major components, whi ch are
i nformati on:
Powertrain Control Module - The Powertrai n
Control Modul e (PCM) i s l ocated on the l eft i nner
fender shi el d i n the engi ne compartment near the
dash panel . (Refer to 8 - ELECTRI CAL/ELEC-
TRONI C CONTROL MODULES/POWERTRAI N
CONTROL MODULE - DESCRI PTI ON).
Sentry Key Immobilizer Module - The Sentry
Key I mmobi l i zer Modul e (SKI M) i s l ocated beneath
the steeri ng col umn shrouds on the ri ght si de of the
steeri ng col umn near the i gni ti on l ock cyl i nder hous-
i ng. (Refer to 8 - ELECTRI CAL/ELECTRONI C CON-
TROL MODULES/SENTRY KEY I MMOBI LI ZER
MODULE - DESCRI PTI ON).
Sentry Key Transponder - The Sentry Key
transponder i s mol ded i nto the head of the i gni ti on
key, and conceal ed by a gray mol ded rubber cap.
(Refer to 8 - ELECTRI CAL/VEHI CLE THEFT SECU-
RI TY/TRANSPONDER KEY - DESCRI PTI ON).
SKIS Indicator - The SKI S i ndi cator i s l ocated
i n the El ectroMechani cal I nstrument Cl uster (EMI C)
on the i nstrument panel i n front of the dri ver si de
front seat. (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER/SPEED CONTROL I NDI CATOR -
DESCRI PTI ON).
OPERATION
The Vehi cl e Theft Securi ty System (VTSS) i s
di vi ded i nto two basi c subsystems: Vehi cl e Theft
Al arm (VTA) and Sentry Key I mmobi l i zer System
(SKI S). Fol l owi ng are paragraphs that bri efl y
descri be the operati on of each of these two sub-
systems.
VEHI CLE THEFT ALARM The Body Control Mod-
ul e (BCM) i s used on thi s model to control and i nte-
grate many of the el ectroni c functi ons and features
i ncl uded i n the Vehi cl e Theft Al arm (VTA). The BCM
recei ves hard wi red i nputs i ndi cati ng the status of
the door ajar swi tches, the door cyl i nder l ock
swi tches, the i gni ti on swi tch, the tai l gate ajar swi tch,
the tai l gate cyl i nder l ock swi tch, the fl i p-up gl ass
ajar swi tch, the power l ock swi tches and, i n vehi cl es
bui l t for certai n markets where i t i s requi red, the
hood ajar swi tch. The programmi ng i n the BCM
al l ows i t to process the i nformati on from al l of these
i nputs and send control outputs to energi ze or de-en-
ergi ze the combi nati on fl asher, the horn rel ay (except
vehi cl es wi th the Rest-Of-Worl d or ROW premi um
versi on of the VTA), and the securi ty i ndi cator. I n
addi ti on, i n vehi cl es bui l t for certai n markets where
the ROW premi um versi on of the VTA i s requi red,
the BCM al so exchanges el ectroni c messages wi th
the I ntrusi on Transcei ver Modul e (I TM) over the Pro-
network to provi de the features found i n thi s versi on
of the VTA.
VTA may be di agnosed and tested usi ng conventi onal
i n the di agnosi s of the Body Control Modul e (BCM),
the I ntrusi on Transcei ver Modul e (I TM), or the Pro-
network. The most rel i abl e, effi ci ent, and accurate
means to di agnose the BCM, the EMI C, the I TM,
and the PCI data bus network i nputs and outputs
rel ated to the VTA requi res the use of a DRBI I I
mati on. Fol l owi ng are paragraphs that bri efl y
descri be the operati on of each of the VTA features.
more i nformati on on the features, use and operati on
of the VTA.
ENABLING - The BCM must have the VTA
functi on el ectroni cal l y enabl ed i n order for the VTA
to perform as desi gned. The l ogi c i n the BCM keeps
i ts VTA functi on dormant unti l i t i s enabl ed usi ng a
DRBI I I scan tool . The VTA functi on of the BCM i s
enabl ed on vehi cl es equi pped wi th the VTA opti on at
the factory, but a servi ce repl acement BCM must be
VTA-enabl ed by the deal er usi ng a DRBI I I scan
PRE-ARMING - The VTA has a pre-armi ng
sequence. Pre-armi ng occurs when a door, the tai l -
gate, or the fl i p-up gl ass i s open when the vehi cl e i s
l ocked usi ng a power l ock swi tch, or when the Lock
button on the Remote Keyl ess Entry (RKE) transmi t-
ter i s depressed. The power l ock swi tch wi l l not i ni -
ti ate the pre-armi ng sequence i f the key i s i n the
i gni ti on swi tch. When the VTA i s pre-armed, the
armi ng sequence i s del ayed unti l al l of the doors, the
tai l gate, and the fl i p-up gl ass are cl osed.
ARMING - Passi ve armi ng of the VTA occurs
when the vehi cl e i s exi ted wi th the key removed from
the i gni ti on swi tch and the doors are l ocked whi l e
they are open usi ng the power l ock swi tch (see Pre-
Armi ng). Acti ve armi ng of the VTA occurs when the
Lock button on the Remote Keyl ess Entry (RKE)
transmi tter i s depressed to l ock the vehi cl e after al l
of the doors, the tai l gate, and the fl i p-up gl ass are
cl osed. The VTA wi l l not arm i f the doors are l ocked
usi ng the key i n a l ock cyl i nder or usi ng a mechani -
cal l ock button. Once the VTA begi ns the passi ve or
acti ve armi ng sequence, the securi ty i ndi cator i n the
i nstrument cl uster wi l l fl ash rapi dl y for about si x-
teen seconds. Thi s i ndi cates that the VTA armi ng
sequence i s i n progress. I f the i gni ti on swi tch i s
turned to the On posi ti on, i f a door i s unl ocked wi th
the power l ock swi tch or the RKE transmi tter, or i f
the tai l gate i s unl ocked by any means duri ng the si x-
teen second armi ng sequence, the securi ty i ndi cator
wi l l stop fl ashi ng and the VTA armi ng sequence wi l l
abort. On vehi cl es equi pped wi th the hood ajar
swi tch, the VTA armi ng sequence wi l l occur regard-
l ess of whether the hood i s open or cl osed, but the
underhood area wi l l not be protected unl ess the hood
i s cl osed when the VTA armi ng sequence begi ns.
Al so, i f the status of the hood ajar swi tch changes
from open (hood cl osed) to cl osed (hood open) duri ng
the si xteen second armi ng sequence, the securi ty
i ndi cator wi l l stop fl ashi ng and the VTA armi ng
sequence wi l l abort. Once the si xteen second armi ng
sequence i s successful l y compl eted, the securi ty i ndi -
cator wi l l fl ash at a sl ower rate, i ndi cati ng that the
VTA i s armed.
DISARMING - For vehi cl es bui l t for the North
Ameri can market, di sarmi ng of the VTA occurs when
the vehi cl e i s unl ocked usi ng the key to unl ock a door
or the tai l gate. Di sarmi ng of the VTA for any market
al so occurs when the vehi cl e i s unl ocked by depress-
i ng the Unl ock button of the Remote Keyl ess Entry
(RKE) transmi tter, or by turni ng the i gni ti on swi tch
to the On posi ti on usi ng a val i d Sentry Key I mmobi -
l i zer System (SKI S) key. Once the al arm has been
acti vated, any of these di sarmi ng methods wi l l al so
deacti vate the al arm.
POWER-UP MODE - When the armed VTA
senses that the battery has been di sconnected and
reconnected, i t enters i ts power-up mode. I n the pow-
er-up mode the al arm system returns to the mode
that was l ast sel ected pri or to the battery fai l ure or
di sconnect. I f the VTA was armed pri or to the battery
di sconnect or fai l ure, the techni ci an or vehi cl e opera-
tor wi l l have to acti vel y or passi vel y di sarm the sys-
tem after the battery i s reconnected. The power-up
mode wi l l al so appl y i f the battery goes dead whi l e
the system i s armed, and battery jump-starti ng i s
then attempted. The VTA wi l l remai n armed unti l
the techni ci an or vehi cl e operator has acti vel y or pas-
si vel y di sarmed the system. I f the VTA i s i n the di s-
armed mode pri or to a battery di sconnect or fai l ure,
i t wi l l remai n di sarmed after the battery i s recon-
nected or repl aced, or i f jump-starti ng i s attempted.
ALARM - The VTA al arm output vari es by the
versi on of the VTA wi th whi ch the vehi cl e i s
equi pped. I n al l cases, the al arm provi des both vi sual
and audi bl e outputs; however, the ti me i nterval s of
these outputs vary by the requi rements of the mar-
ket for whi ch the vehi cl e i s manufactured. I n al l
cases, the vi sual output wi l l be a fl ashi ng on and off
of the exteri or l amps. For vehi cl es equi pped wi th the
North Ameri can or the ROW base versi on of the
VTA, the audi bl e output wi l l be a pul si ng of the horn.
For vehi cl es wi th the ROW premi um versi on of the
VTA, the audi bl e output wi l l be a cycl i ng of the
al arm si ren. See the owners manual i n the vehi cl e
gl ove box for detai l s of the al arm output requi re-
ments of the speci fi c market for whi ch the vehi cl e
was manufactured. The i nputs that wi l l tri gger the
al arm i ncl ude the door ajar swi tches, the tai l gate
ajar swi tch, the fl i p-up gl ass ajar swi tch, and i n vehi -
cl es bui l t for certai n markets where they are
requi red, the hood ajar swi tch and the I ntrusi on
Transcei ver Modul e (I TM).
TAMPER ALERT - The VTA tamper al ert fea-
ture wi l l pul se the horn (or the al arm si ren for the
ROW premi um versi on of the VTA) three ti mes upon
VTA di sarmi ng, i f the al arm was tri ggered and has
si nce ti med-out. Thi s feature al erts the vehi cl e oper-
ator that the VTA al arm was acti vated whi l e the
vehi cl e was unattended.
INTRUSION ALARM - The i ntrusi on al arm i s
an excl usi ve feature of the ROW premi um versi on of
the VTA, whi ch i s onl y avai l abl e i n certai n markets
where i t i s requi red. When the VTA i s armed, a
moti on sensor i n the I ntrusi on Transcei ver Modul e
(I TM) moni tors the i nteri or of the vehi cl e for move-
ment. I f moti on i s detected, the I TM sends an el ec-
troni c message to the BCM over the PCI data bus to
i nvoke the vi sual al arm feature, and sends an el ec-
troni c message to the al arm si ren i n the engi ne com-
partment over a dedi cated seri al bus to i nvoke the
audi bl e al arm feature. The moti on detect feature of
the I TM can be di sabl ed by depressi ng the Lock
button on the RKE transmi tter three ti mes wi thi n
fi fteen seconds duri ng VTA armi ng, whi l e the secu-
ri ty i ndi cator i s sti l l fl ashi ng rapi dl y. The VTA pro-
vi des a si ngl e short si ren chi rp as an audi bl e
confi rmati on that the moti on detect di sabl e request
has been recei ved. The I TM must be el ectroni cal l y
enabl ed i n order for the i ntrusi on al arm to perform
as desi gned. The l ogi c i n the I TM keeps i ts i ntrusi on
al arm functi on dormant unti l i t i s enabl ed usi ng a
DRBI I I scan tool . The i ntrusi on al arm functi on of
the I TM i s enabl ed on vehi cl es equi pped wi th thi s
opti on at the factory, but a servi ce repl acement I TM
must be confi gured and enabl ed by the deal er usi ng a
ti c i nformati on.
SENTRY KEY I MMOBI LI ZER SYSTEM The Sen-
try Key I mmobi l i zer System (SKI S) i s desi gned to
provi de passi ve protecti on agai nst unauthori zed vehi -
cl e use by di sabl i ng the engi ne after about two sec-
onds of runni ng, whenever any method other than a
val i d Sentry Key i s used to start the vehi cl e. The
SKI S i s consi dered a passi ve protecti on system
because i t i s al ways acti ve when the i gni ti on system
i s energi zed and does not requi re any customer i nter-
venti on. The SKI S uses Radi o Frequency (RF) com-
muni cati on to obtai n confi rmati on that the key i n the
i gni ti on swi tch i s a val i d key for operati ng the vehi -
cl e. The mi croprocessor-based SKI S hardware and
software al so use el ectroni c messages to communi -
cate wi th other el ectroni c modul es i n the vehi cl e over
the Programmabl e Communi cati ons I nterface (PCI )
data bus. (Refer to 8 - ELECTRI CAL/ELECTRONI C
CONTROL MODULES/COMMUNI CATI ON - OPER-
ATI ON).
Pre-programmed Sentry Key transponders are pro-
vi ded wi th the vehi cl e from the factory. Each Sentry
Key I mmobi l i zer Modul e (SKI M) wi l l recogni ze a
maxi mum of ei ght Sentry Keys. I f the customer
woul d l i ke addi ti onal keys other than those provi ded
wi th the vehi cl e, they may be purchased from any
authori zed deal er. These addi ti onal keys must be pro-
grammed to the SKI M i n the vehi cl e i n order for the
system to recogni ze them as val i d keys. Thi s can be
done by the deal er usi ng a DRBI I I scan tool or, i f
Customer Learn programmi ng i s an avai l abl e SKI S
feature i n the market where the vehi cl e was pur-
chased, the customer can program the addi ti onal
keys, as l ong as at l east two val i d Sentry Keys are
al ready avai l abl e. (Refer to 8 - ELECTRI CAL/VEHI -
CLE THEFT SECURI TY - STANDARD PROCE-
DURE - TRANSPONDER PROGRAMMI NG).
store faul t i nformati on i n the form of Di agnosti c
Troubl e Codes (DTCs) i f a system mal functi on i s
detected. The SKI S can be di agnosed, and any stored
DTCs can be retri eved usi ng a DRBI I I scan tool .
DIAGNOSIS AND TESTING - VEHICLE THEFT
SECURITY SYSTEM
The Vehi cl e Theft Securi ty System (VTSS) i s
di vi ded i nto two basi c subsystems: Vehi cl e Theft
Al arm (VTA) and Sentry Key I mmobi l i zer System
(SKI S). Fol l owi ng are the recommended procedures
for di agnosi s and testi ng of each of these two sub-
systems.
PERSONAL INJURY.
VEHICLE THEFT ALARM
Model s equi pped wi th the Rest-Of-Worl d (ROW)
premi um versi on of the Vehi cl e Theft Al arm (VTA)
provi de some prel i mi nary di agnosti c feedback by i l l u-
mi nati ng the securi ty i ndi cator l ocated i n the El ec-
troMechani cal I nstrument Cl uster (EMI C). I f the
securi ty i ndi cator i l l umi nates wi th the i gni ti on
swi tch i n the On posi ti on, i t i ndi cates that there i s a
communi cati on probl em between the I ntrusi on
Transcei ver Modul e (I TM) and the Body Control
Modul e (BCM), or between the I TM and the si ren
modul e. The BCM wi l l al so turn on the securi ty i ndi -
cator i f i t recei ves a message from the I TM i ndi cati ng
that the I TM has stored a Di agnosti c Troubl e Code
(DTC) for a si ren modul e faul t.
VTA may be di agnosed and tested usi ng conventi onal
i n the di agnosi s of the Body Control Modul e (BCM),
the I ntrusi on Transcei ver Modul e (I TM), or the Pro-
network. The most rel i abl e, effi ci ent, and accurate
means to di agnose the BCM, the EMI C, the I TM,
and the PCI data bus network i nputs and outputs
rel ated to the VTA requi res the use of a DRBI I I
mati on.
SENTRY KEY IMMOBILIZER SYSTEM
SENTRY KEY IMMOBILIZER SYSTEM DIAGNOSIS
SKIS INDICATOR FAILS TO
LIGHT DURING BULB TEST
1. SKIS indicator faulty. 1. Test and replace the instrument cluster as
required.
2. Fuse faulty. 2. Test and replace the SKIM fused B(+) and
fused ignition switch output (run-start) fuses in the
Junction Block (JB) as required.
3. Ground circuit faulty. 3. Test and repair the SKIM ground circuit as
required.
4. Fused B(+) circuit faulty. 4. Test and repair the SKIM fused B(+) circuit as
required.
5. Fused ignition switch
output circuit faulty.
5. Test and repair the SKIM fused ignition switch
output (run-start) circuit as required.
SKIS INDICATOR FLASHES
WHEN IGNITION SWITCH IS
TURNED TO ON
POSITION
1. Invalid key in ignition
switch lock cylinder.
1. Replace the key with a known valid key.
2. Key-related fault. 2. Use a DRBIII scan tool to diagnose the
key-related fault. Refer to the appropriate
SKIS INDICATOR LIGHTS
SOLID FOLLOWING BULB
TEST
1. SKIS system malfunction/
fault detected.
1. Use a DRBIII scan tool to diagnose the SKIS.
2. SKIS system inoperative. 2. Use a DRBIII scan tool to diagnose the SKIS.
SKIS INDICATOR FAILS TO LIGHT DURING BULB TEST
I f the Sentry Key I mmobi l i zer System (SKI S) i ndi -
cator i n the i nstrument cl uster fai l s to i l l umi nate for
about three seconds after the i gni ti on swi tch i s
turned to the On posi ti on (bul b test), perform the
i nstrument cl uster actuator test. (Refer to 8 - ELEC-
AND TESTI NG). I f the SKI S i ndi cator sti l l fai l s to
l i ght duri ng the bul b test, a wi ri ng probl em resul ti ng
i n the l oss of battery current or ground to the Sentry
Key I mmobi l i zer Modul e (SKI M) shoul d be sus-
pected, and the fol l owi ng procedure shoul d be used
for di agnosi s. Refer to the appropri ate wi ri ng i nfor-
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Sentry Key Immobilizer System requires the use of
a DRBIII scan tool. Refer to the appropriate diag-
nostic information.
I f not OK, repai r the open B(+) ci rcui t between the
JB and the battery as requi red.
start) fuse (Fuse 15 - 10 ampere) i n the JB. I f OK, go
output (run-start) fuse (Fuse 15 - 10 ampere) i n the
JB. I f OK, go to Step 5. I f not OK, repai r the open
between the JB and the i gni ti on swi tch as requi red.
connector for the Sentry Key I mmobi l i zer Modul e
(SKI M) from the SKI M connector receptacl e. Check
for conti nui ty between each of the two ground ci rcui t
cavi ti es of the i nstrument panel wi re harness connec-
tor for the SKI M and a good ground. There shoul d be
open ground ci rcui t(s) to ground (G202) as requi red.
(6) Reconnect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
i nstrument panel wi re harness connector for the
SKI M. I f OK, go to Step 7. I f not OK, repai r the open
fused B(+) ci rcui t between the SKI M and the JB as
requi red.
output (run-start) ci rcui t cavi ty of the i nstrument
panel wi re harness connector for the SKI M. I f OK,
use a DRBI I I scan tool to compl ete the di agnosi s of
the SKI S. Refer to the appropri ate di agnosti c i nfor-
mati on. I f not OK, repai r the open fused i gni ti on
swi tch output (run-start) ci rcui t between the SKI M
and the JB as requi red.
SKIS INDICATOR FLASHES UPON IGNITION ON OR
LIGHTS SOLID FOLLOWING BULB TEST
A SKI S i ndi cator that fl ashes fol l owi ng the i gni ti on
swi tch bei ng turned to the On posi ti on i ndi cates that
an i nval i d key has been detected, or that a key-re-
l ated faul t has been set. A SKI S i ndi cator that l i ghts
sol i d fol l owi ng a successful bul b test i ndi cates that
the SKI M has detected a system mal functi on or that
the SKI S i s i noperati ve. I n ei ther case, faul t i nforma-
ti on wi l l be stored i n the SKI M memory. For retri eval
of thi s faul t i nformati on and further di agnosi s of the
SKI S, the PCI data bus, the SKI M el ectroni c mes-
sage outputs to the i nstrument cl uster that control
the SKI S i ndi cator and chi me, or the el ectroni c mes-
sage i nputs and outputs between the SKI M and the
Powertrai n Control Modul e (PCM) that control
engi ne operati on, a DRBI I I scan tool i s requi red.
Refer to the appropri ate di agnosti c i nformati on. Fol -
l owi ng are prel i mi nary troubl eshooti ng gui del i nes to
be fol l owed duri ng di agnosi s usi ng a DRBI I I scan
tool :
(1) Usi ng the DRBI I I scan tool , read and record
the faul ts as they exi st i n the SKI M when you fi rst
begi n your di agnosi s of the vehi cl e. I t i s i mportant to
document these faul ts because the SKI M does not
di fferenti ate between hi stori cal faul ts (those that
have occurred i n the past) and acti ve faul ts (those
that are currentl y present). I f thi s probl em turns out
to be an i ntermi ttent condi ti on, thi s i nformati on may
become i nval uabl e to your di agnosi s.
(2) Usi ng the DRBI I I scan tool , erase al l of the
faul ts from the SKI M.
(3) Cycl e the i gni ti on swi tch to the Off posi ti on,
then back to the On posi ti on.
(4) Usi ng the DRBI I I scan tool , read any faul ts
that are now present i n the SKI M. These are the
acti ve faul ts.
(5) Usi ng thi s acti ve faul t i nformati on, refer to the
proper procedure i n the appropri ate di agnosti c i nfor-
mati on for the speci fi c addi ti onal di agnosti c steps.
STANDARD PROCEDURE
STANDARD PROCEDURE - SKIS
INITIALIZATION
The Sentry Key I mmobi l i zer System (SKI S) must
be i ni ti al i zed fol l owi ng a Sentry Key I mmobi l i zer
Modul e (SKI M) repl acement. SKI S i ni ti al i zati on
requi res the use of a DRBI I I scan tool . I ni ti al i zati on
wi l l al so requi re that you have access to the uni que
four-di gi t PI N code that was assi gned to the ori gi nal
SKI M. The PI N code must be used to enter the
Secured Access Mode i n the SKI M. Thi s PI N number
may be obtai ned from the vehi cl e owner, from the
ori gi nal vehi cl e i nvoi ce, or from the Dai ml erChrysl er
Customer Center. (Refer to 8 - ELECTRI CAL/ELEC-
TRONI C CONTROL MODULES - STANDARD PRO-
CEDURE - PCM/SKI M PROGRAMMI NG).
NOTE: If a Powertrain Control Module (PCM) is
replaced on a vehicle equipped with the Sentry Key
Immobilizer System (SKIS), the unique Secret Key
data must be transferred from the Sentry Key
Immobilizer Module (SKIM) to the new PCM using
the PCM replacement procedure. This procedure
also requires the use of a DRBIII scan tool and the
unique four-digit PIN code to enter the Secured
Access Mode in the SKIM. Refer to the appropriate
diagnostic information for the proper PCM replace-
ment procedures.
STANDARD PROCEDURE - SENTRY KEY
TRANSPONDER PROGRAMMING
Al l Sentry Keys i ncl uded wi th the vehi cl e are pre-
programmed to work wi th the Sentry Key I mmobi -
l i zer System (SKI S) when i t i s shi pped from the
factory. The Sentry Key I mmobi l i zer Modul e (SKI M)
can be programmed to recogni ze up to a total of ei ght
Sentry Keys. When programmi ng a bl ank Sentry Key
transponder, the key must fi rst be cut to match the
i gni ti on swi tch l ock cyl i nder i n the vehi cl e for whi ch
i t wi l l be used. Once the addi ti onal or new key has
been cut, the SKI M must be programmed to recog-
ni ze i t as a val i d key. There are two possi bl e methods
to program the SKI M to recogni ze a new or addi -
ti onal val i d key, the Secured Access Method and the
Customer Learn Method. Fol l owi ng are the detai l s of
these two programmi ng methods.
SECURED ACCESS METHOD
The Secured Access method appl i es to al l vehi cl es.
Thi s method requi res the use of a DRBI I I scan tool .
Thi s method wi l l al so requi re that you have access to
the uni que four-di gi t PI N code that was assi gned to
the ori gi nal SKI M. The PI N code must be used to
enter the Secured Access Mode i n the SKI M. Thi s
PI N number may be obtai ned from the vehi cl e owner,
from the ori gi nal vehi cl e i nvoi ce, or from the
Dai ml erChrysl er Customer Center. Refer to the
appropri ate di agnosti c i nformati on for the proper
Secured Access method programmi ng procedures.
CUSTOMER LEARN METHOD
The Customer Learn feature i s onl y avai l abl e on
domesti c vehi cl es, or those vehi cl es whi ch have a
U.S. country code desi gnator. Thi s programmi ng
method al so requi res access to at l east two val i d Sen-
try Keys. I f two val i d Sentry Keys are not avai l abl e,
or i f the vehi cl e does not have a U.S. country code
desi gnator, the Secured Access Method must be used
to program new or addi ti onal val i d keys to the SKI M.
The Customer Learn programmi ng method proce-
dures are as fol l ows:
(1) Obtai n the bl ank Sentry Key(s) that are to be
programmed as val i d keys for the vehi cl e. Cut the
bl ank key(s) to match the i gni ti on swi tch l ock cyl i n-
der mechani cal key codes.
(2) I nsert one of the two val i d Sentry Keys i nto the
i gni ti on swi tch and turn the i gni ti on swi tch to the
On posi ti on.
(3) After the i gni ti on swi tch has been i n the On
posi ti on for l onger than three seconds, but no more
than fi fteen seconds, cycl e the i gni ti on swi tch back to
the Off posi ti on. Repl ace the fi rst val i d Sentry Key i n
the i gni ti on swi tch l ock cyl i nder wi th the second
val i d Sentry Key and turn the i gni ti on swi tch back to
the On posi ti on. The second val i d Sentry Key must
be i nserted i n the l ock cyl i nder wi thi n fi fteen seconds
of removi ng the fi rst val i d key.
(4) About ten seconds after the compl eti on of Step
3, the SKI S i ndi cator i n the i nstrument cl uster wi l l
start to fl ash and a si ngl e audi bl e chi me tone wi l l
sound to i ndi cate that the system has entered the
Customer Learn programmi ng mode.
(5) Wi thi n si xty seconds of enteri ng the Customer
Learn programmi ng mode, turn the i gni ti on swi tch to
the Off posi ti on, repl ace the val i d Sentry Key wi th a
bl ank Sentry Key transponder, and turn the i gni ti on
swi tch back to the On posi ti on.
(6) About ten seconds after the compl eti on of Step 5,
a si ngl e audi bl e chi me tone wi l l sound and the SKI S
i ndi cator wi l l stop fl ashi ng, stay on sol i d for three sec-
onds, then turn off to i ndi cate that the bl ank Sentry
Key has been successful l y programmed. The SKI S wi l l
i mmedi atel y exi t the Customer Learn programmi ng
mode and the vehi cl e may now be started usi ng the
newl y programmed val i d Sentry Key.
Each of these steps must be repeated and com-
pl eted i n thei r enti rety for each addi ti onal Sentry
Key that i s to be programmed. I f the above steps are
not compl eted i n the gi ven sequence, or wi thi n the
al l otted ti me, the SKI S wi l l exi t the Customer Learn
programmi ng mode and the programmi ng wi l l be
unsuccessful . The SKI S wi l l al so automati cal l y exi t
the Customer Learn programmi ng mode i f i t sees a
non-bl ank Sentry Key transponder when i t shoul d
see a bl ank, i f i t has al ready programmed ei ght (8)
val i d Sentry Keys, or i f the i gni ti on swi tch i s turned
to the Off posi ti on for more than about fi fty seconds.
NOTE: If an attempt is made to start the vehicle
while in the Customer Learn mode (SKIS indicator
flashing), the SKIS will respond as though the vehi-
cle were being started with an invalid key. In other
words, the engine will stall after about two seconds
of operation. No faults will be set.
NOTE: Once a Sentry Key has been programmed as
a valid key to a vehicle, it cannot be programmed
as a valid key for use on any other vehicle.
DOOR CYLINDER LOCK
SWITCH
DESCRIPTION
Vehi cl es manufactured for North Ameri can mar-
kets that are equi pped wi th the opti onal Vehi cl e
Fig. 2 Door Cylinder Lock Switch
1 - SWITCH
3 - DOOR LOCK CYLINDER
Theft Securi ty System (VTSS) have a door cyl i nder
l ock swi tch secured to the back of the key l ock cyl i n-
der i nsi de each front door (Fi g. 2). The door cyl i nder
l ock swi tch i s a resi stor mul ti pl exed momentary
swi tch that i s hard wi red i n seri es between the door
l ock swi tch ground and ri ght or l eft cyl i nder l ock
swi tch mux ci rcui ts of the Body Control Modul e
(BCM) through the front door wi re harness. The door
cyl i nder l ock swi tches are dri ven by the key l ock cyl -
i nders and contai n two i nternal resi stors. One resi s-
tor val ue i s used for the Lock posi ti on, and one for
the Unl ock posi ti on.
The door cyl i nder l ock swi tches cannot be adjusted
or repai red and, i f faul ty or damaged, they must be
repl aced.
OPERATION
The door cyl i nder l ock swi tches are actuated by the
key l ock cyl i nder when the key i s i nserted i n the l ock
cyl i nder and turned to the l ock or unl ock posi ti ons.
The door cyl i nder l ock swi tch cl ose a ci rcui t between
the door l ock swi tch ground ci rcui t and the l eft or
ri ght cyl i nder l ock swi tch mux ci rcui ts through one of
two i nternal resi stors for the Body Control Modul e
(BCM) when ei ther front door key l ock cyl i nder i s i n
the Lock, or Unl ock posi ti ons. The BCM reads the
swi tch status through an i nternal pul l -up, then uses
thi s i nformati on as an i nput for the Vehi cl e Theft
Securi ty System (VTSS) operati on.
The door cyl i nder l ock swi tches and ci rcui ts can be
di agnosed usi ng conventi onal di agnosti c tool s and
methods.
DIAGNOSIS AND TESTING - DOOR CYLINDER
LOCK SWITCH
(1) Di sconnect the door cyl i nder l ock swi tch pi gtai l
wi re connector from the door wi re harness connector.
(2) Usi ng a ohmmeter, check the swi tch resi stance
checks between the two termi nal s i n the door cyl i n-
der l ock swi tch pi gtai l wi re connector. Actuate the
swi tch by rotati ng the key i n the door l ock cyl i nder
to test for the proper resi stance val ues i n each of the
two swi tch posi ti ons, as shown i n the Door Cyl i nder
Lock Swi tch Test tabl e.
DOOR CYLINDER LOCK SWITCH TEST
Switch Position Resistance
(10%)
Left Side Right Side
Lock (Clockwise) Unlock
(Counterclockwise)
473 Ohms
Unlock
(Counterclockwise)
Lock (Clockwise) 1.994 Kilohms
(3) I f a door cyl i nder l ock swi tch fai l s ei ther of the
resi stance tests, repl ace the faul ty swi tch.
REMOVAL
cabl e.
(2) Remove the outsi de door handl e uni t from the
outer door panel . (Refer to 23 - BODY/DOOR -
FRONT/EXTERI OR HANDLE - REMOVAL).
(3) Remove the retai ner cl i p from the pi n on the
back of the door l ock cyl i nder (Fi g. 3).
(4) Remove the l ock l ever from the pi n on the back
of the door l ock cyl i nder.
(5) Remove the door cyl i nder l ock swi tch from the
back of the l ock cyl i nder.
INSTALLATION
(1) Posi ti on the door cyl i nder l ock swi tch onto the
back of the l ock cyl i nder wi th i ts pi gtai l wi re harness
ori ented toward the bottom (Fi g. 3).
Fig. 3 Lock Cylinder Lever Retainer Remove/Install
1 - LEVER
2 - RETAINER
3 - LOCK CYLINDER
4 - SWITCH
5 - PLIERS
DOOR CYLINDER LOCK SWITCH (Continued)
(2) Posi ti on the l ock l ever onto the pi n on the back
of the door l ock cyl i nder wi th the l ever ori ented
toward the rear.
(3) I nstal l the retai ner cl i p onto the pi n on the
back of the door l ock cyl i nder. Be certai n that the
center tab of the retai ner i s engaged i n the retenti on
hol e on the l ock l ever.
(4) Rei nstal l the outsi de door handl e uni t onto the
outer door panel . (Refer to 23 - BODY/DOOR -
FRONT/EXTERI OR HANDLE - I NSTALLATI ON).
HOOD AJ AR SWITCH
DESCRIPTION
The hood ajar swi tch i s a normal l y cl osed, si ngl e
pol e momentary swi tch that i s used onl y on vehi cl es
equi pped wi th the Vehi cl e Theft Securi ty System
(VTSS) for sal e i n certai n markets where i t i s
requi red equi pment (Fi g. 4). Thi s swi tch consi sts of a
mol ded pl asti c body wi th a mol ded pl asti c mounti ng
bezel . The swi tch body has an i ntegral mol ded con-
nector receptacl e on the l ower end, whi l e the spri ng-
l oaded swi tch pl unger extends from the upper end.
Two external l atches i ntegral to the mounti ng bezel
l ock the swi tch i nto a keyed mounti ng hol e i n the
stamped steel swi tch mounti ng bracket. The mount-
i ng bracket i s fastened wi th two screws to the ri ght
i nner fender shi el d near the fender l edge i n the
engi ne compartment. A mol ded pl asti c stri ker wi th
an i ntegral retai ner and mounti ng tab i s secured to
the undersi de of the hood panel i nner rei nforcement
to actuate the swi tch pl unger as the hood panel i s
cl osed (Fi g. 5). A si ngl e take out of the headl amp and
dash wi re harness connects the swi tch to the vehi cl e
el ectri cal system. The swi tch recei ves a path to
ground at al l ti mes through another take out of the
headl amp and dash wi re harness wi th an eyel et ter-
the l eft i nner fender shi el d i n the engi ne compart-
ment.
The hood ajar swi tch cannot be adjusted or
repl aced. The hood ajar swi tch stri ker i s not i ntended
for reuse. I f the stri ker i s removed from the hood
i nner rei nforcement for any reason, i t must be
repl aced wi th a new uni t.
Fig. 4 Hood Ajar Switch
1 - INNER FENDER
2 - SCREW (2)
3 - BRACKET
4 - HOOD AJAR SWITCH
Fig. 5 Hood Ajar Switch Striker
1 - STRIKER
2 - TAB
3 - INNER HOOD REINFORCEMENT
4 - RETAINER
DOOR CYLINDER LOCK SWITCH (Continued)
OPERATION
The hood ajar swi tch i s normal l y hel d open as the
spri ng-l oaded swi tch pl unger i s depressed by the
stri ker on the hood panel when the hood panel i s
cl osed and l atched. When the hood i s opened, the
spri ng-l oaded swi tch pl unger extends from the swi tch
body and the swi tch contacts are cl osed. The hood
ajar swi tch i s connected i n seri es between ground
and the hood ajar swi tch sense i nput of the Body
Control Modul e (BCM). The BCM uses an i nternal
resi stor pul l up to moni tor the state of the hood ajar
swi tch contacts. The hood ajar swi tch can be di ag-
ods.
DIAGNOSIS AND TESTING - HOOD AJAR
SWITCH
ness connector for the hood ajar swi tch from the
(2) Check for conti nui ty between the two termi nal s
i n the connector receptacl e of the hood ajar swi tch.
There shoul d be conti nui ty wi th the swi tch pl unger
extended, and no conti nui ty wi th the swi tch pl unger
depressed. I f not OK, repl ace the faul ty hood ajar
swi tch.
REMOVAL
(1) Unl atch and open the hood.
cabl e.
(3) From the top of the hood ajar swi tch mounti ng
bracket, squeeze the two swi tch l atch tabs together
and pul l the swi tch upward (Fi g. 6).
(4) Pul l the hood ajar swi tch up through the hol e
i n the mounti ng bracket far enough to access and
di sconnect the headl amp and dash wi re harness con-
nector for the hood ajar swi tch from the swi tch con-
nector receptacl e.
(5) Remove the hood ajar swi tch from the mount-
i ng bracket.
INSTALLATION
(1) Posi ti on the hood ajar swi tch near the hol e i n
the mounti ng bracket (Fi g. 6).
connector for the hood ajar swi tch to the swi tch con-
nector receptacl e.
(3) From the top of the hood ajar swi tch mounti ng
bracket, use hand pressure to press the swi tch down-
ward i nto the mounti ng bracket unti l the l atch tabs
l ock i t i nto pl ace.
(5) Cl ose and l atch the hood.
Fig. 6 Hood Ajar Switch Remove/Install
1 - INNER FENDER
2 - SCREW (2)
3 - BRACKET
HOOD AJ AR SWITCH (Continued)
HOOD AJ AR SWITCH
BRACKET
REMOVAL
(1) Remove the hood ajar swi tch from the mount-
i ng bracket. (Refer to 8 - ELECTRI CAL/VEHI CLE
THEFT SECURI TY/HOOD AJAR SWI TCH -
REMOVAL).
(2) I f necessary, remove and set asi de the engi ne
ai r cl eaner housi ng for access to the hood ajar swi tch
mounti ng bracket screws.
(3) Remove the two screws that secure the hood
ajar swi tch bracket to the ri ght fender i nner shi el d
(Fi g. 7).
(4) Remove the hood ajar swi tch bracket from the
ri ght fender i nner shi el d.
INSTALLATION
(1) Posi ti on the hood ajar swi tch bracket onto the
ri ght fender i nner shi el d (Fi g. 7).
the hood ajar swi tch bracket to the ri ght fender i nner
shi el d. Ti ghten the screws to 7 Nm (60 i n. l bs.).
(3) I f removed, rei nstal l the engi ne ai r cl eaner
housi ng.
(4) Rei nstal l the hood ajar swi tch i nto the mount-
i ng bracket. (Refer to 8 - ELECTRI CAL/VEHI CLE
THEFT SECURI TY/HOOD AJAR SWI TCH -
I NSTALLATI ON).
HOOD AJ AR SWITCH STRIKER
REMOVAL
The hood ajar swi tch stri ker i s not i ntended for
reuse. I f the stri ker i s removed from the hood i nner
rei nforcement for any reason, i t must be repl aced
wi th a new uni t.
fl at-bl aded tool , gentl y pry the rearward end of the
hood ajar swi tch stri ker away from the i nner hood
panel rei nforcement far enough to di sengage the i nte-
gral retai ner from i ts mounti ng hol e (Fi g. 8).
(3) Move the hood ajar swi tch stri ker sl i ghtl y rear-
ward to di sengage the i ntegral mounti ng tab from
the forward mounti ng hol e.
(4) Remove the hood ajar swi tch stri ker from the
i nner hood panel rei nforcement and di scard.
Fig. 7 Hood Ajar Switch Bracket Remove/Install
1 - INNER FENDER
2 - SCREW (2)
3 - BRACKET
Fig. 8 Hood Ajar Switch Striker Remove/Install
1 - STRIKER
2 - TAB
3 - INNER HOOD REINFORCEMENT
4 - RETAINER
INSTALLATION
The hood ajar swi tch stri ker i s not i ntended for
reuse. I f the stri ker i s removed from the hood i nner
rei nforcement for any reason, i t must be repl aced
wi th a new uni t.
(1) Posi ti on the new hood ajar swi tch stri ker to the
i nner hood panel rei nforcement (Fi g. 8).
(2) I nsert the i ntegral mounti ng tab on the front of
the hood ajar swi tch stri ker i nto the forward mount-
i ng hol e i n the i nner hood panel rei nforcement.
(3) Al i gn the i ntegral retai ner on the rear of the
hood ajar swi tch stri ker wi th the rearward mounti ng
hol e i n the i nner hood panel rei nforcement.
(4) Usi ng hand pressure, fi rml y press the hood
ajar swi tch stri ker rearward and upward agai nst the
i nner hood panel rei nforcement unti l the hood ajar
swi tch stri ker retai ner i s ful l y engaged i n the rear-
ward mounti ng hol e i n the i nner hood panel rei n-
forcement.
INTRUSION TRANSCEIVER
MODULE
DESCRIPTION
An I ntrusi on Transcei ver Modul e (I TM) i s part of
the Rest-Of-Worl d (ROW) premi um versi on of the
Vehi cl e Theft Al arm (VTA) i n the Vehi cl e Theft Secu-
ri ty System (VTSS) (Fi g. 9). The ROW premi um ver-
si on of the VTA i s onl y avai l abl e i n vehi cl es bui l t for
certai n markets, where the addi ti onal features
offered by thi s system are requi red. The I TM i s
l ocated i n the passenger compartment, on the l ower
surface of the headl i ner near the center of the vehi -
cl e. Thi s uni t i s desi gned to provi de i nteri or moti on
detecti on, and serve as an i nterface between the
Body Control Modul e (BCM) and the al arm si ren
modul e.
The I TM i s conceal ed beneath a dedi cated mol ded
pl asti c tri m cover that approxi mates the si ze and
shape of a typi cal dome l amp housi ng. However,
rather than a l ens, the I TM features three sets of
l ouvered openi ngs i n a mol ded l ateral center ri b for-
mati on. One set of l ouvered openi ngs i s l ocated at
each outboard end of the center ri b, whi l e the thi rd
set i s centered. Each of the l ouvered openi ngs i s cov-
ered on the i nsi de by a si ngl e mol ded bl ack pl asti c
si ght shi el d that extends the l ength of the center ri b
for appearance. The modul e i s secured to a mol ded
pl asti c mounti ng bracket above the headl i ner by four
l atch features that are i ntegral to the undersi de of
the modul e housi ng. Besi des the I TM, the tri m cover
al so conceal s two pl asti c pi ns i ntegral to the mount-
i ng bracket that are used to secure the bracket to the
headl i ner wi th two stamped nuts that are i nstal l ed
from bel ow. An adhesi ve-backed foam pad i s i nstal l ed
above the I TM bracket between the headl i ner and
the roof panel to provi de addi ti onal headl i ner stabi l i -
zati on and support for the I TM mounti ng. Two smal l
notch-l i ke servi ce hol es on the rear edge of the tri m
cover afford access to the two i ntegral rear l atches of
the I TM for servi ce removal (Fi g. 10).
The I TM ci rcui try i s contai ned wi thi n a bl ack
mol ded pl asti c housi ng wi th four i ntegral mounti ng
tabs that are secured to the back of the tri m cover
wi th four screws. Conceal ed wi thi n the housi ng i s the
Fig. 9 Intrusion Transceiver Module
1 - ITM
2 - HEADLINER
Fig. 10 Intrusion Transceiver Module
1 - TRIM COVER
3 - HOUSING
4 - SCREW (4)
5 - SERVICE HOLE (2)
6 - LATCH FEATURE (4)
HOOD AJ AR SWITCH STRIKER (Continued)
el ectroni c ci rcui try of the I TM whi ch i ncl udes a
mi croprocessor, and an ul trasoni c recei ve transducer.
A mol ded pl asti c connector receptacl e contai ni ng si x
termi nal pi ns that i s sol dered to a smal l ci rcui t board
and extends through a cl earance hol e i n the l eft front
corner of the I TM housi ng, and an ul trasoni c trans-
mi t transducer housi ng extends from the center of
the ri ght si de of the I TM housi ng. Both the transmi t
transducer on the ri ght si de of the modul e and the
recei ve transducer on the I TM ci rcui t board are
ai med through two smal l round hol es i n the si ght
shi el d of the tri m cover. The I TM i s connected to the
vehi cl e el ectri cal system by a dedi cated take out and
connector of the overhead wi re harness that i s i nte-
gral to the headl i ner.
The I TM uni t cannot be adjusted or repai red and,
i f faul ty or damaged, i t must be repl aced. The I TM i s
servi ced as a uni t wi th the tri m cover.
OPERATION
The mi croprocessor i n the I ntrusi on Transcei ver
Modul e (I TM) contai ns the moti on sensor l ogi c ci r-
cui ts and control s al l of the features of the premi um
versi on of the Vehi cl e Theft Al arm (VTA). The I TM
uses On-Board Di agnosti cs (OBD) and can communi -
cate wi th other el ectroni c modul es i n the vehi cl e as
wel l as wi th the DRBI I I scan tool usi ng the Pro-
network. Thi s method of communi cati on i s used by
the I TM to communi cate wi th the Body Control Mod-
ul e (BCM) and for di agnosi s and testi ng through the
l ower edge of the i nstrument panel . The I TM al so
communi cates wi th the al arm si ren over a dedi cated
seri al bus ci rcui t.
The I TM mi croprocessor conti nuousl y moni tors
i nputs from i ts on-board moti on sensor ci rcui try as
wel l as i nputs from the BCM and the al arm si ren
modul e. The on-board I TM moti on sensor ci rcui try
transmi ts ul trasoni c si gnal s i nto the vehi cl e cabi n
through a transmi t transducer, then l i stens to the
returni ng si gnal s as the bounce off of objects i n the
vehi cl e i nteri or. I f an object i s movi ng i n the i nteri or,
a detecti on ci rcui t i n the I TM senses thi s movement
through the modul ati on of the returni ng ul trasoni c
si gnal s that occurs due to the Doppl er effect. The
moti on detect functi on of the I TM can be di sabl ed by
depressi ng the Lock button on the Remote Keyl ess
Entry (RKE) transmi tter three ti mes wi thi n fi fteen
seconds, whi l e the securi ty i ndi cator i s sti l l fl ashi ng
rapi dl y. The I TM wi l l si gnal the al arm si ren modul e
to provi de a si ngl e si ren chi rp as an audi bl e confi r-
mati on that the moti on sensor functi on has been di s-
abl ed.
I f movement i s detected, the I TM sends an el ec-
troni c message to the BCM over the PCI data bus to
fl ash the exteri or l i ghti ng and sends an el ectroni c
message to the al arm si ren modul e over a dedi cated
seri al bus l i ne to sound the si ren. When the BCM
detects a breach i n the peri meter protecti on through
a door, tai l gate, fl i p-up gl ass, or hood ajar swi tch
i nput, i t sends an el ectroni c message to the I TM and
the I TM sends an el ectroni c message to the BCM
over the PCI data bus to fl ash the exteri or l i ghti ng
and sends an el ectroni c message to the al arm si ren
modul e over a dedi cated seri al bus l i ne to sound the
si ren. The I TM al so moni tors i nputs from the al arm
si ren modul e for si ren battery or si ren i nput/output
ci rcui t tamper al erts, and si ren battery condi ti on
al erts, then sets acti ve and stored Di agnosti c Troubl e
Codes (DTC) for any moni tored system faul ts i t
detects. An acti ve faul t onl y remai ns for the current
i gni ti on swi tch cycl e, whi l e a stored faul t causes a
DTC to be stored i n memory by the I TM. I f a faul t
does not recur for fi fty i gni ti on cycl es, the I TM wi l l
automati cal l y erase the stored DTC.
The I TM i s connected to the vehi cl e el ectri cal sys-
the overhead wi re harness. The I TM recei ves battery
current on a fused B(+) ci rcui t through a fuse i n the
Juncti on Bl ock (JB), and recei ves ground through a
ground ci rcui t and take out of the body wi re harness.
Thi s ground take out has a si ngl e eyel et termi nal
connector that i s secured by a ground screw to the
base of the l eft D-pi l l ar behi nd the quarter tri m
panel . These connecti ons al l ow the I TM to remai n
operati onal , regardl ess of the i gni ti on swi tch posi ti on.
The hard wi red i nputs and outputs for the I TM may
be di agnosed and tested usi ng conventi onal di agnos-
ti c tool s and procedures. However, conventi onal di ag-
nosti c methods wi l l not prove concl usi ve i n the
di agnosi s of the I TM, the PCI data bus network, or
the el ectroni c message i nputs to and outputs from
the I TM. The most rel i abl e, effi ci ent, and accurate
means to di agnose the I TM, the PCI data bus net-
work, and the el ectroni c message i nputs to and out-
puts from the I TM requi res the use of a DRBI I I
mati on.
REMOVAL
cabl e.
(2) Whi l e pul l i ng downward l i ghtl y on ei ther rear
corner of the I ntrusi on Transcei ver Modul e (I TM)
tri m cover, i nsert a smal l thi n-bl aded screwdri ver
through each of the servi ce hol es on the rear edge of
the tri m cover to depress and rel ease the two i nte-
gral rear l atch features of the modul e from the
(3) Pul l the I TM tri m cover rearward far enough
to di sengage the two i ntegral front l atch features of
INTRUSION TRANSCEIVER MODULE (Continued)
the modul e from the mounti ng bracket above the
headl i ner.
(4) Pul l the I TM and tri m cover down from the
headl i ner far enough to access and di sconnect the
overhead wi re harness connector for the I TM from
the modul e connector receptacl e.
(5) Remove the I TM from the headl i ner.
INSTALLATION
(1) Posi ti on the I ntrusi on Transcei ver Modul e
(I TM) to the headl i ner.
(2) Reconnect the overhead wi re harness connector
for the I TM to the modul e connector receptacl e.
(3) Al i gn the two i ntegral front l atch features of
the I TM wi th the two front l atch receptacl es of the
(4) Push the I TM tri m cover forward far enough to
i nsert the two i ntegral rear l atch features of the
modul e i nto the two rear l atch receptacl es of the
mounti ng bracket above the headl i ner.
(5) Push upward fi rml y and evenl y on the rear
edge of the I TM tri m cover unti l the two i ntegral
rear l atch features of the modul e are engaged i n the
l atch receptacl es of the mounti ng bracket above the
headl i ner.
NOTE: If the Intrusion Transceiver Module (ITM) has
been replaced with a new unit, the new ITM MUST
be initialized before the Vehicle Theft Security Sys-
tem can operate as designed. The use of a DRBIII
scan tool is required to initialize the ITM. Refer to
the appropriate diagnostic information.
SIREN
DESCRIPTION
An al arm si ren modul e i s part of the Rest-Of-Worl d
(ROW) premi um versi on of the Vehi cl e Theft Al arm
(VTA) i n the Vehi cl e Theft Securi ty System (VTSS)
(Fi g. 13). The ROW premi um versi on of the VTA i s
onl y avai l abl e i n vehi cl es bui l t for certai n markets,
where the addi ti onal features offered by thi s system
are requi red. The al arm si ren modul e i s l ocated i n
Fig. 11 Intrusion Transceiver Module Remove
1 - SMALL SCREWDRIVER
2 - HEADLINER
3 - SERVICE HOLES
4 - ITM
Fig. 12 Intrusion Transceiver Module Mounting
Bracket
1 - STAMPED NUT (2)
3 - HEADLINER
4 - LATCH RECEPTACLES (4)
Fig. 13 Siren Module
1 - BRACKET
2 - NUT (3)
4 - SIREN MODULE
INTRUSION TRANSCEIVER MODULE (Continued)
the engi ne compartment, on the front extensi on of
the ri ght front wheel house panel bel ow and behi nd
the ri ght headl amp. Thi s uni t i s desi gned to provi de
the audi bl e al ert requi rements for the ROW premi um
VTA.
The al arm si ren modul e consi sts of mi croprocessor-
based el ectroni c control ci rcui try, the si ren, and a
ni ckel metal hydri de backup battery. Al l of the al arm
modul e components are protected and seal ed wi thi n
a bl ack mol ded pl asti c housi ng. A stamped steel
mounti ng bracket i s secured to the modul e wi th
three stud pl ates and nuts that fi t i nto sl otted hol es
at the top and each si de of the bracket. The front
surface of the bracket features a ti ghtl y grouped
seri es of smal l hol es that serves as an outl et for the
audi bl e output of the al arm si ren. The bottom of the
mounti ng bracket i s bent at a ri ght angl e and has an
i ntegral l ocati ng tab feature. Two mounti ng hol es i n
the hori zontal surface of the bracket are used to
secure the al arm si ren modul e to the wheel house
extensi on wi th two screws. An i ntegral connector
receptacl e extends forward from the upper l eft corner
of the al arm si ren housi ng, and connects the uni t to
the vehi cl e el ectri cal system through a dedi cated
take out and connector of the headl amp and dash
wi re harness.
The al arm si ren modul e cannot be repai red or
adjusted and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
The mi croprocessor wi thi n the al arm si ren modul e
performs the tasks requi red to provi de the si ren uni t
features and functi ons based upon i nternal program-
mi ng and el ectroni c arm and di sarm message i nputs
recei ved from the I ntrusi on Transcei ver Modul e
(I TM) over a dedi cated seri al bus communi cati on ci r-
cui t. The al arm si ren modul e wi l l sel f-detect prob-
l ems wi th i ts i nternal and external power suppl y and
communi cati on ci rcui ts, then send el ectroni c mes-
sages i ndi cati ng the probl em to the I TM upon recei v-
i ng a request from the I TM. The I TM wi l l store a
Di agnosti c Troubl e Code (DTC) for a detected al arm
si ren modul e faul t that can be retri eved wi th the
DRBI I I scan tool over the Programmabl e Communi -
cati ons I nterface (PCI ) data bus network through the
l ower edge of the i nstrument panel .
When the Rest-Of-Worl d (ROW) premi um versi on
of the Vehi cl e Theft Al arm (VTA) i s armed, the al arm
si ren modul e mi croprocessor conti nuousl y moni tors
i nputs from the I TM for messages to sound i ts i nter-
nal si ren and enters i ts auto-detect mode. Whi l e i n
the auto-detect mode, i f the al arm si ren modul e
detects that i ts power suppl y or communi cati on ci r-
cui ts are bei ng tampered wi th or have been sabo-
taged, i t wi l l sound an al arm and conti nue to operate
through i ts on-board backup battery. I f the arm si ren
modul e i s i n i ts di sarmed mode when i ts power sup-
pl y or communi cati on ci rcui ts are i nterrupted, the
si ren wi l l not sound. The al arm modul e wi l l al so
noti fy the I TM when the backup battery requi res
chargi ng, and the I TM wi l l send a message that wi l l
al l ow the backup battery to be charged through the
battery current and ground ci rcui ts to the al arm
modul e onl y when the i gni ti on swi tch i s i n the On
posi ti on and the engi ne i s runni ng. Thi s wi l l prevent
the chargi ng of the al arm backup battery from
depl eti ng the charge i n the mai n vehi cl e battery
whi l e the vehi cl e i s not bei ng operated.
The al arm si ren modul e recei ves battery current
on a fused B(+) ci rcui t through a fuse i n the Power
Di stri buti on Center (PDC), and recei ves ground
through a ground ci rcui t and take out of the head-
l amp and dash wi re harness. Thi s ground take out
has a si ngl e eyel et termi nal connector that i s secured
by a ground screw to the l eft i nner fender shi el d i n
the engi ne compartment. These connecti ons al l ow the
al arm si ren modul e to remai n operati onal , regardl ess
of the i gni ti on swi tch posi ti on. The hard wi red i nputs
and outputs for the al arm si ren modul e may be di ag-
nosed and tested usi ng conventi onal di agnosti c tool s
and procedures. However, conventi onal di agnosti c
methods wi l l not prove concl usi ve i n the di agnosi s of
the i nternal ci rcui try or the backup battery of the
al arm si ren modul e, the I TM, the seri al bus commu-
ni cati on l i ne, or the el ectroni c message i nputs to and
outputs from the al arm si ren modul e. The most rel i -
abl e, effi ci ent, and accurate means to di agnose the
al arm si ren modul e, the I TM, the seri al bus commu-
ni cati on l i ne, and the el ectroni c message i nputs to
and outputs from the al arm si ren modul e requi res
the use of a DRBI I I scan tool . Refer to the appro-
pri ate di agnosti c i nformati on.
REMOVAL
cabl e.
ness connector for the al arm si ren modul e from the
modul e connector receptacl e (Fi g. 14).
(3) Remove the two screws that secure the al arm
si ren modul e to the front extensi on of the ri ght front
wheel house panel .
(4) Remove the al arm si ren modul e from the front
extensi on of the ri ght front wheel house panel .
INSTALLATION
(1) Posi ti on the al arm si ren modul e onto the front
extensi on of the ri ght front wheel house panel (Fi g.
14).
SIREN (Continued)
the al arm si ren modul e to the front extensi on of the
ri ght front wheel house panel . Ti ghten the screws to
6 Nm (50 i n. l bs.).
connector for the al arm si ren modul e to the modul e
NOTE: If the alarm siren module has been replaced
with a new unit, the new unit MUST be configured
in the Intrusion Transceiver Module (ITM) before the
Vehicle Theft Security System can operate as
designed. The use of a DRBIII scan tool is required
to configure the alarm siren module settings in the
ITM. Refer to the appropriate diagnostic informa-
tion.
TRANSPONDER KEY
DESCRIPTION
Each i gni ti on key used i n the Sentry Key I mmobi -
l i zer System (SKI S) has an i ntegral transponder chi p
(Fi g. 15). I gni ti on keys wi th thi s feature can be
readi l y i denti fi ed by a gray rubber cap mol ded onto
the head of the key, whi l e conventi onal i gni ti on keys
have a bl ack mol ded rubber cap. The transponder
chi p i s conceal ed beneath the mol ded rubber cap,
where i t i s mol ded wi thi n a pl asti c mount i nto the
head of the metal key. I n addi ti on to bei ng cut to
match the mechani cal codi ng of the i gni ti on l ock cyl -
i nder, each new Sentry Key has a uni que transpon-
der i denti fi cati on code permanentl y programmed i nto
i t by the manufacturer. The Sentry Key transponder
cannot be adjusted or repai red. I f faul ty or damaged,
the enti re key must be repl aced.
OPERATION
When the i gni ti on swi tch i s turned to the On posi -
ti on, the Sentry Key I mmobi l i zer Modul e (SKI M)
communi cates through i ts antenna wi th the Sentry
Key transponder usi ng a Radi o Frequency (RF) si g-
nal . The SKI M then l i stens for a RF response from
the transponder through the same antenna. The Sen-
try Key transponder chi p i s wi thi n the range of the
SKI M transcei ver antenna ri ng when i t i s i nserted
i nto the i gni ti on l ock cyl i nder. The SKI M determi nes
whether a val i d key i s present i n the i gni ti on l ock
cyl i nder based upon the response from the transpon-
der. I f a val i d key i s detected, that fact i s communi -
cated by the SKI M to the Powertrai n Control Modul e
I nterface (PCI ) data bus, and the PCM al l ows the
engi ne to conti nue runni ng. I f the PCM recei ves an
i nval i d key message, or recei ves no message from the
SKI M over the PCI data bus, the engi ne wi l l be di s-
abl ed after about two seconds of operati on. The El ec-
troMechani cal I nstrument Cl uster (EMI C) wi l l al so
respond to the i nval i d key message on the PCI data
bus by fl ashi ng the SKI S i ndi cator on and off.
Fig. 14 Siren Remove/Install
1 - SCREW (2)
3 - SIREN
Fig. 15 Sentry Key Immobilizer Transponder
1 - MOLDED CAP
2 - TRANSPONDER CHIP
3 - MOLDED CAP REMOVED
4 - TRANSPONDER KEY
SIREN (Continued)
Each Sentry Key has a uni que transponder i denti -
fi cati on code permanentl y programmed i nto i t by the
manufacturer. Li kewi se, the SKI M has a uni que
Secret Key code programmed i nto i t by the manufac-
turer. When a Sentry Key i s programmed i nto the
memory of the SKI M, the SKI M stores the transpon-
der i denti fi cati on code from the Sentry Key, and the
Sentry Key l earns the Secret Key code from the
SKI M. Once the Sentry Key l earns the Secret Key
code of the SKI M, i t i s permanentl y stored i n the
memory of the transponder. Therefore, once a Sentry
Key has been programmed to a parti cul ar vehi cl e, i t
cannot be used on any other vehi cl e. (Refer to 8 -
ELECTRI CAL/VEHI CLE THEFT SECURI TY -
STANDARD PROCEDURE - TRANSPONDER PRO-
GRAMMI NG).
store key-rel ated faul t i nformati on i n the form of
Di agnosti c Troubl e Codes (DTCs) i n SKI M memory i f
a Sentry Key transponder probl em i s detected. The
Sentry Key transponder chi p can be di agnosed, and
any stored DTCs can be retri eved usi ng a DRBI I I
scan tool . Refer to the appropri ate di agnosti c
i nformati on.
TRANSPONDER KEY (Continued)
WIPERS/WASHERS
TABLE OF CONTENTS
page page
FRONT WIPERS/WASHERS . . . . . . . . . . . . . . . . . . 1 REAR WIPERS/WASHERS . . . . . . . . . . . . . . . . . . 27
FRONT WIPERS/WASHERS
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - FRONT WIPER &
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . 6
CLEANING - FRONT WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSPECTION - FRONT WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT CHECK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT WASHER HOSES/TUBES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT WASHER NOZZLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
FRONT WIPER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
FRONT WIPER BLADE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
FRONT WIPER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
FRONT WIPER/WASHER SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
WASHER FLUID LEVEL SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
WASHER PUMP/MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
WASHER RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
WIPER HIGH/LOW RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSIS AND TESTING - WIPER HIGH/
LOW RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
WIPER ON/OFF RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - WIPER ON/OFF
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
KJ WIPERS/WASHERS 8R - 1
DESCRIPTION
Fig. 1 Front Wiper & Washer System
1 - WASHER RESEVOIR FILLER TUBE
2 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL
SWITCH
3 - WIPER MODULE
4 - WASHER NOZZLE (2)
5 - WIPER ARM & BLADE (2)
6 - MULTI-FUNCTION SWITCH RIGHT (WIPER) CONTROL
STALK
8R - 2 FRONT WIPERS/WASHERS KJ
An el ectri cal l y operated i ntermi ttent front wi per
and washer system i s standard factory-i nstal l ed
safety equi pment on thi s model (Fi g. 1). The front
wi per and washer system i ncl udes the fol l owi ng
detai l el sewhere i n thi s servi ce i nformati on:
- DESCRI PTI ON).
Front Check Valve - The front washer system
check val ve i s i ntegral to the wye fi tti ng l ocated i n
the washer pl umbi ng between the cowl pl enum
washer hose and the front washer nozzl es, and i s
conceal ed beneath the cowl pl enum cover/gri l l e panel
at the base of the wi ndshi el d.
Front Washer Nozzle - Two fl ui di c front
washer nozzl es are secured wi th i ntegral snap fea-
tures to dedi cated openi ngs i n the cowl pl enum cover/
gri l l e panel l ocated near the base of the wi ndshi el d.
Front Washer Plumbing - The pl umbi ng for
the front washer system consi sts of rubber hoses and
mol ded pl asti c fi tti ngs. The pl umbi ng i s routed al ong
the ri ght si de of the engi ne compartment from the
washer reservoi r, and through the dash panel i nto
the cowl pl enum to the front washer nozzl e fi tti ngs
beneath the cowl pl enum cover/gri l l e panel .
Front Wiper Arm - The two front wi per arms
are secured wi th nuts to the threaded studs on the
ends of the two wi per pi vot shafts, whi ch extend
through the cowl pl enum cover/gri l l e panel l ocated
near the base of the wi ndshi el d.
Front Wiper Blade - The two front wi per
bl ades are secured to the two front wi per arms wi th
an i ntegral l atch, and are parked on the gl ass near
the bottom of the wi ndshi el d when the front wi per
system i s not i n operati on.
Front Wiper Module - The front wi per pi vot
shafts are the onl y vi si bl e components of the front
wi per modul e. The remai nder of the modul e i s con-
ceal ed wi thi n the cowl pl enum area beneath the cowl
pl enum cover/gri l l e panel . The front wi per modul e
i ncl udes the wi per modul e bracket, four rubber-i so-
l ated wi per modul e mounts, the front wi per motor,
the wi per motor crank arm, the two wi per dri ve
l i nks, and the two front wi per pi vots.
ri ght (wi per) control stal k. The ri ght control stal k i s
dedi cated to provi di ng al l of the dri ver control s for
both the front and rear wi per systems. (Refer to 8 -
MULTI -FUNCTI ON SWI TCH - DESCRI PTI ON).
Washer Fluid Level Switch - The washer fl ui d
l evel swi tch i s l ocated i n a dedi cated hol e near the
center of the rearward faci ng surface of the washer
reservoi r, behi nd the ri ght front wheel house spl ash
shi el d.
Washer Pump/Motor - The reversi bl e el ectri c
washer pump/motor uni t i s l ocated i n a dedi cated
hol e on the l ower outboard si de of the washer reser-
voi r, behi nd the ri ght front wheel house spl ash
shi el d. Thi s si ngl e reversi bl e washer pump/motor
provi des washer fl ui d to ei ther the front or rear
washer system pl umbi ng, dependi ng upon the di rec-
ti on of the pump motor rotati on.
Washer Reservoir - The washer reservoi r i s
conceal ed behi nd the ri ght front wheel house spl ash
shi el d ahead of the ri ght front wheel . The washer
reservoi r fi l l er neck i s the onl y vi si bl e porti on of the
reservoi r, and i t i s accessed from the ri ght front cor-
ner of the engi ne compartment.
Wiper High-Low Relay - The wi per hi gh-l ow
rel ay i s an I nternati onal Standards Organi zati on
(I SO) mi cro rel ay l ocated i n the Power Di stri buti on
Center (PDC) i n the engi ne compartment near the
battery.
Wiper On-Off Relay - The wi per on-off rel ay i s
an I nternati onal Standards Organi zati on (I SO) mi cro
rel ay l ocated i n the Power Di stri buti on Center (PDC)
i n the engi ne compartment near the battery.
Hard wi red ci rcui try connects the front wi per and
washer system components to the el ectri cal system of
the vehi cl e. These hard wi red ci rcui ts are i ntegral to
several wi re harnesses, whi ch are routed throughout
the vehi cl e and retai ned by many di fferent methods.
vehi cl e el ectri cal system and to the front wi per and
washer system components through the use of a com-
bi nati on of sol dered spl i ces, spl i ce bl ock connectors,
and many di fferent types of wi re harness termi nal
connectors and i nsul ators. Refer to the appropri ate
procedures, further detai l s on wi re harness routi ng
and retenti on, as wel l as pi n-out and l ocati on vi ews
for the vari ous wi re harness connectors, spl i ces and
grounds.
OPERATI NG MODES The components of the front
wi per and washer system are desi gned to work i n
concert to provi de the fol l owi ng operati ng modes:
Continuous Wipe Mode - The control knob on
the ri ght (wi per) control stal k of the mul ti -functi on
swi tch has two conti nuous wi pe posi ti ons, Low and
Hi gh. When sel ected, these swi tch posi ti ons wi l l
cause the two-speed front wi per motor to operate i n a
conti nuous l ow or hi gh speed cycl e.
KJ FRONT WIPERS/WASHERS 8R - 3
FRONT WIPERS/WASHERS (Continued)
Intermittent Wipe Mode - The control knob on
swi tch has fi ve mi nor detent i ntermi ttent wi pe posi -
ti ons. When sel ected, these swi tch posi ti ons wi l l
cause the front wi per system to operate wi th one of
fi ve del ay i nterval s between compl ete wi pe cycl es.
Mist Wipe Mode - The ri ght (wi per) control
stal k of the mul ti -functi on swi tch has a momentary
Mi st posi ti on. When sel ected, thi s swi tch posi ti on
wi l l operate the front wi pers i n a l ow speed conti nu-
ous cycl e for as l ong as the swi tch i s hel d cl osed,
then wi l l compl ete the current wi pe cycl e and park
the front wi per bl ades near the base of the wi nd-
shi el d when the swi tch i s rel eased.
Washer Mode - When the momentary front
wash posi ti on of the ri ght (wi per) control stal k of the
mul ti -functi on swi tch i s sel ected wi th the front wi per
system operati ng i n a conti nuous wi pe mode, washer
fl ui d wi l l be di spensed onto the wi ndshi el d gl ass
through the washer nozzl es for as l ong as the washer
swi tch i s hel d cl osed. When the front washer swi tch
i s actuated wi th the front wi per system operati ng i n
an i ntermi ttent wi pe mode, washer fl ui d i s sti l l di s-
pensed unti l the swi tch i s rel eased; however, the
front wi pers wi l l operate i n a l ow speed conti nuous
cycl e from the ti me the washer swi tch i s cl osed unti l
several wi pe cycl es after the swi tch i s rel eased,
before returni ng to the sel ected i ntermi ttent wi pe
mode.
Wipe-After-Wash Mode - When the momentary
front wash posi ti on of the ri ght (wi per) control stal k
of the mul ti -functi on swi tch i s sel ected wi th the front
wi per system turned Off, the i nternal ci rcui try of the
BCM provi des a wi pe-after-wash feature. When
sel ected, thi s feature wi l l operate the washer pump/
motor and the front wi pers for as l ong as the front
washer swi tch i s hel d cl osed, then provi de several
addi ti onal wi pe cycl es after the swi tch i s rel eased
before parki ng the front wi per bl ades near the base
of the wi ndshi el d.
OPERATION
The front wi per and washer system i s desi gned to
provi de the vehi cl e operator wi th a conveni ent, safe,
and rel i abl e means of mai ntai ni ng vi si bi l i ty through
the wi ndshi el d gl ass. The vari ous components of thi s
system are desi gned to convert el ectri cal energy pro-
duced by the vehi cl e el ectri cal system i nto the
mechani cal acti on of the wi per bl ades to wi pe the
outsi de surface of the gl ass, as wel l as i nto the
hydraul i c acti on of the washer system to appl y
washer fl ui d stored i n an on-board reservoi r to the
area of the gl ass to be wi ped. When combi ned, these
components provi de the means to effecti vel y mai n-
tai n cl ear vi si bi l i ty for the vehi cl e operator by remov-
i ng excess accumul ati ons of rai n, snow, bugs, mud, or
other mi nor debri s from the outsi de wi ndshi el d gl ass
surface that mi ght be encountered whi l e dri vi ng the
vehi cl e under numerous types of i ncl ement operati ng
condi ti ons.
The vehi cl e operator i ni ti ates al l front wi per and
washer system functi ons wi th the ri ght (wi per) con-
trol stal k of the mul ti -functi on swi tch that extends
from the ri ght si de of the steeri ng col umn, just bel ow
the steeri ng wheel . Rotati ng the control knob on the
end of the control stal k, sel ects the Off, Del ay, Low,
or Hi gh front wi per system operati ng modes. I n the
Del ay mode, the control knob al so al l ows the vehi cl e
operator to sel ect from one of fi ve i ntermi ttent wi pe
Del ay i nterval s. Pul l i ng the ri ght control stal k down-
wards actuates the momentary front wi per system
Mi st mode swi tch, whi l e pul l i ng the ri ght control
stal k towards the steeri ng wheel actuates the
momentary front washer system swi tch. The mul ti -
functi on swi tch provi des hard wi red resi stor mul ti -
pl exed i nputs to the Body Control Modul e (BCM) for
al l of the front wi per system functi ons, as wel l as a
separate hard wi red sense i nput to the BCM for the
front washer system functi on.
The front wi per and washer system wi l l onl y oper-
ate when the i gni ti on swi tch i s i n the Accessory or
On posi ti ons. Battery current i s di rected from a B(+)
fuse i n the Power Di stri buti on Center (PDC) to the
wi per and washer system ci rcui t breaker i n the Junc-
ti on Bl ock (JB) through a fused i gni ti on swi tch out-
put (run-acc) ci rcui t. The automati c resetti ng ci rcui t
breaker then provi des battery current through a
fused i gni ti on swi tch output (run-acc) ci rcui t to the
wi per hi gh/l ow rel ay, the wi per on/off rel ay, and the
park swi tch wi thi n the front wi per motor. A separate
fuse i n the JB provi des battery current through
another fused i gni ti on swi tch output (run-acc) ci rcui t
to the mul ti -functi on swi tch. The mul ti -functi on
swi tch ci rcui try uses thi s battery feed and a ground
ci rcui t i nput to di rectl y control the operati on and
di recti on of the reversi bl e el ectri c washer pump/mo-
tor uni t. The BCM uses l ow si de dri vers to control
front wi per system operati on by energi zi ng or de-en-
ergi zi ng the wi per hi gh/l ow and wi per on/off rel ays.
front wi per and washer system may be di agnosed
and tested usi ng conventi onal di agnosti c tool s and
procedures. However, conventi onal di agnosti c meth-
ods may not prove concl usi ve i n the di agnosi s of the
Body Control Modul e (BCM), or the i nputs to or out-
puts from the BCM that control the front wi per and
washer system operati ng modes. The most rel i abl e,
effi ci ent, and accurate means to di agnose the BCM,
or the BCM i nputs and outputs rel ated to the vari ous
front wi per and washer system operati ng modes
operati on of each of the front wi per and washer sys-
tem operati ng modes.
CONTI NUOUS WI PE MODE When the Low posi -
ti on of the control knob on the ri ght (wi per) control
stal k of the mul ti -functi on swi tch i s sel ected, the
Body Control Modul e (BCM) energi zes the wi per
on/off rel ay. Thi s di rects battery current through the
normal l y open contacts of the energi zed wi per on/off
rel ay and the normal l y cl osed contacts of the de-en-
ergi zed wi per hi gh/l ow rel ay to the l ow speed brush
of the front wi per motor, causi ng the front wi pers to
cycl e at l ow speed. When the Hi gh posi ti on of the
control knob i s sel ected, the BCM energi zes both the
wi per on/off rel ay and the wi per hi gh/l ow rel ay. Thi s
di rects battery current through the normal l y open
contacts of the energi zed wi per on/off rel ay and the
normal l y open contacts of the energi zed wi per hi gh/
l ow rel ay to the hi gh speed brush of the front wi per
motor, causi ng the front wi pers to cycl e at hi gh
speed.
When the Off posi ti on of the control knob i s
sel ected, the BCM de-energi zes both the wi per on/off
and wi per hi gh l ow rel ays, then one of two events
wi l l occur. The event that occurs depends upon the
posi ti on of the wi per bl ades on the wi ndshi el d at the
moment that the control knob Off posi ti on i s sel ected.
I f the wi per bl ades are i n the down posi ti on on the
wi ndshi el d when the Off posi ti on i s sel ected, the
park swi tch that i s i ntegral to the front wi per motor
i s cl osed to ground and the wi per motor ceases to
operate. I f the wi per bl ades are not i n the down posi -
ti on on the wi ndshi el d at the moment the Off posi -
ti on i s sel ected, the park swi tch i s cl osed to battery
current from the fused i gni ti on swi tch output (run-
acc) ci rcui t of the front wi per motor. The park swi tch
di rects thi s battery current to the l ow speed brush of
the wi per motor through the wi per park swi tch sense
ci rcui t and the normal l y cl osed contacts of the de-en-
ergi zed wi per on/off and wi per hi gh/l ow rel ays. Thi s
causes the wi per motor to conti nue runni ng at l ow
speed unti l the wi per bl ades are i n the down posi ti on
on the wi ndshi el d and the park swi tch i s agai n
cl osed to ground.
I NTERMI TTENT WI PE MODE When the control
knob on the ri ght (wi per) control stal k of the mul ti -
functi on swi tch i s moved to one of the Del ay i nterval
posi ti ons, the BCM el ectroni c i ntermi ttent wi pe l ogi c
ci rcui t responds by cal cul ati ng the correct l ength of
ti me between wi per sweeps based upon the sel ected
del ay i nterval i nput. The BCM moni tors the chang-
i ng state of the wi per motor park swi tch through a
hard wi red front wi per park swi tch sense ci rcui t
i nput. Thi s i nput al l ows the BCM to determi ne the
proper i nterval s at whi ch to energi ze and de-energi ze
the wi per on/off rel ay to operate the front wi per
motor i ntermi ttentl y for one l ow speed cycl e at a
ti me. The BCM l ogi c i s al so programmed to provi de
an i mmedi ate wi pe cycl e and begi n a new del ay
i nterval ti mi ng cycl e each ti me a shorter del ay i nter-
val i s sel ected, and to add the remai ni ng del ay ti m-
i ng i nterval to the new del ay i nterval ti mi ng before
the next wi pe cycl e occurs each ti me a l onger del ay
i nterval i s sel ected.
MI ST WI PE MODE When the ri ght (wi per) control
stal k of the mul ti -functi on swi tch i s moved to the
momentary Mi st posi ti on, the BCM energi zes the
wi per on/off rel ay for as l ong as the Mi st swi tch i s
hel d cl osed, then de-energi zes the rel ay when the
state of the Mi st swi tch i nput changes to open. The
BCM can operate the front wi per motor i n thi s mode
for onl y one l ow speed cycl e at a ti me, or for an
i ndefi ni te number of sequenti al l ow speed cycl es,
dependi ng upon how l ong the Mi st swi tch i s hel d
cl osed.
WASH MODE When the ri ght (wi per) control stal k
of the mul ti -functi on swi tch i s moved to the momen-
tary front Wash posi ti on whi l e the control knob i s i n
the Low or Hi gh posi ti ons, the ci rcui try wi thi n the
swi tch di rects battery current and ground to the
washer pump/motor uni t. Thi s wi l l cause the washer
pump/motor uni t to be energi zed for as l ong as the
front Wash swi tch i s hel d cl osed, and to de-energi ze
when the front Wash swi tch i s rel eased. When the
ri ght (wi per) control stal k of the mul ti -functi on
swi tch i s moved to the momentary front Wash posi -
ti on whi l e the control knob i s i n one of the Del ay
i nterval posi ti ons, the front washer pump/motor oper-
ati on i s the same. However, the BCM energi zes the
wi per on/off rel ay to overri de the sel ected del ay i nter-
val and operate the front wi per motor i n a conti nu-
ous l ow speed mode for as l ong as the front Wash
swi tch i s hel d cl osed, then de-energi zes the rel ay and
reverts to the sel ected del ay mode i nterval several
wi pe cycl es after the front Wash swi tch i s rel eased.
The BCM detects the front Wash swi tch state
through a hard wi red washer pump dri ver ci rcui t
i nput from the mul ti -functi on swi tch.
WI PE-AFTER-WASH MODE When the ri ght
(wi per) control stal k of the mul ti -functi on swi tch i s
moved to the momentary front Wash posi ti on whi l e
the control knob i s i n the Off posi ti on, the BCM
detects that swi tch state through a hard wi red
washer pump dri ver ci rcui t i nput from the mul ti -
functi on swi tch. The BCM responds to thi s i nput by
energi zi ng the wi per on/off rel ay for as l ong as the
Wash swi tch i s hel d cl osed, then de-energi zes the
rel ay several wi pe cycl es after the front Wash swi tch
i s rel eased. The BCM moni tors the changi ng state of
the wi per motor park swi tch through a hard wi red
front wi per park swi tch sense ci rcui t i nput. Thi s
i nput al l ows the BCM to count the number of wi pe
cycl es that occur after the front Wash swi tch state
changes to open, and to determi ne the proper i nter-
val at whi ch to de-energi ze the wi per on/off rel ay to
compl ete the wi pe-after-wash mode cycl e.
DIAGNOSIS AND TESTING - FRONT WIPER &
WASHER SYSTEM
FRONT WIPER SYSTEM
I f the front wi per motor operates, but the wi pers
do not move on the wi ndshi el d, repl ace the faul ty
front wi per modul e. I f the wi pers operate, but chat-
ter, l i ft, or do not cl ear the gl ass, cl ean and i nspect
the front wi per system components as requi red.
(Refer to 8 - ELECTRI CAL/FRONT WI PERS/WASH-
ERS - I NSPECTI ON) and (Refer to 8 - ELECTRI -
CAL/FRONT WI PERS/WASHERS - CLEANI NG). For
di agnosi s and testi ng of the mul ti -functi on swi tch
EXTERI OR/MULTI -FUNCTI ON SWI TCH - DI AG-
NOSI S AND TESTI NG). Refer to the appropri ate
and grounds.
front wi per and washer system may be di agnosed
and tested usi ng conventi onal di agnosti c tool s and
procedures. However, conventi onal di agnosti c meth-
ods may not prove concl usi ve i n the di agnosi s of the
Body Control Modul e (BCM), or the i nputs to or out-
puts from the BCM that control the vari ous front
wi per and washer system operati ng modes. The most
the BCM, or the BCM i nputs and outputs rel ated to
the vari ous front wi per and washer system operati ng
modes requi res the use of a DRBI I I scan tool . Refer
SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
FRONT WASHER SYSTEM
The di agnosi s found here addresses an el ectri cal l y
i noperati ve front washer system. I f the washer
pump/motor operates, but no washer fl ui d i s emi tted
from the front washer nozzl es, be certai n to check
the fl ui d l evel i n the reservoi r. Al so i nspect the front
washer system components as requi red. (Refer to 8 -
ELECTRI CAL/FRONT WI PERS/WASHERS -
I NSPECTI ON). Refer to the appropri ate wi ri ng i nfor-
Turn the control knob on the ri ght (wi per) control
stal k of the mul ti -functi on swi tch to the On posi ti on.
Check whether the front wi per system i s operati ng.
I f OK, go to Step 2. I f not OK, test and repai r the
front wi per system before conti nui ng wi th these
tests. Refer to FRONT WI PER SYSTEM .
(2) Turn the control ri ng on the ri ght (wi per) con-
trol stal k of the mul ti -functi on swi tch to the rear
Wash posi ti on. Check whether the rear washer sys-
tem i s operati ng. I f OK, test the mul ti -functi on
swi tch. (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR/MULTI -FUNCTI ON SWI TCH -
DI AGNOSI S AND TESTI NG). I f the mul ti -functi on
swi tch tests OK, go to Step 3. I f the mul ti -functi on
swi tch does not test OK, repl ace the faul ty swi tch.
Di sconnect the headl amp and dash wi re harness con-
nector for the washer pump/motor uni t from the
pump/motor uni t connector receptacl e. Check for con-
ti nui ty between the washer pump dri ver ci rcui t cav-
for the washer pump/motor uni t and a good ground.
There shoul d be no conti nui ty. I f OK, go to Step 4. I f
not OK, repai r the shorted washer pump dri ver ci r-
cui t between the washer pump/motor uni t and the
mul ti -functi on swi tch as requi red.
(4) Check for conti nui ty between the washer pump
dri ver ci rcui t cavi ti es of the headl amp and dash wi re
harness connector for the washer pump/motor uni t
and the i nstrument panel wi re harness connector for
the mul ti -functi on swi tch (Connector C-2). There
repai r the open washer pump dri ver ci rcui t between
the washer pump/motor uni t and the mul ti -functi on
swi tch as requi red.
sense ci rcui t cavi ty of the headl amp and dash wi re
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 6. I f not OK, repai r the shorted
washer pump sense ci rcui t between the washer
pump/motor uni t and the mul ti -functi on swi tch as
requi red.
sense ci rcui t cavi ti es of the headl amp and dash wi re
shoul d be conti nui ty. I f OK, repl ace the faul ty washer
pump/motor uni t. I f not OK, repai r the open washer
pump sense ci rcui t between the washer pump/motor
uni t and the mul ti -functi on swi tch as requi red.
CLEANING - FRONT WIPER & WASHER
SYSTEM
FRONT WIPER SYSTEM
The squeegees of wi per bl ades exposed to the el e-
ments for a l ong ti me tend to l ose thei r wi pi ng effec-
ti veness. Peri odi c cl eani ng of the squeegees i s
suggested to remove any deposi ts of sal t or road fi l m.
The wi per bl ades, arms, and wi ndshi el d gl ass shoul d
onl y be cl eaned usi ng a sponge or soft cl oth and
wi ndshi el d washer fl ui d, a mi l d detergent, or a non-
abrasi ve cl eaner. I f the wi per bl ades conti nue to
l eave streaks, smears, hazi ng, or beadi ng on the
gl ass after thorough cl eani ng of the squeegees and
the gl ass, the enti re wi per bl ade assembl y must be
repl aced.
CAUTION: Protect the rubber squeegees of the
wiper blades from any petroleum-based cleaners,
solvents, or contaminants. These products can rap-
idly deteriorate the rubber squeegees.
FRONT WASHER SYSTEM
I f the washer system i s contami nated wi th forei gn
materi al , drai n the washer reservoi r by removi ng the
washer pump/motor from the reservoi r. Cl ean forei gn
materi al from the i nsi de of the washer pump/motor
i nl et fi l ter screen and the washer reservoi r usi ng
cl ean washer fl ui d, a mi l d detergent, or a non-abra-
si ve cl eaner. Fl ush forei gn materi al from the washer
system pl umbi ng by fi rst di sconnecti ng the washer
hoses from the washer nozzl es, then runni ng the
washer pump/motor to run cl ean washer fl ui d or
water through the system. Pl ugged or restri cted
washer nozzl es shoul d be careful l y back-fl ushed
usi ng compressed ai r. I f the washer nozzl e obstruc-
ti on cannot be cl eared, repl ace the washer nozzl e.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegees of the wiper blades.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - FRONT WIPER & WASHER
SYSTEM
FRONT WIPER SYSTEM
The front wi per bl ades and wi per arms shoul d be
i nspected peri odi cal l y, not just when wi per perfor-
mance probl ems are experi enced. Thi s i nspecti on
shoul d i ncl ude the fol l owi ng poi nts:
(1) I nspect the wi per arms for any i ndi cati ons of
damage, or contami nati on. I f the wi per arms are con-
tami nated wi th any forei gn materi al , cl ean them as
requi red. (Refer to 8 - ELECTRI CAL/FRONT WI P-
ERS/WASHERS - CLEANI NG). I f a wi per arm i s
damaged or corrosi on i s evi dent, repl ace the wi per
arm wi th a new uni t. Do not attempt to repai r a
wi per arm that i s damaged or corroded.
(2) Careful l y l i ft the wi per bl ade off of the gl ass.
Note the acti on of the wi per arm hi nge. The wi per
arm shoul d pi vot freel y at the hi nge, but wi th no l at-
eral l ooseness evi dent. I f there i s any bi ndi ng evi dent
i n the wi per arm hi nge, or there i s evi dent l ateral
pl ay i n the wi per arm hi nge, repl ace the wi per arm.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(3) Once proper hi nge acti on of the wi per arm i s
confi rmed, check the hi nge for proper spri ng tensi on.
Remove the wi per bl ade from the wi per arm. Ei ther
pl ace a smal l postal scal e between the bl ade end of
the wi per arm and the gl ass, or careful l y l i ft the
bl ade end of the arm away from the gl ass usi ng a
smal l fi sh scal e. Compare the scal e readi ngs between
the ri ght and l eft wi per arms. Repl ace a wi per arm i f
i t has comparati vel y l ower spri ng tensi on, as evi -
denced by a l ower scal e readi ng.
(4) I nspect the wi per bl ades and squeegees for any
i ndi cati ons of damage, contami nati on, or rubber dete-
ri orati on (Fi g. 2). I f the wi per bl ades or squeegees
are contami nated wi th any forei gn materi al , cl ean
them and the gl ass as requi red. (Refer to 8 - ELEC-
TRI CAL/FRONT WI PERS/WASHERS - CLEANI NG).
After cl eani ng the wi per bl ade and the gl ass, i f the
wi per bl ade sti l l fai l s to cl ear the gl ass wi thout
smeari ng, streaki ng, chatteri ng, hazi ng, or beadi ng,
repl ace the wi per bl ade. Al so, i f a wi per bl ade i s
damaged or the squeegee rubber i s damaged or dete-
ri orated, repl ace the wi per bl ade wi th a new uni t. Do
not attempt to repai r a wi per bl ade that i s damaged.
FRONT WASHER SYSTEM
The washer system components shoul d be
i nspected peri odi cal l y, not just when washer perfor-
(1) Check for i ce or other forei gn materi al i n the
washer reservoi r. I f contami nated, cl ean and fl ush
the washer system. (Refer to 8 - ELECTRI CAL/
FRONT WI PERS/WASHERS - CLEANI NG).
(2) I nspect the washer pl umbi ng for pi nched, l eak-
i ng, deteri orated, or i ncorrectl y routed hoses and
damaged or di sconnected hose fi tti ngs. Repl ace dam-
aged or deteri orated hoses and hose fi tti ngs. Leaki ng
washer hoses can someti mes be repai red by cutti ng
the hose at the l eak and spl i ci ng i t back together
usi ng an i n-l i ne connector fi tti ng. Si mi l arl y, secti ons
of deteri orated hose can be cut out and repl aced by
spl i ci ng i n new secti ons of hose usi ng i n-l i ne connec-
tor fi tti ngs. Whenever routi ng a washer hose or a
wi re harness contai ni ng a washer hose, i t must be
routed away from hot, sharp, or movi ng parts. Al so,
sharp bends that mi ght pi nch the washer hose must
be avoi ded.
FRONT CHECK VALVE
DESCRIPTION
A front washer system check val ve (Fi g. 3) i s stan-
dard equi pment on thi s model . The front check val ve
i s i ntegral to the front washer nozzl e pl umbi ng wye
fi tti ng l ocated i n the cowl pl enum area beneath on
the back of the cowl pl enum cover/gri l l e panel near
the base of the wi ndshi el d. The check val ve consi sts
of a mol ded pl asti c body wi th a round center secti on.
An arrow formati on mol ded i nto the center secti on of
the val ve body i ndi cates the di recti on of fl ow through
the val ve. Three barbed hose ni ppl es are formed i n a
wye confi gurati on on the outsi de ci rcumference of the
center secti on of the val ve body. The front check
val ve cannot be adjusted or repai red and, i f faul ty or
damaged, i t must be repl aced.
Fig. 2 Wiper Blade Inspection
1 - WORN OR UNEVEN EDGES
2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
OPERATION
The front check val ve provi des more than one func-
ti on i n thi s appl i cati on. I t serves as a wye connector
fi tti ng between the cowl gri l l e panel and washer noz-
zl e secti ons of the front washer suppl y hose. I t al so
prevents washer fl ui d from drai ni ng out of the front
washer suppl y hoses back to the washer reservoi r.
Thi s drai n-back woul d resul t i n a l engthy del ay when
the front washer swi tch i s actuated unti l washer
fl ui d was di spensed through the front washer noz-
zl es, because the washer pump woul d have to refi l l
the front washer pl umbi ng from the reservoi r to the
nozzl es. Fi nal l y, the front check val ve prevents
washer fl ui d from si phoni ng through the front
washer nozzl es after the front washer system i s
turned Off.
Wi thi n the check val ve body, a smal l check val ve i s
hel d i n pl ace agai nst a seat by a smal l coi l ed spri ng
to restri ct fl ow through the uni t unti l the val ve i s
unseated by a predetermi ned i nl et fl ui d pressure.
When the washer pump pressuri zes and pumps
washer fl ui d from the reservoi r through the front
washer pl umbi ng, the fl ui d pressure overri des the
spri ng pressure appl i ed to the check val ve and
unseats the val ve, al l owi ng washer fl ui d to fl ow
toward the front washer nozzl es. When the washer
pump stops operati ng, spri ng pressure seats the
check val ve and fl ui d fl ow i n ei ther di recti on wi thi n
the front washer pl umbi ng i s prevented.
REMOVAL
(2) Remove both front wi per arms from the wi per
pi vots. (Refer to 8 - ELECTRI CAL/WI PERS/WASH-
ERS - FRONT/FRONT WI PER ARM - REMOVAL).
(3) Remove the cowl pl enum cover/gri l l e panel
from over the cowl pl enum. (Refer to 23 - BODY/EX-
TERI OR/COWL GRI LLE - REMOVAL).
(4) From the undersi de of the cowl pl enum cover/
gri l l e panel , di sconnect the cowl pl enum and washer
nozzl e hoses from the three barbed ni ppl es of the
front check val ve (Fi g. 4).
(5) Remove the front check val ve from the under-
si de of the cowl pl enum cover/gri l l e panel .
INSTALLATION
(1) Posi ti on the front check val ve to the undersi de
of the cowl pl enum cover/gri l l e panel (Fi g. 4). Be cer-
tai n that the fl ow di recti on arrow mol ded i nto the
front check val ve body i s ori ented towards the front
washer nozzl es.
gri l l e panel , reconnect the cowl pl enum and washer
nozzl e hoses to the three barbed ni ppl es of the front
check val ve.
(3) Rei nstal l the cowl pl enum cover/gri l l e panel
over the cowl pl enum. (Refer to 23 - BODY/EXTERI -
OR/COWL GRI LLE - I NSTALLATI ON).
(4) Rei nstal l both front wi per arms onto the wi per
pi vots. (Refer to 8 - ELECTRI CAL/FRONT WI PERS/
WASHERS/FRONT WI PER ARM - I NSTALLATI ON).
Fig. 3 Front Check Valve
1 - INLET NIPPLE
2 - FRONT CHECK VALVE
3 - OUTLET NIPPLE (2)
4 - FLOW DIRECTION ARROW
Fig. 4 Front Check Valve Remove/Install
1 - WASHER NOZZLE HOSE (RIGHT)
2 - FRONT CHECK VALVE
3 - COWL PLENUM WASHER HOSE
4 - ROUTING CLIP
5 - COWL GRILLE COVER (UNDERSIDE)
6 - WASHER NOZZLE HOSE (LEFT)
FRONT CHECK VALVE (Continued)
FRONT WASHER HOSES/
TUBES
DESCRIPTION
The front washer pl umbi ng consi sts of a smal l
di ameter rubber hose that i s routed from the barbed
outl et ni ppl e of the reversi bl e el ectri c washer pump/
motor uni t on the washer reservoi r through a trough
mol ded i nto the reservoi r forward of the washer
pump and al ong the reservoi r fi l l er neck i nto the
engi ne compartment (Fi g. 5). Wi thi n the engi ne com-
partment, the front washer hose i s routed si de by
si de wi th the engi ne compartment rear washer hose
al ong the top of the ri ght front fender wheel house to
the dash panel . Mol ded pl asti c routi ng cl i ps secure
the hoses to the headl amp and dash wi re harness i n
the engi ne compartment (Fi g. 6).
The front washer hose i s connected i n the engi ne
compartment to the barbed ni ppl e of a mol ded pl asti c
i n-l i ne fi tti ng i nstal l ed through a rubber grommet i n
a hol e i n the ri ght si de of the dash pl enum panel .
The barbed ni ppl e of the i n-l i ne fi tti ng protrudes
through the other si de of the rubber grommet i nto
the cowl pl enum area, where the cowl pl enum
washer hose joi ns the front washer hose to the front
check val ve/wye fi tti ng. The cowl pl enum washer
hose i s routed through i ntegral routi ng cl i ps on the
undersi de of the cowl pl enum cover/gri l l e panel to the
mol ded pl asti c wye fi tti ng. The cowl pl enum washer
hose i s connected to one ni ppl e on the wye fi tti ng and
the two washer nozzl e hoses are connected to the
other two wye fi tti ng ni ppl es. The washer nozzl e
hoses are then routed al ong the undersi de of the cowl
pl enum cover/gri l l e panel to the two front washer
nozzl es.
Washer hose i s avai l abl e for servi ce onl y as rol l
stock, whi ch must then be cut to l ength. The mol ded
pl asti c washer hose fi tti ngs cannot be repai red. I f
these fi tti ngs are faul ty or damaged, they must be
repl aced.
OPERATION
Washer fl ui d i n the washer reservoi r i s pressuri zed
and fed by the washer pump/motor through the front
washer system pl umbi ng and fi tti ngs to the two front
washer nozzl es. Whenever routi ng the washer hose
or a wi re harness contai ni ng a washer hose, i t must
be routed away from hot, sharp, or movi ng parts;
and, sharp bends that mi ght pi nch the hose must be
avoi ded.
Fig. 5 Reservoir Washer Hose
1 - WASHER RESERVOIR
2 - RIGHT FRONT WHEEL HOUSE
3 - WASHER PUMP
4 - FRONT WASHER HOSE
5 - RESERVOIR REAR WASHER HOSE
6 - WASHER FLUID LEVEL SWITCH
Fig. 6 Engine Compartment Washer Hose
1 - RESERVOIR FILLER CAP
2 - ROUTING CLIP (3)
3 - ROUTING CLIP (1)
5 - IN-LINE HOSE FITTING
6 - PLENUM PANEL GROMMET
7 - DASH PANEL GROMMET
8 - REAR WASHER HEADLINER HOSE
FRONT WASHER NOZZLE
DESCRIPTION
The two front washer nozzl es have i ntegral snap
features and an anti -rotati on tab that secure them i n
dedi cated hol es i n the cowl pl enum cover/gri l l e panel
l ocated near the base of the wi ndshi el d (Fi g. 7). The
domed upper surface of the washer nozzl e i s vi si bl e
on the top of the pl enum cover/gri l l e panel , and the
nozzl e ori fi ce i s ori ented towards the wi ndshi el d
gl ass. The washer pl umbi ng fi tti ngs for the washer
nozzl es are conceal ed beneath the cowl pl enum cover/
gri l l e panel . These fl ui di c washer nozzl es are con-
structed of mol ded pl asti c. The cowl pl enum cover/
gri l l e panel must be removed from the vehi cl e to
access the nozzl es for servi ce. The washer nozzl es
cannot be adjusted or repai red. I f faul ty or damaged,
they must be repl aced.
OPERATION
The two front washer nozzl es are desi gned to di s-
pense washer fl ui d i nto the wi per pattern area on the
outsi de of the wi ndshi el d gl ass. Pressuri zed washer
fl ui d i s fed to each nozzl e from the washer reservoi r
by the washer pump/motor uni t through a si ngl e
hose, whi ch i s attached to a barbed ni ppl e on each
front washer nozzl e bel ow the cowl pl enum cover/
gri l l e panel . The washer nozzl es i ncorporate a fl ui di c
desi gn, whi ch causes the nozzl e to emi t the pressur-
i zed washer fl ui d as an osci l l ati ng stream to more
effecti vel y cover a l arger area of the gl ass area to be
cl eaned.
REMOVAL
ERS/FRONT WI PER ARM - REMOVAL).
gri l l e panel , di sconnect the washer nozzl e hose from
the barbed ni ppl e of the front washer nozzl e (Fi g. 8).
(5) From the undersi de of the cowl gri l l e cover,
rel ease the i ntegral snap features of the front washer
nozzl e and push the nozzl e out through the mounti ng
hol e toward the top si de of the cowl pl enum cover/gri l l e
panel .
(6) Remove the front washer nozzl e from the top of
the cowl pl enum cover/gri l l e panel .
INSTALLATION
(1) From the top of the cowl pl enum cover/gri l l e
panel , posi ti on the ni ppl e end of the front washer
nozzl e through the mounti ng hol e and engage the
anti -rotati on tab of the ni ppl e i nto the anti -rotati on
notch i n the mounti ng hol e.
washer nozzl e unti l the i ntegral snap features l ock
i nto pl ace on the undersi de of the cowl pl enum cover/
gri l l e panel .
(3) From the undersi de of the cowl gri l l e cover,
reconnect the washer hose to the barbed ni ppl e of the
front washer nozzl e (Fi g. 8).
(4) Rei nstal l the washer hose for the front washer
nozzl e i nto i ts routi ng cl i ps on the undersi de of the
cowl pl enum cover/gri l l e panel .
Fig. 7 Front Washer Nozzle
1 - NIPPLE
2 - ANTI-ROTATION TAB
3 - FRONT WASHER NOZZLE
4 - ORIFICE
5 - LATCH (2)
Fig. 8 Front Washer Nozzle Remove/Install
1 - COWL GRILLE COVER (UNDERSIDE)
2 - FRONT WASHER NOZZLE
3 - WASHER NOZZLE HOSE
FRONT WIPER ARM
DESCRIPTION
The front wi per arms are the ri gi d members l ocated
between the wi per pi vots that protrude from the cowl
pl enum cover/gri l l e panel near the base of the wi nd-
shi el d and the wi per bl ades on the wi ndshi el d gl ass
(Fi g. 9). These wi per arms feature an over-center hi nge
that al l ows easy access to the wi ndshi el d gl ass for
cl eani ng. The wi per arm has a di e cast metal pi vot end
wi th a l arge tapered mounti ng hol e at one end. A
mol ded bl ack pl asti c cap fi ts over the wi per arm retai n-
i ng nut to conceal the nut and thi s mounti ng hol e fol -
l owi ng wi per arm i nstal l ati on. The wi de end of a
tapered, stamped steel channel hi nges on and i s secured
wi th a hi nge pi n to the bl ade end of the wi per arm pi vot
end. One end of a l ong, ri gi d, stamped steel strap, wi th
a smal l hol e near i ts pi vot end, i s ri veted and cri mped
wi thi n the narrow end of the stamped steel channel .
The ti p of the wi per bl ade end of thi s strap i s bent back
under i tsel f to form a smal l hook. Conceal ed wi thi n the
stamped steel channel , one end of a l ong spri ng i s
engaged wi th a wi re hook on the undersi de of the di e
cast pi vot end, whi l e the other end of the spri ng i s
hooked through the smal l hol e i n the steel strap. The
enti re wi per arm has a sati n bl ack fi ni sh appl i ed to al l
of i ts vi si bl e surfaces.
A wi per arm cannot be adjusted or repai red. I f
damaged or faul ty, the enti re wi per arm uni t must be
repl aced.
OPERATION
The front wi per arms are desi gned to mechani cal l y
transmi t the moti on from the wi per pi vots to the wi per
bl ades. The wi per arm must be properl y i ndexed to the
wi per pi vot i n order to mai ntai n the proper wi per bl ade
travel on the gl ass. The tapered mounti ng hol e i n the
wi per arm pi vot end i nterl ocks wi th the serrati ons on
the tapered outer ci rcumference of the wi per pi vot shaft,
al l owi ng posi ti ve engagement and fi ni te adjustment of
thi s connecti on. The mounti ng nut l ocks the wi per arm
to the threaded stud of the wi per pi vot shaft. The
spri ng-l oaded wi per arm hi nge control s the down-force
appl i ed through the ti p of the wi per arm to the wi per
bl ade on the gl ass. The hook formati on on the ti p of the
wi per arm provi des a cradl e for securi ng and l atchi ng
the wi per bl ade pi vot bl ock to the wi per arm.
REMOVAL
(1) Li ft the front wi per arm to i ts over-center posi -
ti on to hol d the wi per bl ade off of the gl ass and
rel i eve the spri ng tensi on on the wi per arm to wi per
pi vot shaft connecti on.
(2) Careful l y pry the pl asti c nut cap off of the
pi vot end of the wi per arm (Fi g. 10).
(3) Remove the nut that secures the wi per arm to
the wi per pi vot shaft.
Fig. 9 Front Wiper Arm
1 - HOOK
2 - STRAP
3 - CHANNEL
4 - PIVOT END
5 - PIVOT HOLE
6 - HINGE PIN
7 - TENSION SPRING
Fig. 10 Front Wiper Arm Remove/Install
1 - FRONT WIPER BLADE & ARM (2)
2 - CAP (2)
3 - NUT (2)
4 - PIVOT SHAFT (2)
5 - T-SHAPED ALIGNMENT MARK (2)
FRONT WASHER NOZZLE (Continued)
(4) I f necessary, use a sui tabl e battery termi nal
pul l er to di sengage the wi per arm from the wi per
pi vot shaft (Fi g. 11).
(5) Remove the front wi per arm pi vot end from the
wi per pi vot shaft.
INSTALLATION
NOTE: Be certain that the wiper motor is in the park
position before attempting to install the front wiper
arms. Turn the ignition switch to the On position
and move the control knob on the right (wiper) con-
trol stalk of the multi-function switch to its Off posi-
tion. If the wiper pivots move, wait until they stop
moving, then turn the ignition switch back to the
Off position. The wiper motor is now in its park
position.
(1) The front wi per arms must be i ndexed to the
wi per pi vot shafts wi th the wi per motor i n the park
posi ti on to be properl y i nstal l ed. Posi ti on the front
wi per arm pi vot ends onto the wi per pi vot shafts so
that the ti p of the wi per bl ade i s al i gned wi th the
T-shaped wi per al i gnment l i nes l ocated i n the l ower
edge of the wi ndshi el d gl ass (Fi g. 10).
(2) Once the wi per bl ade i s al i gned, l i ft the wi per
arm away from the wi ndshi el d sl i ghtl y to rel i eve the
spri ng tensi on on the pi vot end and push the pi vot
hol e on the end of the wi per arm down fi rml y and
evenl y over the wi per pi vot shaft.
wi per arm to the wi per pi vot shaft. Ti ghten the nut
to 24 Nm (18 ft. l bs.).
(4) Wet the wi ndshi el d gl ass, then operate the
front wi pers. Turn the front wi pers Off, then check
for the correct wi per arm posi ti on and readjust as
requi red.
(5) Rei nstal l the pl asti c nut cap onto the wi per
arm pi vot nut.
FRONT WIPER BLADE
DESCRIPTION
Each front wi per bl ade i s secured by an i ntegral
l atchi ng pi vot bl ock to the hook formati on on the ti p
of the front wi per arms, and rests on the gl ass near
the base of the wi ndshi el d when the wi pers are not
i n operati on (Fi g. 12). The wi per bl ade consi sts of the
fol l owi ng components:
Superstructure - The superstructure i ncl udes
several stamped steel bri dges and l i nks wi th cl aw
formati ons that gri p the wi per bl ade el ement. Al so
i ncl uded i n thi s uni t i s the l atchi ng, mol ded pl asti c
pi vot bl ock that secures the superstructure to the
wi per arm. The dri ver si de front wi per bl ade has an
addi ti onal mol ded bl ack pl asti c ai rfoi l secured to the
superstructure, whi ch i s ori ented toward the base of
the wi ndshi el d when the front wi pers are i n thei r
parked posi ti on. Al l of the metal components of the
wi per bl ade have a sati n bl ack fi ni sh appl i ed.
Element - The wi per el ement or squeegee i s the
resi l i ent rubber member of the wi per bl ade that con-
tacts the gl ass.
Flexor - The fl exor i s a ri gi d metal component
runni ng al ong the l ength of each si de of the wi per
Fig. 11 Wiper Arm Puller - Typical
1 - WIPER ARM
2 - WIPER PIVOT SHAFT
Fig. 12 Front Wiper Blade
1 - SUPERSTRUCTURE
2 - ELEMENT
3 - PIVOT BLOCK
4 - RELEASE TAB
5 - PIVOT PIN
6 - CLAWS
7 - FLEXOR
FRONT WIPER ARM (Continued)
el ement where i t i s gri pped by the cl aws of the
superstructure.
Al l model s have two 47.50 centi meter (18.70 i nch)
l ong front wi per bl ades wi th non-repl aceabl e rubber
el ements (squeegees). The wi per bl ades cannot be
adjusted or repai red. I f faul ty, worn, or damaged the
enti re wi per bl ade uni t must be repl aced.
OPERATION
The wi per bl ades are moved back and forth across
the gl ass by the wi per arms when the wi pers are
bei ng operated. The wi per bl ade superstructure i s
the fl exi bl e frame that gri ps the wi per bl ade el ement
and evenl y di stri butes the force of the spri ng-l oaded
wi per arm al ong the l ength of the el ement. The com-
bi nati on of the wi per arm force and the fl exi bi l i ty of
the superstructure makes the el ement conform to
and mai ntai n proper contact wi th the gl ass, even as
the bl ade i s moved over the vari ed curvature that
may be encountered across the gl ass surface. The
wi per el ement fl exor provi des the cl aws of the bl ade
superstructure wi th a ri gi d, yet fl exi bl e component
on the el ement whi ch can be gri pped. The rubber el e-
ment i s desi gned to be sti ff enough to mai ntai n an
even cl eani ng edge as i t i s drawn across the gl ass,
yet resi l i ent enough to conform to the gl ass surface
and fl i p from one cl eani ng edge to the other each
ti me the wi per bl ade changes di recti ons. The ai rfoi l
used on the dri ver si de wi per bl ade i s desi gned to
reduce the l i fti ng effect caused by ai r movi ng over
the vehi cl e at hi gher hi ghway speeds.
REMOVAL
NOTE: The notched end of the wiper element flexor
should always be oriented towards the end of the
wiper blade that is nearest to the wiper pivot.
(1) Li ft the front wi per arm to rai se the wi per
bl ade and el ement off of the gl ass, unti l the wi per
arm hi nge i s i n i ts over-center posi ti on.
(2) To remove the wi per bl ade from the wi per arm,
depress the pi vot bl ock l atch rel ease tab under the
ti p of the arm and sl i de the bl ade away from the ti p
towards the pi vot end of the arm far enough to di s-
engage the pi vot bl ock from the hook formati on on
the end of the arm (Fi g. 13).
(3) Extract the hook formati on on the ti p of the
wi per arm through the openi ng i n the wi per bl ade
superstructure just ahead of the wi per bl ade pi vot
bl ock/l atch uni t.
(4) Gentl y l ower the ti p of the wi per arm onto the
gl ass.
INSTALLATION
wiper blade that is nearest to the wiper pivot.
(1) Li ft the front wi per arm off of the wi ndshi el d
gl ass, unti l the wi per arm hi nge i s i n i ts over-center
posi ti on.
(2) Posi ti on the front wi per bl ade near the hook
formati on on the ti p of the arm wi th the notched end
of the wi per el ement fl exor ori ented towards the end
of the wi per arm that i s nearest to the wi per pi vot.
(3) I nsert the hook formati on on the ti p of the
wi per arm through the openi ng i n the wi per bl ade
superstructure ahead of the wi per bl ade pi vot bl ock/
l atch uni t far enough to engage the pi vot bl ock i nto
the hook (Fi g. 13).
(4) Sl i de the wi per bl ade pi vot bl ock/l atch up i nto
the hook formati on on the ti p of the wi per arm unti l
the l atch rel ease tab snaps i nto i ts l ocked posi ti on.
Latch engagement wi l l be accompani ed by an audi bl e
cl i ck.
(5) Gentl y l ower the wi per bl ade onto the gl ass.
Fig. 13 Front Wiper Blade Remove/Install
1 - SUPERSTRUCTURE
2 - WIPER ARM
3 - PIVOT BLOCK
4 - RELEASE TAB
5 - HOOK
6 - ELEMENT
FRONT WIPER BLADE (Continued)
FRONT WIPER MODULE
DESCRIPTION
The front wi per modul e bracket i s secured wi th
two nuts bel ow the wi per motor through rubber i nsu-
l ators to two wel d studs on the bottom of the cowl
pl enum panel beneath the cowl pl enum cover/gri l l e
panel (Fi g. 14). Two screws secure the top of the
modul e bracket to the cowl pl enum panel through
rubber i nsul ators l ocated on the outboard end of each
pi vot bracket. The ends of the wi per pi vot shafts that
protrude through dedi cated openi ngs i n the cowl pl e-
num cover/gri l l e panel to dri ve the wi per arms and
bl ades are the onl y vi si bl e components of the front
wi per modul e. The front wi per modul e consi sts of the
fol l owi ng major components:
Bracket - The front wi per modul e bracket con-
si sts of a l ong tubul ar steel mai n member that has a
di e cast pi vot bracket formati on near each end where
the two wi per pi vots are secured. A stamped steel
mounti ng pl ate for the wi per motor i s secured wi th
wel ds near the center of the mai n member. A short
stamped steel tab that extends l ateral l y from one
si de of the mounti ng pl ate provi des a mounti ng l oca-
ti on for the wi per motor pi gtai l wi re connector.
Crank Arm - The front wi per motor crank arm
i s a stamped steel uni t wi th a sl otted hol e on the
dri ven end that i s secured to the wi per motor output
shaft wi th a nut, and has a bal l stud secured to the
dri ve end.
Linkage - Two stamped steel dri ve l i nks con-
nect the wi per motor crank arm to the wi per pi vot
l ever arms. The ri ght si de dri ve l i nk has a pl asti c
socket-type bushi ng on each end. The l eft si de dri ve
l i nk has a pl asti c socket-type bushi ng on one end,
and a pl asti c sl eeve-type bushi ng on the other end.
The socket-type bushi ng on one end of each dri ve
l i nk i s snap-fi t over the bal l stud on the l ever arm of
i ts respecti ve pi vot. The l eft si de dri ve l i nk sl eeve-
type bushi ng end i s then fi t over the motor crank
arm bal l stud, and the other socket-type bushi ng of
the ri ght si de dri ve l i nk i s snap-fi t over the exposed
end of the wi per motor crank arm bal l stud.
Motor - The front wi per motor i s secured wi th
three screws to the motor mounti ng pl ate near the
center of the wi per modul e bracket. The wi per motor
output shaft passes through a hol e i n the modul e
bracket, where a nut secures the wi per motor crank
arm to the motor output shaft. The two-speed perma-
nent magnet wi per motor features an i ntegral trans-
mi ssi on, an i nternal park swi tch, and an i nternal
automati c resetti ng ci rcui t breaker. A mol ded pl asti c
shi el d covers the top of the motor.
Pivots - The two front wi per pi vots are secured
wi thi n the di e cast pi vot brackets on the outboard
ends of the wi per modul e mai n member. The l ever
arms that extend from the center of the pi vot shafts
each have a bal l stud on thei r end. The upper end of
each pi vot shaft where the wi per arms wi l l be fas-
tened each i s tapered and serrated wi th a threaded
stud formati on at the ti p. The l ower ends of the pi vot
shafts are i nstal l ed through l ubri cated bushi ngs i n
the pi vot brackets and are secured wi th snap ri ngs. A
mol ded pl asti c shi el d covers each pi vot shaft where i t
enters the pi vot bracket.
The front wi per modul e cannot be adjusted or
repai red. I f any component of the modul e i s faul ty or
damaged, the enti re front wi per modul e uni t must be
repl aced.
OPERATION
The front wi per modul e operati on i s control l ed by
the battery current i nputs recei ved by the wi per
motor from the wi per on/off and wi per hi gh/l ow
rel ays. The wi per motor speed i s control l ed by cur-
rent fl ow to ei ther the l ow speed or the hi gh speed
set of brushes. The park swi tch i s a si ngl e pol e, si n-
gl e throw, momentary swi tch wi thi n the wi per motor
that i s mechani cal l y actuated by the wi per motor
transmi ssi on components. The park swi tch al ter-
natel y cl oses the wi per park swi tch sense ci rcui t to
ground or to battery current, dependi ng upon the
posi ti on of the wi pers on the gl ass. Thi s feature
Fig. 14 Front Wiper Module
1 - PIVOT BRACKET (2)
2 - MOTOR COVER
3 - MOTOR BRACKET
4 - LINKAGE BUSHING (4)
5 - DRIVE LINK (2)
6 - PIVOT SHAFT (2)
7 - INSULATOR (4)
8 - PIVOT CRANK ARM (2)
9 - PIVOT COVER
10 - MOTOR CRANK ARM
11 - PIGTAIL WIRE CONNECTOR
al l ows the motor to compl ete i ts current wi pe cycl e
after the wi per system has been turned Off, and to
park the wi per bl ades i n the l owest porti on of the
wi pe pattern. The automati c resetti ng ci rcui t breaker
protects the motor from overl oads. The wi per motor
crank arm, the two wi per l i nkage members, and the
two wi per pi vots mechani cal l y convert the rotary out-
put of the wi per motor to the back and forth wi pi ng
moti on of the wi per arms and bl ades on the gl ass.
REMOVAL
cabl e.
ERS - FRONT/FRONT WI PER ARM - REMOVAL).
ness connector for the front wi per motor from the
motor pi gtai l wi re connector (Fi g. 15).
(6) Remove the two screws that secure the front
wi per modul e to the top of the cowl pl enum panel at
the pi vot brackets.
(7) Remove the two nuts that secure the front
wi per modul e to the two wel d studs on the bottom of
the cowl pl enum panel .
(8) Li ft the front wi per modul e up from the cowl
pl enum panel far enough to di sengage the two l ower
i nsul ators from the wel d studs on the bottom of the
pl enum panel .
(9) Remove the front wi per modul e from the cowl
pl enum panel as a uni t.
INSTALLATION
(1) Posi ti on the front wi per modul e to the cowl pl e-
num as a uni t (Fi g. 15).
(2) Lower the front wi per modul e l ower mounti ng
i nsul ators over the two wel d studs on the bottom of
the cowl pl enum panel .
(3) I nstal l the two screws that secure the front
wi per modul e to the top of the cowl pl enum panel at
the pi vot brackets. Ti ghten the screw on the dri ver
si de, fol l owed by the screw on the passenger si de.
(4) I nstal l and ti ghten the two nuts that secure
the front wi per modul e to the two wel d studs on the
bottom of the cowl pl enum panel . Ti ghten the nuts to
8 Nm (72 i n. l bs.).
connector for the front wi per motor to the motor pi g-
tai l wi re connector.
FRONT WIPER/WASHER
SWITCH
DESCRIPTION
The front wi per and washer swi tches are i ntegral
to the ri ght (wi per) control stal k of the mul ti -functi on
DESCRI PTI ON).
OPERATION
The front wi per and washer swi tches are i ntegral
to the ri ght (wi per) control stal k of the mul ti -functi on
OPERATI ON).
Fig. 15 Front Wiper Module Remove/Install
1 - NUT (2)
2 - SCREW (2)
3 - FRONT WIPER MODULE
4 - STUD (2)
FRONT WIPER MODULE (Continued)
WASHER FLUID LEVEL
SWITCH
DESCRIPTION
The washer fl ui d l evel swi tch i s a si ngl e pol e, si n-
gl e throw reed-type swi tch mounted at the rear of
the sump area near the bottom of the washer reser-
voi r (Fi g. 16). Onl y the mol ded pl asti c swi tch mount-
i ng fl ange and the i ntegral connector receptacl e are
vi si bl e when the swi tch i s i nstal l ed i n the reservoi r.
A short ni ppl e formati on extends from the i nner sur-
face of the swi tch mounti ng fl ange, and a barb on the
ni ppl e near the swi tch mounti ng fl ange i s pressed
through a rubber grommet seal i nstal l ed i n the
mounti ng hol e of the reservoi r. A smal l , mol ded pl as-
ti c fl oat has two pi vot pi ns near i ts center that are
snapped i nto two receptacl es near the ends of two
stanchi ons that extend toward the fl oat from the
swi tch ni ppl e formati on. A smal l magnet i s secured
wi thi n the end of the fl oat nearest the swi tch ni ppl e
formati on, and a reed swi tch i s conceal ed wi thi n the
ni ppl e. A di agnosti c resi stor i s connected between the
two swi tch termi nal s wi thi n the swi tch mounti ng
fl ange. The washer fl ui d l evel swi tch cannot be
adjusted or repai red. I f faul ty or damaged, the swi tch
must be repl aced.
OPERATION
The washer fl ui d l evel swi tch uses a pi voti ng,
obl ong fl oat to moni tor the l evel of the washer fl ui d
i n the washer reservoi r. The fl oat contai ns a smal l
magnet. When the fl oat pi vots, the proxi mi ty of thi s
magnet to a stati onary reed swi tch wi thi n the ni ppl e
formati on of the swi tch changes. When the fl ui d l evel
i n the washer reservoi r i s at or above the fl oat l evel ,
the fl oat moves to a verti cal posi ti on, the i nfl uence of
the fl oat magneti c fi el d i s removed from the reed
swi tch, and the normal l y open reed swi tch contacts
open. When the fl ui d l evel i n the washer reservoi r
fal l s bel ow the l evel of the pi voti ng fl oat, the fl oat
moves to a hori zontal posi ti on, the i nfl uence of the
fl oat magneti c fi el d i s appl i ed to the reed swi tch, and
the contacts of the normal l y open reed swi tch cl ose.
The washer fl ui d l evel swi tch i s connected to the
out and connector of the headl amp and dash wi re
harness. The swi tch i s connected i n seri es between
ground and the washer fl ui d swi tch sense i nput to
the El ectroMechani cal I nstrument Cl uster (EMI C).
The swi tch recei ves a path to ground at al l ti mes
through another take out of the headl amp and dash
wi re harness wi th a si ngl e eyel et termi nal connector
that i s secured under a ground screw near the front
of the l eft front fender i nner shi el d i n the engi ne
compartment. When the swi tch cl oses, the EMI C
senses the ground on the washer fl ui d swi tch sense
ci rcui t. The EMI C i s programmed to respond to thi s
i nput by i l l umi nati ng the washer fl ui d i ndi cator and
by soundi ng an audi bl e chi me tone warni ng.
The washer fl ui d l evel swi tch i nput to the EMI C
can be di agnosed usi ng conventi onal di agnosti c tool s
and methods. (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER/WASHER FLUI D I NDI CATOR -
DI AGNOSI S AND TESTI NG).
REMOVAL
The washer fl ui d l evel swi tch can be removed from
the washer reservoi r wi thout removi ng the reservoi r
from the vehi cl e.
cabl e.
(3) Remove the spl ash shi el d from the ri ght front
fender wheel house. (Refer to 23 - BODY/EXTERI OR/
FRONT WHEELHOUSE SPLASH SHI ELD -
REMOVAL).
(4) Di sconnect the front or rear washer hose from
one of the barbed outl et ni ppl es of the washer pump/
motor uni t and al l ow the washer fl ui d to drai n i nto a
cl ean contai ner for reuse.
the swi tch connector receptacl e (Fi g. 17).
Fig. 16 Washer Fluid Level Switch
1 - MOUNTING FLANGE
2 - BARBED NIPPLE
3 - FLOAT
4 - RESERVOIR
5 - GROMMET SEAL
6 - PIVOT
7 - MAGNET
NOTE: The pivoting float of the washer fluid level
switch must be in a horizontal position within the
reservoir in order to be removed. With the reservoir
empty and in an upright position, the pivoting float
will orient itself to the horizontal position when the
switch connector receptacle is pointed straight
downwards.
fl at-bl aded tool , gentl y pry the barbed ni ppl e of the
washer fl ui d l evel swi tch out of the rubber grommet
seal on the back of the reservoi r sump. Care must be
taken not to damage the reservoi r.
(7) Remove the washer fl ui d l evel swi tch from the
washer reservoi r.
(8) Remove the rubber grommet seal from the
washer fl ui d l evel swi tch mounti ng hol e i n the
washer reservoi r and di scard.
INSTALLATION
(1) I nstal l a new rubber grommet seal i nto the
washer fl ui d l evel swi tch mounti ng hol e i n the
washer reservoi r. Al ways use a new rubber grommet
seal on the reservoi r.
(2) I nsert the fl oat of the washer fl ui d l evel swi tch
through the rubber grommet seal and i nto the
washer reservoi r. The connector receptacl e of the
washer fl ui d l evel swi tch shoul d be poi nted down-
ward.
on the washer fl ui d l evel swi tch mounti ng fl ange
unti l the barbed ni ppl e i s ful l y seated i n the rubber
grommet seal i n the washer reservoi r mounti ng hol e.
connector for the washer fl ui d l evel swi tch to the
(5) Reconnect the removed washer hose to the
barbed outl et ni ppl e of the washer pump/motor uni t.
(6) Rei nstal l the spl ash shi el d i nto the ri ght front
FRONT WHEELHOUSE SPLASH SHI ELD -
I NSTALLATI ON).
(8) Refi l l the washer reservoi r wi th the washer
fl ui d drai ned from the reservoi r duri ng the removal
procedure.
WASHER PUMP/MOTOR
DESCRIPTION
The washer pump/motor uni t (Fi g. 18) i s l ocated on
the outboard si de of the washer reservoi r, on the out-
board si de of the ri ght front frame rai l behi nd the
ri ght front wheel house spl ash shi el d. A smal l perma-
nentl y l ubri cated and seal ed reversi bl e el ectri c motor
i s coupl ed to the rotor-type washer pump. The use of
an i ntegral shuttl e val ve al l ows the washer pump/
motor uni t to provi de washer fl ui d to ei ther the front
or the rear washer systems, dependi ng upon the
di recti on of the motor/pump i mpel l er rotati on. A seal
fl ange wi th a barbed i nl et ni ppl e on the pump hous-
i ng passes through a rubber grommet seal i nstal l ed
i n a dedi cated mounti ng hol e of the washer reservoi r.
When the pump i s i nstal l ed i n the reservoi r the front
barbed outl et ni ppl e on the pump shuttl e val ve hous-
i ng connects the uni t to the front washer hose and
the rear barbed outl et ni ppl e connects the uni t to the
rear washer hose. The l etters F and R mol ded
i nto the shuttl e val ve housi ng adjacent to each ni ppl e
provi de further cl ari fi cati on of the ni ppl e assi gn-
ments.
The washer pump/motor uni t i s retai ned on the
reservoi r by the i nterference fi t between the barbed
pump i nl et ni ppl e and the grommet seal , whi ch i s a
l i ght press fi t. The top of the washer pump i s al so
secured to the washer reservoi r by the use of a snap
post on the motor and a snap post receptacl e mol ded
i nto the reservoi r that al l ows for mounti ng of the
washer pump wi thout the use of fasteners. An i nte-
gral connector receptacl e on the top of the motor
Fig. 17 Washer Fluid Level Switch Remove/Install
2 - WIRE HARNESS
3 - WASHER PUMP/MOTOR
5 - REAR WASHER HOSE
WASHER FLUID LEVEL SWITCH (Continued)
housi ng connects the uni t to the vehi cl e el ectri cal
the headl amp and dash wi re harness. The washer
pump/motor uni t cannot be repai red. I f faul ty or
damaged, the enti re washer pump/motor uni t must
be repl aced.
OPERATION
The washer pump/motor uni t features a reversi bl e
el ectri c motor. The di recti on of the motor i s con-
trol l ed by hard wi red outputs from the momentary
front and rear washer swi tch ci rcui try contai ned
wi thi n the ri ght (wi per) control stal k of the mul ti -
functi on swi tch. When battery current and ground
are appl i ed to the two pump motor termi nal s, the
motor rotates i n one di recti on. When the pol ari ty of
these connecti ons i s reversed, the motor rotates i n
the opposi te di recti on. When the pump motor i s ener-
gi zed, the rotor-type pump pressuri zes the washer
fl ui d and forces i t through one of the two pump out-
l et ni ppl es, and i nto the front or rear washer pl umb-
i ng.
Washer fl ui d i s gravi ty-fed from the washer reser-
voi r to the i nl et port of the washer pump housi ng. An
i ntegral shuttl e val ve i s l ocated i n a housi ng on the
outl et port si de of the pump housi ng (Fi g. 19). Thi s
shuttl e val ve control s whi ch washer system pl umbi ng
recei ves the washer fl ui d bei ng pressuri zed by the
pump. When the pump i mpel l er rotates i n the coun-
tercl ockwi se di recti on (vi ewed from the bottom), pres-
suri zed washer fl ui d i s pushed out the front washer
system port and bi ases the shuttl e val ve to the l eft,
seal i ng off the rear washer system outl et ni ppl e.
When the pump i mpel l er rotates i n the cl ockwi se
di recti on (vi ewed from the bottom), pressuri zed
washer fl ui d i s pushed out the rear washer system
port and bi ases the shuttl e val ve to the ri ght, seal i ng
off the front washer system outl et ni ppl e.
The washer pump/motor uni t can be di agnosed
REMOVAL
(1) Turn the front wheel s ful l l ock to the ri ght.
cabl e.
(4) Unsnap and l i ft the cover over the access hol e
at the front of the ri ght front wheel house spl ash
shi el d.
(5) Pl ace a cl ean contai ner on the fl oor beneath the
washer pump/motor l ocati on to catch any washer
fl ui d that i s spi l l ed duri ng the fol l owi ng procedure.
the top of the washer pump/motor housi ng.
Fig. 18 Washer Pump/Motor
1 - SNAP POST
3 - MOTOR
4 - PUMP
5 - FRONT WASHER OUTLET NIPPLE
6 - SHUTTLE VALVE
7 - REAR WASHER OUTLET NIPPLE
8 - INLET NIPPLE
9 - FILTER SCREEN
Fig. 19 Washer Pump Fluid Flow
1 - IMPELLER ROTATION (VIEWED FROM BOTTOM)
2 - IMPELLER OUTPUT
3 - REAR WASHER OUTLET NIPPLE
4 - SHUTTLE VALVE
5 - FRONT WASHER OUTLET NIPPLE
WASHER PUMP/MOTOR (Continued)
(7) Pul l l i ghtl y outward on the top of the washer
pump/motor housi ng away from the washer reservoi r
far enough to di sengage the snap post on the top of
the motor from the receptacl e i n the reservoi r (Fi g.
20).
(8) Pul l the washer pump/motor uni t strai ght out
from the washer reservoi r far enough to di sengage
the barbed pump i nl et ni ppl e from the rubber grom-
met seal i n the reservoi r.
ness connector from the washer pump/motor uni t
connector receptacl e on the top of the motor housi ng
(Fi g. 21).
(10) Di sconnect the two washer hoses from the two
washer pump/motor uni t outl et ni ppl es.
(11) Remove washer pump/motor uni t through the
access hol e at the front of the ri ght front fender
wheel house spl ash shi el d.
(12) Remove the rubber grommet seal from the
washer reservoi r and di scard.
INSTALLATION
(1) I nstal l a new rubber grommet seal i nto the
washer pump mounti ng hol e i n the washer reservoi r.
Al ways use a new rubber grommet seal on the reser-
voi r.
(2) Posi ti on the barbed i nl et ni ppl e of the washer
pump to the rubber grommet seal i n the washer res-
ervoi r (Fi g. 20).
(3) Usi ng hand pressure, press on the washer
pump/motor uni t fi rml y and evenl y unti l the barbed
i nl et ni ppl e i s ful l y seated i n the rubber grommet
seal i n the washer reservoi r mounti ng hol e.
(4) Al i gn the washer pump/motor snap post on the
top of the motor housi ng wi th the snap post recepta-
cl e i n the washer reservoi r.
on the top of washer pump/motor uni t unti l the snap
post snaps i nto the washer reservoi r receptacl e.
connector for the washer pump/motor uni t to the con-
nector receptacl e on the top of the motor housi ng
(Fi g. 21).
(7) Reconnect the front and rear washer hoses to
the two barbed pump outl et ni ppl es. Be certai n that
the hose i n the trough of the reservoi r behi nd the
pump i s connected to the rear ni ppl e, and the hose i n
the trough i n front of the pump i s connected to the
front ni ppl e.
hol e at the front of the ri ght front wheel house
spl ash shi el d.
(11) Refi l l the washer reservoi r wi th cl ean washer
fl ui d.
Fig. 20 Washer Pump/Motor Remove/Install
2 - SNAP POST
3 - INLET NIPPLE
4 - GROMMET SEAL
Fig. 21 Washer Pump/Motor Connections
2 - WIRE HARNESS
5 - REAR WASHER HOSE
WASHER PUMP/MOTOR (Continued)
WASHER RESERVOIR
DESCRIPTION
A si ngl e washer fl ui d reservoi r i s used for both the
front and rear washer systems (Fi g. 22). The mol ded
pl asti c washer fl ui d reservoi r i s mounted on the out-
board si de of the ri ght front frame rai l i n front of the
ri ght front wheel , where i t i s conceal ed by the ri ght
front wheel house spl ash shi el d. The onl y vi si bl e
component of the washer reservoi r i s the fi l l er neck
and cap uni t, whi ch extends through a hol e i n the
ri ght front wheel house extensi on panel i nto the
engi ne compartment. A bri ght yel l ow pl asti c fi l l er cap
wi th an i ntegral bai l strap and fi l l er neck mounti ng
bracket i s l abel ed wi th an I nternati onal Control and
Di spl ay Symbol i con for Wi ndshi el d Washer and the
text Washer Fl ui d Onl y mol ded i nto i t. The cap
snaps over the open end of the fi l l er neck.
There i s a dedi cated hol e on the outboard si de of
the reservoi r provi ded for the mounti ng of the
washer pump/motor uni t, and another dedi cated hol e
on the rear of the reservoi r for the washer fl ui d l evel
swi tch. A snap post receptacl e mol ded i nto the reser-
voi r al l ows for mounti ng of the washer pump wi thout
the use of fasteners. The reservoi r al so features i nte-
gral hose routi ng troughs on i ts outboard si de and
i ntegral routi ng cl i ps al ong i ts top. The washer res-
ervoi r i s secured to the outboard si de of the ri ght
front frame rai l by two screws and an i ntegral
mol ded tab that engages i n a sl ot i n the ri ght front
frame rai l . Another screw secures the reservoi r fi l l er
neck to the upper radi ator crossmember i n the front
of the engi ne compartment. The ri ght front fender
wheel house spl ash shi el d must be removed to access
the washer reservoi r for servi ce.
OPERATION
The washer fl ui d reservoi r provi des a secure,
on-vehi cl e storage l ocati on for a l arge reserve of
washer fl ui d for operati on of the front and rear
washer systems. The washer reservoi r fi l l er neck pro-
vi des a cl earl y marked and readi l y accessi bl e poi nt
from whi ch to add washer fl ui d to the reservoi r. The
washer/pump motor uni t i s l ocated i n a sump area
near the front of the reservoi r to be certai n that
washer fl ui d wi l l be avai l abl e to the pump as the
fl ui d l evel i n the reservoi r becomes depl eted. The
washer pump/motor uni t i s mounted i n the l owest
posi ti on i n the sump. The washer fl ui d l evel swi tch i s
mounted just above the sump area of the reservoi r so
that there wi l l be adequate warni ng to the vehi cl e
operator that the washer fl ui d l evel i s l ow, before the
washer system wi l l no l onger operate.
REMOVAL
(1) Turn the front wheel s ful l l ock to the ri ght.
cabl e.
(4) Remove the ai r cl eaner housi ng from the top of
the ri ght front fender wheel house. (Refer to 9 -
ENGI NE/AI R I NTAKE SYSTEM/AI R CLEANER
ELEMENT - REMOVAL).
(5) Remove the screw that secures the washer res-
ervoi r fi l l er neck support to upper radi ator cross-
member (Fi g. 23).
Fig. 22 Washer Reservoir
1 - CAP
2 - RESERVOIR
3- SNAP POST RECEPTACLE
4 - FRONT HOSE TROUGH
5 - WASHER PUMP HOLE
6 - REAR HOSE TROUGH
7 - HOOK
Fig. 23 Washer Reservoir Cap Remove/Install
1 - SCREW (1)
2 - CAP
(7) Remove the spl ash shi el d from the ri ght front
WHEELHOUSE SPLASH SHI ELD - REMOVAL).
(8) Rel ease the W cl i p that secures the front
bumper fasci a to the front bumper support. Thi s cl i p
i s l ocated behi nd the bumper support and bel ow the
ri ght front l amp uni t.
(9) Pl ace a cl ean contai ner on the fl oor beneath the
washer pump/motor l ocati on to catch any washer
fl ui d that i s spi l l ed duri ng the fol l owi ng procedure.
(10) Di sconnect the front and rear washer hoses
from the washer pump/motor uni t outl et ni ppl es and
al l ow the washer fl ui d to drai n i nto the contai ner for
reuse (Fi g. 24).
ness connector for the washer pump/motor uni t from
the connector receptacl e on the top of the motor
housi ng.
the connector receptacl e on the bottom of the swi tch.
(13) Di sengage the front and rear washer hoses
from the i ntegral washer reservoi r troughs and rout-
i ng cl i ps.
(14) Usi ng a l ong extensi on wi th a swi vel socket
and pul l i ng forward on the front bumper fasci a,
remove the screw that secures the washer reservoi r
to the ri ght front frame rai l .
(15) Remove the screw that secures the rear of the
washer reservoi r to the ri ght front frame rai l .
(16) Di sengage the mounti ng tab at the back of the
washer reservoi r from the sl ot i n the ri ght front
frame rai l .
(17) Lower the washer reservoi r far enough for the
fi l l er neck to be removed from the cl earance hol e i n
the ri ght front fender wheel house panel extensi on.
(18) Remove the washer reservoi r from the ri ght
front fender wheel house.
INSTALLATION
(1) Posi ti on the washer reservoi r i nto the ri ght
front fender wheel house.
(2) I nsert the washer reservoi r fi l l er neck through
the cl earance hol e i n the ri ght front fender wheel
house panel extensi on (Fi g. 24).
(3) Rai se the washer reservoi r far enough to
engage the mounti ng tab at the back of the reservoi r
i nto the sl ot i n the ri ght front frame rai l .
rear of the washer reservoi r to the ri ght front frame
rai l . Ti ghten the screw to 7 Nm (65 i n. l bs.).
(5) Usi ng a l ong extensi on wi th a swi vel socket
and pul l i ng forward on the front bumper fasci a,
i nstal l and ti ghten the screw that secures the washer
reservoi r to the ri ght front frame rai l . Ti ghten the
(6) Engage the front and rear washer hoses i nto
the i ntegral washer reservoi r troughs and routi ng
cl i ps. Be certai n that the rear washer hose i s routed
rearward of the washer pump/motor uni t, and the
front washer hose i s routed forward of the washer
pump/motor uni t. The rear washer hose can be i den-
ti fi ed by an i n-l i ne hose connector that joi ns the res-
ervoi r hose to the engi ne compartment hose l ocated
near the top of mai n body of the reservoi r.
connector for the washer fl ui d l evel swi tch to the con-
nector receptacl e on the bottom of the swi tch.
connector for the washer pump/motor uni t to the con-
nector receptacl e on the top of the motor housi ng.
(9) Reconnect the front and rear washer hoses to
the washer pump/motor uni t outl et ni ppl es. Be cer-
tai n that the rear washer hose i n the trough rear-
ward of the washer pump/motor uni t i s connected to
the rear ni ppl e, and the hose i n the trough forward
Fig. 24 Washer Reservoir Remove/Install
1 - FRONT WHEEL HOUSE INNER PANEL
4 - SCREW (2)
7 - MOUNTING TAB
8 - SLOT
WASHER RESERVOIR (Continued)
of the washer pump/motor uni t i s connected to the
front ni ppl e.
(10) Engage the W cl i p that secures the front
bumper fasci a to the front bumper support. Thi s cl i p
i s l ocated behi nd the bumper support and bel ow the
ri ght front l amp uni t.
(11) Rei nstal l the spl ash shi el d i nto the ri ght front
WHEELHOUSE SPLASH SHI ELD - I NSTALLA-
TI ON).
washer reservoi r fi l l er neck support to upper radi ator
crossmember (Fi g. 23). Ti ghten the screw to 7 Nm
(65 i n. l bs.).
(14) Rei nstal l the ai r cl eaner housi ng onto the top
of the ri ght front fender wheel house. (Refer to 9 -
ENGI NE/AI R I NTAKE SYSTEM/AI R CLEANER
ELEMENT - I NSTALLATI ON).
(15) Refi l l the washer reservoi r wi th the washer
fl ui d drai ned from the reservoi r duri ng the removal
procedure.
WIPER HIGH/LOW RELAY
DESCRIPTION
The wi per hi gh/l ow rel ay i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
ment near the battery. The wi per hi gh/l ow rel ay i s a
conventi onal I nternati onal Standards Organi zati on
(I SO) mi cro rel ay (Fi g. 25). Rel ays conformi ng to the
I SO speci fi cati ons have common physi cal di mensi ons,
current capaci ti es, termi nal patterns, and termi nal
functi ons. The rel ay i s contai ned wi thi n a smal l , rect-
angul ar, mol ded pl asti c housi ng and i s connected to
al l of the requi red i nputs and outputs by fi ve i ntegral
mal e spade-type termi nal s that extend from the bot-
tom of the rel ay base.
The wi per hi gh/l ow rel ay cannot be adjusted or
repl aced.
OPERATION
The wi per hi gh/l ow rel ay i s an el ectromechani cal
put to the front wi per motor. The movabl e common
feed contact poi nt i s hel d agai nst the fi xed normal l y
The wi per hi gh/l ow rel ay termi nal s are connected
receptacl e i n the Power Di stri buti on Center (PDC).
The i nputs and outputs of the wi per hi gh/l ow rel ay
i ncl ude:
termi nal (30) i s connected to the output of the wi per
on/off rel ay at al l ti mes through the wi per on/off
rel ay output ci rcui t.
Control Modul e (BCM) through a front wi per hi gh/
l ow rel ay control ci rcui t. The BCM control s front
wi per motor operati on by control l i ng a ground path
a ci rcui t breaker i n the Juncti on Bl ock (JB) through
a fused i gni ti on swi tch output (run-acc) ci rcui t.
termi nal (87) i s connected to the hi gh speed brush of
the front wi per motor through a front wi per hi gh/l ow
rel ay hi gh speed output ci rcui t, and i s connected to
the hi gh speed brush whenever the rel ay i s ener-
gi zed.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
WASHER RESERVOIR (Continued)
cl osed termi nal (87A) i s connected to the l ow speed
brush of the front wi per motor through a front wi per
hi gh/l ow rel ay l ow speed output ci rcui t, and i s con-
nected to the l ow speed brush whenever the rel ay i s
de-energi zed.
The wi per hi gh/l ow rel ay can be di agnosed usi ng
DIAGNOSIS AND TESTING - WIPER HIGH/LOW
RELAY
The wi per hi gh/l ow rel ay (Fi g. 26) i s l ocated i n the
partment near the battery. Refer to the appropri ate
and grounds.
(1) Remove the wi per hi gh/l ow rel ay from the
PDC. (Refer to 8 - ELECTRI CAL/WI PERS/WASH-
ERS/WI PER HI GH/LOW RELAY - REMOVAL).
REMOVAL
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 27).
(3) Remove the wi per hi gh/l ow rel ay by graspi ng i t
i n the PDC.
INSTALLATION
(1) Posi ti on the wi per hi gh/l ow rel ay to the proper
receptacl e i n the Power Di stri buti on Center (PDC)
(Fi g. 27).
(2) Al i gn the wi per hi gh/l ow rel ay termi nal s wi th
the termi nal cavi ti es i n the PDC receptacl e.
(3) Push fi rml y and evenl y on the top of the wi per
hi gh/l ow rel ay unti l the termi nal s are ful l y seated i n
the termi nal cavi ti es i n the PDC receptacl e.
(4) Rei nstal l the cover onto the PDC.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
Fig. 27 Power Distribution Center
1 - FUEL PUMP RELAY
2 - STARTER MOTOR RELAY
3 - BLOWER MOTOR RELAY
4 - A/C COMPRESSOR CLUTCH RELAY
5 - OXYGEN SENSOR DOWNSTREAM RELAY
6 - AUTO SHUT DOWN RELAY
7 - SPARE
8 - SPARE
9a - (M/T) CLUTCH INTERLOCK RELAY
9b - (A/T) TRANSMISSION CONTROL RELAY
10 - SPARE
11 - WIPER HIGH/LOW RELAY
12 - WIPER ON/OFF RELAY
WIPER HIGH/LOW RELAY (Continued)
WIPER ON/OFF RELAY
DESCRIPTION
The wi per on/off rel ay i s l ocated i n the Power Di s-
tri buti on Center (PDC) i n the engi ne compartment
near the battery. The wi per on/off rel ay i s a conven-
The wi per on/off rel ay cannot be adjusted or
repl aced.
OPERATION
The wi per on/off rel ay i s an el ectromechani cal
put to the front wi per motor. The movabl e common
feed contact poi nt i s hel d agai nst the fi xed normal l y
The wi per on/off rel ay termi nal s are connected to
receptacl e i n the Power Di stri buti on Center (PDC).
The i nputs and outputs of the wi per on/off rel ay
i ncl ude:
termi nal (30) i s connected to the common feed termi -
nal of the wi per hi gh/l ow rel ay at al l ti mes through
the wi per on/off rel ay output ci rcui t.
Control Modul e (BCM) through a front wi per on/off
rel ay control ci rcui t. The BCM control s front wi per
motor operati on by control l i ng a ground path through
thi s ci rcui t.
a ci rcui t breaker i n the Juncti on Bl ock (JB) through
a fused i gni ti on swi tch output (run-acc) ci rcui t.
from a ci rcui t breaker i n the Juncti on Bl ock (JB)
through a fused i gni ti on swi tch output (run-acc) ci r-
cui t, and provi des battery current to the front wi per
on/off rel ay output ci rcui t whenever the rel ay i s ener-
gi zed.
cl osed termi nal (87A) i s connected to the wi per park
swi tch i n the front wi per motor through the front
wi per park swi tch sense ci rcui t, and i s connected to
the wi per park swi tch whenever the rel ay i s de-ener-
gi zed.
The wi per on/off rel ay can be di agnosed usi ng con-
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
DIAGNOSIS AND TESTING - WIPER ON/OFF
RELAY
The wi per on/off rel ay (Fi g. 29) i s l ocated i n the
partment near the battery. Refer to the appropri ate
and grounds.
(1) Remove the wi per on/off rel ay from the PDC.
(Refer to 8 - ELECTRI CAL/WI PERS/WASHERS/
WI PER ON/OFF RELAY - REMOVAL).
REMOVAL
cabl e.
Center (PDC) (Fi g. 30).
(3) Remove the wi per on/off rel ay by graspi ng i t
i n the PDC.
INSTALLATION
(1) Posi ti on the wi per on/off rel ay to the proper
receptacl e i n the Power Di stri buti on Center (PDC)
(Fi g. 30).
(2) Al i gn the wi per on/off rel ay termi nal s wi th the
termi nal cavi ti es i n the PDC receptacl e.
(3) Push fi rml y and evenl y on the top of the wi per
on/off rel ay unti l the termi nal s are ful l y seated i n the
termi nal cavi ti es i n the PDC receptacl e.
(4) Rei nstal l the cover onto the PDC.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
Fig. 30 Power Distribution Center
1 - FUEL PUMP RELAY
2 - STARTER MOTOR RELAY
3 - BLOWER MOTOR RELAY
4 - A/C COMPRESSOR CLUTCH RELAY
5 - OXYGEN SENSOR DOWNSTREAM RELAY
6 - AUTO SHUT DOWN RELAY
7 - SPARE
8 - SPARE
9a - (M/T) CLUTCH INTERLOCK RELAY
9b - (A/T) TRANSMISSION CONTROL RELAY
10 - SPARE
11 - WIPER HIGH/LOW RELAY
12 - WIPER ON/OFF RELAY
WIPER ON/OFF RELAY (Continued)
REAR WIPERS/WASHERS
TABLE OF CONTENTS
page page
REAR WIPERS/WASHERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSIS AND TESTING - REAR WIPER &
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . 30
CLEANING - REAR WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSPECTION - REAR WIPER & WASHER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REAR CHECK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
REAR WASHER HOSES/TUBES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REAR WASHER NOZZLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
REAR WIPER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
REAR WIPER BLADE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR WIPER MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REAR WIPER/WASHER SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
WIPER ARM PARK RAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REAR WIPERS/WASHERS
DESCRIPTION
An el ectri cal l y operated fi xed i nterval i ntermi ttent
rear wi per and washer system i s standard factory-i n-
stal l ed equi pment on thi s model (Fi g. 1). The rear
wi per and washer system i ncl udes the fol l owi ng
detai l el sewhere i n thi s servi ce i nformati on:
ri ght (wi per) control stal k. The ri ght control stal k i s
dedi cated to provi di ng al l of the dri ver control s for
both the front and rear wi per systems. (Refer to 8 -
MULTI -FUNCTI ON SWI TCH - DESCRI PTI ON).
Rear Check Valve - The rear washer system
check val ve i s l ocated i n the washer pl umbi ng
between the rear roof header and the roof outer
panel near the rear washer nozzl e.
Rear Washer Nozzle - The rear washer nozzl e
i s secured by a snap fi t i nto a mounti ng hol e i n the
roof outer panel above the rear fl i p-up gl ass openi ng.
Rear Washer Plumbing - The pl umbi ng for
the rear washer system consi sts of rubber hoses and
mol ded pl asti c fi tti ngs. The pl umbi ng i s routed al ong
the ri ght si de of the engi ne compartment from the
washer reservoi r, through the dash i nto the passen-
ger compartment, up the ri ght cowl si de and A-pi l l ar
to the headl i ner, and above the headl i ner to the rear
washer nozzl e fi tti ng wi thi n the rear roof header.
Rear Wiper Arm- The si ngl e rear wi per arm i s
secured by a nut di rectl y to the rear wi per motor out-
put shaft, whi ch extends through the center of the
tai l gate outer panel near the base of the rear fl i p-up
gl ass.
Rear Wiper Arm Park Ramp - The mol ded
rubber rear wi per arm park ramp i s secured wi th a
screw to the tai l gate outer panel to the ri ght of the
rear wi per motor output shaft bezel . When the rear
wi per system i s not i n operati on, the rear wi per arm
i s parked off of the rear fl i p-up gl ass on thi s ramp so
that i t wi l l not i nterfere wi th or be damaged by the
fl i p-up gl ass operati on.
Rear Wiper Blade - The si ngl e rear wi per
bl ade i s secured to the rear wi per arm wi th an i nte-
gral l atch, and i s parked off of the rear fl i p-up gl ass
when the rear wi per system i s not i n operati on.
KJ REAR WIPERS/WASHERS 8R - 27
Fig. 1 Rear Wiper & Washer System
1 - WASHER NOZZLE
2 - WIPER MODULE
3 - WIPER ARM & BLADE
4 - PARK RAMP
8R - 28 REAR WIPERS/WASHERS KJ
REAR WIPERS/WASHERS (Continued)
Rear Wiper Module - The rear wi per motor
output shaft i s the onl y vi si bl e component of the rear
wi per modul e. The remai nder of the modul e i s con-
ceal ed wi thi n the tai l gate bel ow the rear fl i p-up gl ass
openi ng. The rear wi per modul e i ncl udes the modul e
bracket, the rear wi per motor, and the rear wi per
el ectroni c control ci rcui try.
Washer Pump/Motor - The reversi bl e el ectri c
washer pump/motor uni t i s l ocated i n a dedi cated
hol e on the l ower outboard si de of the washer reser-
voi r, behi nd the ri ght front wheel house spl ash
shi el d. Thi s si ngl e reversi bl e washer pump/motor
provi des washer fl ui d to ei ther the front or rear
washer system pl umbi ng, dependi ng upon the di rec-
ti on of the pump motor rotati on. (Refer to 8 - ELEC-
TRI CAL/FRONT WI PERS/WASHERS/WASHER
PUMP MOTOR - DESCRI PTI ON).
Washer Reservoir - The washer reservoi r i s
conceal ed behi nd the ri ght front wheel house spl ash
shi el d ahead of the ri ght front wheel . The washer
reservoi r fi l l er neck i s the onl y vi si bl e porti on of the
reservoi r, and i t i s accessed from the ri ght front cor-
ner of the engi ne compartment. Thi s si ngl e washer
reservoi r i s shared by both the front and rear washer
systems. (Refer to 8 - ELECTRI CAL/FRONT WI P-
ERS/WASHERS/WASHER RESERVOI R - DESCRI P-
TI ON).
Hard wi red ci rcui try connects the rear wi per and
washer system components to the el ectri cal system of
the vehi cl e. These hard wi red ci rcui ts are i ntegral to
several wi re harnesses, whi ch are routed throughout
the vehi cl e and retai ned by many di fferent methods.
vehi cl e el ectri cal system and to the rear wi per and
washer system components through the use of a com-
bi nati on of sol dered spl i ces, spl i ce bl ock connectors,
and many di fferent types of wi re harness termi nal
connectors and i nsul ators. Refer to the appropri ate
procedures, further detai l s on wi re harness routi ng
and retenti on, as wel l as pi n-out and l ocati on vi ews
for the vari ous wi re harness connectors, spl i ces and
grounds.
OPERATI NG MODES The components of the rear
wi per and washer system are desi gned to work i n
concert to provi de the fol l owi ng operati ng modes:
Continuous Wipe Mode - The control ri ng on
swi tch has an On posi ti on. When sel ected, thi s
swi tch posi ti on wi l l cause the rear wi per motor to
operate i n a conti nuous manner at a fi xed wi pe cycl e
speed.
Intermittent Wipe Mode - The control ri ng on
swi tch has a Del ay posi ti on. When sel ected, thi s
swi tch posi ti on wi l l cause the rear wi per motor to
operate i n an i ntermi ttent manner at a fi xed i nterval
wi pe cycl e speed.
Washer Mode - The control ri ng on the ri ght
(wi per) control stal k of the mul ti -functi on swi tch has
two momentary Wash posi ti ons, one at the end of
each di recti on of control ri ng rotati on. When the con-
trol ri ng i s rotated to the downward (countercl ock-
wi se) Wash posi ti on, the rear washer system wi l l
di spense washer fl ui d onto the fl i p-up gl ass and the
rear wi per motor wi l l operate i n a conti nuous mode
for as l ong as the swi tch i s hel d cl osed, then provi de
several addi ti onal wi pe cycl es after the washer
swi tch i s rel eased (wi pe-after-wash mode). When the
control ri ng i s rotated to the upward (cl ockwi se)
Wash posi ti on, the rear washer system wi l l di spense
washer fl ui d onto the fl i p-up gl ass and the rear wi per
motor wi l l operate i n a conti nuous mode for as l ong
as the swi tch i s hel d cl osed, then return to fi xed wi pe
mode operati on after the washer swi tch i s rel eased.
Wipe-After-Wash Mode - The control ri ng on
swi tch has two momentary Wash posi ti ons, one at
the end of each di recti on of control ri ng rotati on.
When the control ri ng i s rotated to the downward
(countercl ockwi se) Wash posi ti on, the rear washer
system wi l l di spense washer fl ui d onto the fl i p-up
gl ass and the rear wi per motor wi l l operate i n a con-
ti nuous mode for as l ong as the swi tch i s hel d cl osed,
then provi de several addi ti onal wi pe cycl es after the
washer swi tch i s rel eased.
OPERATION
The rear wi per and washer system i s desi gned to
provi de the vehi cl e operator wi th a conveni ent, safe,
and rel i abl e means of mai ntai ni ng vi si bi l i ty through
the rear fl i p-up gl ass. The vari ous components of thi s
system are desi gned to convert el ectri cal energy pro-
duced by the vehi cl e el ectri cal system i nto the
mechani cal acti on of the wi per bl ade to wi pe the out-
si de surface of the gl ass, as wel l as i nto the hydraul i c
acti on of the washer system to appl y washer fl ui d
stored i n an on-board reservoi r to the area of the
gl ass to be wi ped. When combi ned, these components
provi de the means to effecti vel y mai ntai n cl ear vi si -
bi l i ty for the vehi cl e operator by removi ng excess
accumul ati ons of rai n, snow, bugs, mud, or other
mi nor debri s from the swi ng gate fl i p up gl ass sur-
face that mi ght be encountered whi l e dri vi ng the
vehi cl e under numerous types of i ncl ement operati ng
condi ti ons.
The vehi cl e operator i ni ti ates al l rear wi per and
washer system functi ons wi th the ri ght (wi per) con-
trol stal k of the mul ti -functi on swi tch that extends
from the ri ght si de of the steeri ng col umn, just bel ow
the steeri ng wheel . Rotati ng the control ri ng on the
control stal k to a detent posi ti on sel ects the Off,
Del ay, or On rear wi per system operati ng modes.
Rotati ng the control ri ng on the control stal k to
ei ther of two Wash posi ti ons actuates the momentary
rear washer system swi tch. The mul ti -functi on
swi tch provi des hard wi red outputs to the rear wi per
modul e and the washer pump/motor uni t for al l rear
wi per and washer system functi ons.
The rear wi per and washer system wi l l onl y oper-
ate when the i gni ti on swi tch i s i n the Accessory or
On posi ti ons, and the rear fl i p-up gl ass and tai l gate
ajar swi tches are cl osed. Battery current i s di rected
from a fuse i n the Juncti on Bl ock (JB) to the mul ti -
functi on swi tch through a fused i gni ti on swi tch out-
put (run-acc) ci rcui t. The i nternal ci rcui try of the
swi tch then provi des battery current si gnal s through
a rear wi per on dri ver ci rcui t and a rear wi per i nter-
mi ttent dri ver ci rcui t to the rear wi per modul e and
to the Body Control Modul e (BCM). The BCM uses
these rear wi per system i nputs as a si gnal to l ock the
rear fl i p-up gl ass and the tai l gate to prevent the rear
fl i p-up gl ass or tai l gate from bei ng opened for as l ong
as the rear wi per i s operati ng. The mul ti -functi on
swi tch ci rcui try al so uses thi s battery current and a
ground ci rcui t i nput to di rectl y control the operati on
and di recti on of the reversi bl e el ectri c washer pump/
motor uni t.
A separate fuse i n the JB provi des battery current
to the el ectroni c control ci rcui try of the rear wi per
modul e through a fused B(+) ci rcui t. The rear wi per
modul e uses thi s fused B(+) i nput to park the rear
wi per bl ade off of the rear fl i p-up gl ass i f the i gni ti on
swi tch i s turned to the Off posi ti on whi l e the rear
wi per i s operati ng, or i f the i gni ti on swi tch i s turned
to the Off posi ti on before the rear wi per bl ade has
parked. However, i f the i gni ti on swi tch i s turned to
the Off posi ti on whi l e the rear wi per i s operati ng,
then turned back On, the rear wi per swi tch must be
cycl ed to the Off posi ti on and back to the On or
Del ay posi ti on before the rear wi per wi l l operate
agai n. I n addi ti on, the rear wi per modul e recei ves an
i nput from the rear fl i p-up gl ass ajar swi tch on a
fl i p-up gl ass ajar swi tch sense ci rcui t, whi ch prevents
the rear wi per from operati ng when the fl i p-up gl ass
i s not cl osed or ful l y l atched.
The hard wi red ci rcui ts and components of the rear
wi per and washer system may be di agnosed and
dures. Fol l owi ng are paragraphs that bri efl y descri be
the operati on of each of the rear wi per and washer
system operati ng modes.
CONTI NUOUS WI PE MODE When the On posi -
ti on of the control ri ng on the ri ght (wi per) control
stal k of the mul ti -functi on swi tch i s sel ected, the
mul ti -functi on swi tch ci rcui try di rects a battery cur-
rent si gnal to the rear wi per modul e through the
rear wi per on dri ver ci rcui t, causi ng the rear wi per to
cycl e conti nuousl y at a fi xed speed.
I NTERMI TTENT WI PE MODE When the Del ay
posi ti on of the control ri ng on the ri ght (wi per) con-
trol stal k of the mul ti -functi on swi tch i s sel ected, the
mul ti -functi on swi tch ci rcui try di rects a battery cur-
rent si gnal to the rear wi per modul e through the
rear wi per i ntermi ttent dri ver ci rcui t, causi ng the
rear wi per to cycl e i ntermi ttentl y at a fi xed del ay
i nterval .
WASH MODE When the momentary Wash (after
On) posi ti on of the control ri ng on the ri ght (wi per)
control stal k of the mul ti -functi on swi tch i s sel ected,
the mul ti -functi on swi tch ci rcui try di rects both bat-
tery current and ground to the washer pump/motor
uni t, and a battery current si gnal to be provi ded to
the rear wi per modul e through the rear wi per on
dri ver ci rcui t. Thi s wi l l cause the washer pump/mo-
tor uni t to be energi zed and the rear wi per to cycl e
conti nuousl y at a fi xed speed for as l ong as the rear
Wash swi tch i s hel d cl osed.
WI PE-AFTER-WASH MODE When the momentary
Wash (before Off) posi ti on of the control ri ng on the
swi tch i s sel ected, the mul ti -functi on swi tch ci rcui try
di rects both battery current and ground to the
washer pump/motor uni t, and a battery current si g-
nal to be provi ded to the rear wi per modul e through
the rear wi per on dri ver ci rcui t. Thi s wi l l cause the
washer pump/motor uni t to be energi zed and the rear
wi per to cycl e conti nuousl y at a fi xed speed for as
l ong as the rear Wash swi tch i s hel d cl osed. When
the control ri ng i s rel eased to the Off posi ti on, the
washer pump/motor i s de-energi zed, but the ci rcui try
wi thi n the rear wi per modul e wi l l provi de several
addi ti onal wi pe cycl es to compl ete the wi pe-after-
wash mode cycl e.
DIAGNOSIS AND TESTING - REAR WIPER &
WASHER SYSTEM
REAR WIPER SYSTEM
i noperati ve rear wi per system. I f the rear wi per
motor operates, but the wi per does not move on the
rear fl i p-up gl ass, i nspect the mechani cal connecti on
between the rear wi per arm and the rear wi per
motor output shaft. I f OK, repl ace the faul ty rear
wi per modul e. I f the wi per operates, but chatters,
l i fts, or does not cl ear the gl ass, cl ean and i nspect
the rear wi per system components as requi red. (Refer
to 8 - ELECTRI CAL/REAR WI PERS/WASHERS -
I NSPECTI ON) and (Refer to 8 - ELECTRI CAL/
REAR WI PERS/WASHERS - CLEANI NG). Refer to
(1) Check that the i nteri or l i ghti ng swi tch on the
l eft (l i ghti ng) control stal k of the mul ti -functi on
swi tch i s not i n the dome l amp di sabl e posi ti on. Wi th
al l four doors and the tai l gate cl osed, open the rear
fl i p-up gl ass. The i nteri or l amps shoul d l i ght. Cl ose
the rear fl i p-up gl ass. Note whether the i nteri or
l amps remai n l i ghted. They shoul d turn off after
about thi rty seconds. I f OK, go to Step 2. I f not OK,
go to Step 9.
I f not OK, repai r the open fused B(+) ci rcui t between
the JB and the Power Di stri buti on Center (PDC) as
requi red.
acc) fuse (Fuse 22 - 10 ampere) i n the JB. I f OK, go
output (run-acc) fuse (Fuse 22 - 10 ampere) i n the
JB. I f OK, turn the i gni ti on swi tch to the Off posi ti on
and go to Step 6. I f not OK, repai r the open fused
i gni ti on swi tch output (run-acc) ci rcui t between the
JB and the i gni ti on swi tch as requi red.
connector for the mul ti -functi on swi tch (Connector
C-2) from the swi tch connector receptacl e. Reconnect
the battery negati ve cabl e. Turn the i gni ti on swi tch
to the On posi ti on. Check for battery vol tage at the
fused i gni ti on swi tch output (run-acc) ci rcui t cavi ty of
the i nstrument panel wi re harness connector for the
mul ti -functi on swi tch (Connector C-2). I f OK, go to
Step 7. I f not OK, repai r the open fused i gni ti on
swi tch output (run-acc) ci rcui t between the mul ti -
functi on swi tch and the JB as requi red.
Test the mul ti -functi on swi tch. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/MULTI -
FUNCTI ON SWI TCH - DI AGNOSI S AND
TESTI NG). I f the mul ti -functi on swi tch tests OK,
reconnect the i nstrument panel wi re harness connec-
tors for the mul ti -functi on swi tch to the swi tch con-
nector receptacl es and go to Step 8. I f the mul ti -
functi on swi tch does not test OK, repl ace the faul ty
swi tch.
(8) Remove the tai l gate i nner tri m panel . Di scon-
nect the tai l gate wi re harness connector for the rear
wi per modul e from the modul e connector receptacl e.
i ty of the tai l gate wi re harness connector for the rear
wi per modul e and a good ground. There shoul d be
open ground ci rcui t to ground (G312) as requi red.
(9) Check for conti nui ty between the fl i p-up gl ass
ajar swi tch sense ci rcui t cavi ty of the tai l gate wi re
harness connector for the rear wi per modul e and a
good ground. There shoul d be conti nui ty wi th the
rear fl i p-up gl ass open, and no conti nui ty wi th the
rear fl i p-up gl ass cl osed. I f OK, go to Step 10. I f not
OK, repai r the open fl i p-up gl ass ajar ci rcui t between
the rear wi per modul e and the fl i p-up gl ass ajar
(10) Reconnect the battery negati ve cabl e. Check
for battery vol tage at the fused B(+) ci rcui t cavi ty of
the tai l gate wi re harness connector for the rear wi per
modul e. I f OK, go to Step 11. I f not OK, repai r the
open fused B(+) ci rcui t between the rear wi per mod-
ul e and the JB as requi red.
Turn the control ri ng on the ri ght (wi per) control
stal k of the mul ti -functi on swi tch to the Del ay posi -
ti on. Check for battery vol tage at the rear wi per
i ntermi ttent dri ver ci rcui t cavi ty of the tai l gate wi re
harness connector for the rear wi per modul e. I f OK,
go to Step 12. I f not OK, repai r the open rear wi per
i ntermi ttent dri ver ci rcui t between the rear wi per
modul e and the mul ti -functi on swi tch as requi red.
(12) Turn the control ri ng on the ri ght (wi per) con-
trol stal k of the mul ti -functi on swi tch to the On posi -
ti on. Check for battery vol tage at the rear wi per on
dri ver ci rcui t cavi ty of the tai l gate wi re harness con-
nector for the rear wi per modul e. I f OK, repl ace the
faul ty rear wi per modul e. I f not OK, repai r the open
rear wi per on dri ver ci rcui t between the rear wi per
modul e and the mul ti -functi on swi tch as requi red.
REAR WASHER SYSTEM
i noperati ve rear washer system. I f the washer pump/
motor operates, but no washer fl ui d i s emi tted from
the rear washer nozzl e, be certai n to check the fl ui d
l evel i n the reservoi r. Al so i nspect the rear washer
system components as requi red. (Refer to 8 - ELEC-
TRI CAL/REAR WI PERS/WASHERS - I NSPECTI ON).
Turn the control ri ng on the ri ght (wi per) control
stal k of the mul ti -functi on swi tch to the On posi ti on.
Check whether the rear wi per system i s operati ng. I f
OK, go to Step 2. I f not OK, test and repai r the rear
wi per system before conti nui ng wi th these tests.
Refer to REAR WI PER SYSTEM .
(2) Pul l the ri ght (wi per) control stal k of the mul ti -
functi on swi tch toward the steeri ng wheel . Check
whether the front washer system i s operati ng. I f OK,
test the mul ti -functi on swi tch. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/MULTI -
FUNCTI ON SWI TCH - DI AGNOSI S AND
TESTI NG). I f the mul ti -functi on swi tch tests OK, go
to Step 3. I f the mul ti -functi on swi tch does not test
OK, repl ace the faul ty swi tch.
Di sconnect the headl amp and dash wi re harness con-
nector for the washer pump/motor uni t from the
pump/motor uni t connector receptacl e. Check for con-
ti nui ty between the washer pump dri ver ci rcui t cav-
for the washer pump/motor uni t and a good ground.
There shoul d be no conti nui ty. I f OK, go to Step 4. I f
not OK, repai r the shorted washer pump dri ver ci r-
cui t between the washer pump/motor uni t and the
mul ti -functi on swi tch as requi red.
dri ver ci rcui t cavi ti es of the headl amp and dash wi re
repai r the open washer pump dri ver ci rcui t between
the washer pump/motor uni t and the mul ti -functi on
sense ci rcui t cavi ty of the headl amp and dash wi re
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 6. I f not OK, repai r the shorted
washer pump sense ci rcui t between the washer
pump/motor uni t and the mul ti -functi on swi tch as
requi red.
sense ci rcui t cavi ti es of the headl amp and dash wi re
shoul d be conti nui ty. I f OK, repl ace the faul ty washer
pump/motor uni t. I f not OK, repai r the open washer
pump sense ci rcui t between the washer pump/motor
uni t and the mul ti -functi on swi tch as requi red.
CLEANING - REAR WIPER & WASHER SYSTEM
REAR WIPER SYSTEM
The squeegee of a wi per bl ade exposed to the el e-
ments for a l ong ti me tends to l ose i ts wi pi ng effec-
ti veness. Peri odi c cl eani ng of the squeegee i s
suggested to remove any deposi ts of sal t or road fi l m.
The wi per bl ade, arm, and rear fl i p-up gl ass shoul d
onl y be cl eaned usi ng a sponge or soft cl oth and
wi ndshi el d washer fl ui d, a mi l d detergent, or a non-
abrasi ve cl eaner. I f the wi per bl ade conti nues to
l eave streaks, smears, hazi ng, or beadi ng on the
gl ass after thorough cl eani ng of the squeegees and
the gl ass, the enti re wi per bl ade assembl y must be
repl aced.
CAUTION: Protect the rubber squeegee of the wiper
blade from any petroleum-based cleaners, solvents,
or contaminants. These products can rapidly deteri-
orate the rubber squeegee.
REAR WASHER SYSTEM
I f the washer system i s contami nated wi th forei gn
materi al , drai n the washer reservoi r by removi ng the
washer pump/motor from the reservoi r. Cl ean forei gn
materi al from the i nsi de of the washer pump/motor
i nl et fi l ter screen and the washer reservoi r usi ng
cl ean washer fl ui d, a mi l d detergent, or a non-abra-
si ve cl eaner. Fl ush forei gn materi al from the washer
system pl umbi ng by fi rst di sconnecti ng the washer
hose from the washer nozzl e, then runni ng the
washer pump/motor to run cl ean washer fl ui d or
water through the system. A pl ugged or restri cted
washer nozzl e shoul d be careful l y back-fl ushed usi ng
compressed ai r. I f the washer nozzl e obstructi on can-
not be cl eared, repl ace the washer nozzl e.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegee of the wiper blade.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - REAR WIPER & WASHER
SYSTEM
REAR WIPER SYSTEM
The rear wi per bl ade and wi per arm shoul d be
i nspected peri odi cal l y, not just when wi per perfor-
(1) I nspect the wi per arm for any i ndi cati ons of
damage, or contami nati on. I f the wi per arm i s con-
tami nated wi th any forei gn materi al , cl ean as
requi red. (Refer to 8 - ELECTRI CAL/REAR WI PERS/
WASHERS - CLEANI NG). I f a wi per arm i s damaged
or corrosi on i s evi dent, repl ace the wi per arm wi th a
new uni t. Do not attempt to repai r a wi per arm that
i s damaged or corroded.
(2) Careful l y l i ft the wi per arm off of the park
ramp. Note the acti on of the wi per arm hi nge. The
wi per arm shoul d pi vot freel y at the hi nge, but wi th
no l ateral l ooseness evi dent. I f there i s any bi ndi ng
evi dent i n the wi per arm hi nge, or there i s evi dent
l ateral pl ay i n the wi per arm hi nge, repl ace the
wi per arm.
(3) Once proper hi nge acti on of the wi per arm i s
confi rmed, check the hi nge for proper spri ng tensi on.
The spri ng tensi on of the wi per arm shoul d be suffi -
ci ent to cause the rubber squeegee to conform to the
curvature of the gl ass. Repl ace a wi per arm i f i t has
l ow or no spri ng tensi on.
(4) I nspect the wi per bl ade and squeegee for any
i ndi cati ons of damage, contami nati on, or rubber dete-
ri orati on (Fi g. 2). I f the wi per bl ade or squeegee i s
contami nated wi th any forei gn materi al , cl ean them
and the gl ass as requi red. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS - CLEANI NG). I f
after cl eani ng the wi per bl ade and the gl ass, the
wi per bl ade fai l s to cl ear the gl ass wi thout smeari ng,
streaki ng, chatteri ng, hazi ng, or beadi ng, repl ace the
wi per bl ade. Al so, i f a wi per bl ade i s damaged or i f
the squeegee rubber i s damaged or deteri orated,
repl ace the wi per bl ade wi th a new uni t. Do not
attempt to repai r a wi per bl ade that i s damaged.
Fig. 2 Wiper Blade Inspection
1 - WORN OR UNEVEN EDGES
2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
REAR WASHER SYSTEM
The washer system components shoul d be
i nspected peri odi cal l y, not just when washer perfor-
(1) Check for i ce or other forei gn materi al i n the
washer reservoi r. I f contami nated, cl ean and fl ush
the washer system. (Refer to 8 - ELECTRI CAL/
REAR WI PERS/WASHERS - CLEANI NG).
(2) I nspect the washer pl umbi ng for pi nched, l eak-
i ng, deteri orated, or i ncorrectl y routed hoses and
damaged or di sconnected hose fi tti ngs. Repl ace dam-
aged or deteri orated hoses and hose fi tti ngs. Leaki ng
washer hoses can someti mes be repai red by cutti ng
the hose at the l eak and spl i ci ng i t back together
usi ng an i n-l i ne connector fi tti ng. Si mi l arl y, secti ons
of deteri orated hose can be cut out and repl aced by
spl i ci ng i n new secti ons of hose usi ng i n-l i ne connec-
tor fi tti ngs. Whenever routi ng a washer hose or a
wi re harness contai ni ng a washer hose, i t must be
routed away from hot, sharp, or movi ng parts. Al so,
sharp bends that mi ght pi nch the washer hose must
be avoi ded.
REAR CHECK VALVE
DESCRIPTION
A rear washer system check val ve i s standard
equi pment on thi s model (Fi g. 3). The rear check
val ve i s l ocated i n the washer pl umbi ng between the
rear roof header and the roof outer panel near the
rear washer nozzl e. The rear check val ve consi sts of
a mol ded pl asti c body wi th a round center secti on
and barbed hose ni ppl es at each end. An arrow for-
mati on mol ded i nto the center secti on of the val ve
body i ndi cates the di recti on of fl ow through the
val ve. The rear check val ve cannot be adjusted or
repl aced.
OPERATION
The rear check val ve prevents washer fl ui d from
drai ni ng out of the rear washer suppl y hoses back to
the washer reservoi r. Thi s drai n-back woul d resul t i n
a l engthy del ay from when the rear washer swi tch i s
actuated unti l washer fl ui d was di spensed through
the rear washer nozzl e, because the washer pump
woul d have to refi l l the rear washer pl umbi ng from
the reservoi r to the nozzl e. The check val ve al so pre-
vents washer fl ui d from si phoni ng through the rear
washer nozzl e after the rear washer system i s turned
Off.
Wi thi n the check val ve body, a smal l check val ve i s
hel d i n pl ace agai nst a seat by a smal l coi l ed spri ng
to restri ct fl ow through the uni t unti l the val ve i s
unseated by a predetermi ned i nl et fl ui d pressure.
When the washer pump pressuri zes and pumps
washer fl ui d from the reservoi r through the rear
washer pl umbi ng, the fl ui d pressure overri des the
spri ng pressure appl i ed to the check bal l wi thi n the
val ve and unseats the val ve, al l owi ng washer fl ui d to
fl ow toward the rear washer nozzl e. When the
washer pump stops operati ng, spri ng pressure seats
the check val ve and fl ui d fl ow i n ei ther di recti on
wi thi n the rear washer pl umbi ng i s prevented.
REMOVAL
cabl e.
(CHMSL) uni t from the rear of the roof panel . (Refer
to 8 - ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI -
OR/CENTER HI GH MOUNTED STOP LAMP UNI T
- REMOVAL).
WARNING: THE EDGES OF THE SHEET METAL
AROUND THE CENTER HIGH MOUNTED STOP
LAMP MOUNTING HOLE IN THE ROOF PANEL.
TAKE THE PROPER PRECAUTIONS TO AVOID PER-
SONAL INJURY.
(3) Reach through the CHMSL uni t mounti ng hol e
i n the rear of the roof panel to access and di sconnect
the rear washer hose at the barbed ni ppl e of the rear
washer nozzl e (Fi g. 4).
(4) Pul l the rear washer hose through the CHMSL
uni t mounti ng hol e far enough to access and di scon-
nect the headl i ner washer hose from the barbed ni p-
pl e of the rear check val ve.
Fig. 3 Rear Check Valve
1 - INLET NIPPLE
2 - REAR CHECK VALVE
3 - OUTLET NIPPLE
4 - FLOW DIRECTION ARROW
(5) Remove the rear check val ve and rear washer
nozzl e hose as a uni t through the CHMSL mounti ng
hol e.
(6) Di sconnect the rear washer nozzl e hose from
the barbed ni ppl e of the rear check val ve.
INSTALLATION
(1) Reconnect the rear washer nozzl e hose to the
barbed ni ppl e of the rear check val ve. Be certai n that
the fl ow di recti on arrow mol ded i nto the rear check
val ve body i s ori ented towards the rear washer noz-
zl e hose.
WARNING: THE EDGES OF THE SHEET METAL
AROUND THE CENTER HIGH MOUNTED STOP
LAMP MOUNTING HOLE IN THE ROOF PANEL.
TAKE THE PROPER PRECAUTIONS TO AVOID PER-
SONAL INJURY.
i n the rear of the roof panel to access and pul l the
headl i ner washer hose i nto the Center Hi gh Mounted
Stop Lamp (CHMSL) uni t mounti ng hol e (Fi g. 4).
(3) Reconnect the headl i ner washer hose to the
barbed ni ppl e of the rear check val ve.
i n the rear of the roof panel to access and reconnect
the rear washer nozzl e hose to the barbed ni ppl e of
the rear washer nozzl e.
(5) Rei nstal l the CHMSL uni t to the rear of the
roof panel . (Refer to 8 - ELECTRI CAL/LAMPS/
LI GHTI NG - EXTERI OR/CENTER HI GH
MOUNTED STOP LAMP UNI T - I NSTALLATI ON).
REAR WASHER HOSES/TUBES
DESCRIPTION
The rear washer pl umbi ng consi sts of smal l di am-
eter rubber hose routed from the barbed outl et ni ppl e
of the reversi bl e el ectri c washer pump/motor uni t on
the washer reservoi r through a trough mol ded i nto
the reservoi r rearward of the washer pump up to the
top of the reservoi r. Near the base of the reservoi r
fi l l er neck an i n-l i ne pl asti c fi tti ng connects the res-
ervoi r rear washer hose to the engi ne compartment
rear washer hose, whi ch i s routed through the reser-
voi r fi l l er neck openi ng i n the front extensi on of the
ri ght front fender wheel house panel i n to the engi ne
compartment. The engi ne compartment rear washer
hose i s routed si de by si de wi th the front washer
hose al ong the top of the ri ght front fender wheel
house to the dash panel . Mol ded pl asti c routi ng cl i ps
secure the hoses to the headl amp and dash wi re har-
ness i n the engi ne compartment.
The engi ne compartment rear washer hose i s con-
nected to the headl i ner washer hose near the ri ght
si de of the dash panel wi th a mol ded pl asti c i n-l i ne
fi tti ng (Fi g. 5). The headl i ner hose has a rubber
grommet that al l ows i t to pass through the dash
panel from the passenger compartment i nto the
engi ne compartment. The headl i ner hose i s routed
bel ow the i nstrument panel i n the passenger com-
partment near the ri ght cowl si de i nner panel . The
hose i s routed up the ri ght A-pi l l ar to the headl i ner.
Mounti ng cl i ps secure the hose to the A-pi l l ar. The
Fig. 4 Rear Check Valve Remove/Install
1 - WASHER NOZZLE HOSE
2 - REAR CHECK VALVE
3 - HEADLINER HOSE
4 - ROOF PANEL
5 - NEEDLE NOSE PLIERS
6 - CHMSL MOUNTING HOLE
Fig. 5 Rear Washer Headliner Hose
1 - COWL SIDE INNER PANEL
2 - A-PILLAR
3 - HEADLINER HOSE
4 - CLIP (3)
5 - GROMMET
6 - DASH PANEL
REAR CHECK VALVE (Continued)
headl i ner hose i s gl ued to top of the headl i ner and
routed al ong the ri ght roof si de rai l to the rear of the
vehi cl e. At the rear of the vehi cl e, the headl i ner hose
passes through a hol e at the rear porti on of the roof
rear i nner header panel and i s connected to the rear
check val ve. From the rear check val ve, there i s a
short secti on of hose that connects the rear check
val ve to the rear washer nozzl e.
Washer hose i s avai l abl e for servi ce onl y as rol l
stock, whi ch must then be cut to l ength. The head-
l i ner washer hose i s i ntegral to the headl i ner uni t
and, i f faul ty or damaged, the headl i ner uni t must be
repl aced. However, the headl i ner hose i s marked
wi th a whi te cut l i ne on the A-pi l l ar where the hose
shoul d be cut and spl i ced wi th a pl asti c i n-l i ne con-
nector fi tti ng to faci l i tate headl i ner removal wi thout
the need to remove the i nstrument panel . (Refer to
23 - BODY/I NTERI OR/HEADLI NER - REMOVAL
AND I NSTALLATI ON). The mol ded pl asti c washer
hose fi tti ngs cannot be repai red. I f these fi tti ngs are
faul ty or damaged, they must be repl aced.
OPERATION
Washer fl ui d i n the washer reservoi r i s pressuri zed
and fed by the washer pump/motor through the rear
washer system pl umbi ng and fi tti ngs to the rear
washer nozzl e l ocated on the roof panel above the
rear fl i p-up gl ass openi ng. Whenever routi ng the
washer hose or a wi re harness contai ni ng a washer
hose, i t must be routed away from hot, sharp, or
movi ng parts; and, sharp bends that mi ght pi nch the
hose must be avoi ded.
REAR WASHER NOZZLE
DESCRIPTION
The rear washer nozzl e i s a fl ui di c-type uni t con-
structed of mol ded pl asti c (Fi g. 6). The nozzl e i s
secured by a snap fi t i n a dedi cated mounti ng hol e
l ocated i n the rear edge of the roof panel above the
rear fl i p-up gl ass openi ng and to the ri ght of the
Center Hi gh Mounted Stop Lamp (CHMSL) uni t. A
rubber gasket on the back of the nozzl e seal s the noz-
zl e to the roof panel openi ng. The back of the nozzl e
i ncl udes an i ntegral al i gnment feature on the l eft
si de, an i ntegral engagement tab on the top, an i nte-
gral l atch feature on the bottom, and the washer
pl umbi ng ni ppl e whi ch are al l conceal ed between the
outer roof panel and the rear roof i nner header. The
rear washer nozzl e l atch feature i s a one ti me com-
ponent, and wi l l be damaged i f the nozzl e i s removed
from i ts mounti ng hol e for servi ce. The rear washer
nozzl e cannot be adjusted or repai red. I f faul ty or
damaged, the enti re nozzl e uni t must be repl aced.
OPERATION
The rear washer nozzl e i s desi gned to di spense
washer fl ui d i nto the wi per pattern area on the out-
si de of the rear fl i p-up gl ass. Pressuri zed washer
fl ui d i s fed to the nozzl e from the washer reservoi r by
the washer pump/motor through a si ngl e hose, whi ch
i s attached to a barbed ni ppl e on the back of the rear
washer nozzl e. The rear washer nozzl e i ncorporates a
fl ui di c desi gn, whi ch causes the nozzl e to emi t the
pressuri zed washer fl ui d as an osci l l ati ng stream to
more effecti vel y cover a l arger area of the gl ass area
to be cl eaned.
REMOVAL
NOTE: The rear washer nozzle latch feature is a one
time component, and will be damaged if the nozzle is
removed from its mounting hole for service. If
removed from its mounting hole for any reason, the
rear washer nozzle must be replaced with a new unit.
fl at-bl aded tool , gentl y pry the bottom of the rear
washer nozzl e away from the roof panel unti l the
l atch feature at the bottom of the nozzl e that secures
i t i n the mounti ng hol e of the roof panel snaps.
(2) Pul l the rear washer nozzl e out from the roof
panel far enough to access the washer hose (Fi g. 7).
(3) Di sconnect the washer hose from the barbed
ni ppl e on the back of the rear washer nozzl e.
(4) Di scard the rear washer nozzl e.
Fig. 6 Rear Washer Nozzle
1 - ENGAGEMENT TAB (TOP)
2 - GASKET
3 - REAR WASHER NOZZLE
4 - ALIGNMENT FEATURE
5 - ORIFICE
6 - LATCH FEATURE (BOTTOM)
7 - NIPPLE
REAR WASHER HOSES/TUBES (Continued)
INSTALLATION
NOTE: The rear washer nozzle latch feature is a one
time component, and will be damaged if the nozzle
is removed from its mounting hole for service. If
removed from its mounting hole for any reason, the
rear washer nozzle must be replaced with a new
unit.
(1) Posi ti on the new rear washer nozzl e to the roof
panel (Fi g. 7). Be certai n that a new rubber gasket i s
i n posi ti on on the back of the nozzl e.
(2) Reconnect the washer hose to the barbed ni p-
pl e on the back of the rear washer nozzl e.
(3) I nsert the rear washer nozzl e suppl y hose and
ni ppl e i nto the mounti ng hol e i n the roof panel and
al i gn the nozzl e wi th the hol e.
(4) Engage the tab at the top of the nozzl e behi nd
the sheet metal at the top of the roof panel mounti ng
hol e.
on the hood of the rear washer nozzl e unti l the l ower
l atch feature snaps i nto pl ace behi nd the sheet metal
at the bottom of the roof panel mounti ng hol e.
REAR WIPER ARM
DESCRIPTION
The rear wi per arm i s the ri gi d member l ocated
between the rear wi per motor output shaft that pro-
trudes from the outer tai l gate panel near the base of
the rear fl i p-up gl ass openi ng and the rear wi per
bl ade (Fi g. 8). Thi s wi per arm features an over-center
hi nge that al l ows easy access to the tai l gate and rear
fl i p-up gl ass for cl eani ng, after the spare ti re i s
removed. The wi per arm has a di e cast metal pi vot
end wi th a l arge tapered mounti ng hol e at one end. A
mol ded pl asti c pi vot cover i s secured l oosel y to and
pi vots on the wi per arm hi nge pi n to conceal the
wi per arm retai ni ng nut. The wi de end of a tapered,
stamped steel channel i s secured wi th a hi nge pi n to
the pi vot end of the wi per arm. One end of a l ong,
ri gi d, stamped steel strap, wi th a smal l hol e near i ts
pi vot end, i s ri veted and cri mped wi thi n the narrow
end of the stamped steel channel . The ti p of the
wi per bl ade end of thi s strap i s bent back under i tsel f
to form a smal l hook. Conceal ed wi thi n the stamped
steel channel , one end of a l ong spri ng i s engaged
wi th a wi re hook on the undersi de of the di e cast
pi vot end, whi l e the other end of the spri ng i s hooked
through the smal l hol e i n the steel strap. A mol ded
pl asti c wi per arm support i s snapped onto the wi per
arm strap where i t exi ts the channel . The enti re
wi per arm has a sati n bl ack fi ni sh appl i ed to al l of
i ts vi si bl e surfaces.
Fig. 7 Rear Washer Nozzle Remove/Install
1 - NOZZLE
2 - ROOF PANEL
3 - HEADLINER HOSE
Fig. 8 Rear Wiper Arm
1 - HOOK
2 - STRAP
3 - CHANNEL
4 - HINGE PIN
5 - COVER
6 - PIVOT END
7 - TENSION SPRING
8 - SUPPORT
REAR WASHER NOZZLE (Continued)
A wi per arm cannot be adjusted or repai red. I f
damaged or faul ty, the enti re wi per arm uni t must be
repl aced.
OPERATION
The rear wi per arm i s desi gned to mechani cal l y
transmi t the moti on from the rear wi per motor out-
put shaft to the rear wi per bl ade. The wi per arm
must be properl y i ndexed to the motor output shaft
i n order to mai ntai n the proper wi per bl ade travel on
the gl ass. The wi per arm support i s desi gned to l i ft
and support the rear wi per arm and bl ade off of the
gl ass when the rear wi per bl ade i s parked. Thi s sup-
port and the park ramp on the tai l gate outer panel
bel ow the gl ass al so provi de an al i gnment reference
to ensure accurate rear wi per arm and bl ade i nstal -
l ati on. The tapered hol e i n the wi per arm pi vot end
i s i nterl ocks wi th the serrati ons on the outer ci rcum-
ference of the tapered motor output shaft, al l owi ng
posi ti ve engagement and fi ni te adjustment of thi s
connecti on. A hex nut secures the wi per arm pi vot
end to the threads on the rear wi per motor output
shaft and the pi vot cover hi nges and snaps over thi s
connecti on for a neat appearance. The spri ng-l oaded
wi per arm hi nge control s the down-force appl i ed
through the ti p of the wi per arm to the wi per bl ade
on the gl ass. The hook formati on on the ti p of the
wi per arm provi des a cradl e for securi ng and l atchi ng
the wi per bl ade pi vot bl ock to the wi per arm.
REMOVAL
(1) Li ft the rear wi per arm pi vot cover by l i fti ng i t
at the rear wi per motor output shaft end of the arm
(Fi g. 9).
(2) Remove the nut that secures the rear wi per
arm to the rear wi per motor output shaft.
(3) I f necessary, use a battery termi nal pul l er to
di sengage the wi per arm from the rear wi per motor
output shaft spl i nes (Fi g. 10).
NOTE: Depending upon the size and type of puller
used, it may be necessary to remove the spare tire
from the tailgate. Refer to the owners manual in the
vehicle glove box for information on removing the
spare tire from the tailgate.
(4) Remove the rear wi per arm pi vot end from the
motor output shaft.
INSTALLATION
NOTE: Always install the wiper arm and blade with
the wiper motor in the Park position.
(1) The rear wi per arm must be i ndexed to the
motor output shaft wi th the rear wi per motor i n the
park posi ti on to be properl y i nstal l ed. Pl ace the
wi per arm onto the tai l gate wi th the wi per arm sup-
port posi ti oned on the park ramp and the tapered
mounti ng hol e on the pi vot end of the arm posi ti oned
over the rear wi per motor output shaft.
(2) Posi ti on the tab on the back of the rear wi per
arm support on the tai l gate park ramp i n the I nstal -
l ati on Posi ti on (Fi g. 11).
(3) Wi th the wi per arm i n the I nstal l ati on Posi -
ti on, push the tapered mounti ng hol e on the pi vot
end of the wi per arm down over the rear wi per motor
output shaft.
Fig. 9 Rear Wiper Arm Remove/Install
1 - SPARE TIRE
2 - WRENCH
3 - FLIP-UP GLASS
4 - PARK RAMP
5 - REAR WIPER ARM
6 - PIVOT COVER
Fig. 10 Wiper Arm Puller - Typical
1 - WIPER ARM
2 - WIPER PIVOT
REAR WIPER ARM (Continued)
rear wi per arm to the rear wi per motor output shaft.
(5) Cl ose the rear wi per arm pi vot cover.
(6) Li ft the rear wi per arm support away from the
park ramp, then pl ace the wi per arm support i n the
park ramp i n the Park Posi ti on (Fi g. 11).
REAR WIPER BLADE
DESCRIPTION
The rear wi per bl ade i s secured by an i ntegral
l atchi ng pi vot bl ock to the hook formati on on the ti p
of the rear wi per arm, and rests off the gl ass on a
park ramp on the tai l gate near the base of the rear
fl i p-up gl ass openi ng when the wi per i s not i n oper-
ati on (Fi g. 12). The rear wi per bl ade consi sts of the
fol l owi ng components:
Superstructure - The superstructure i ncl udes
a stamped steel bri dge and pl asti c l i nks wi th cl aw
formati ons that gri p the wi per bl ade el ement. Al so
i ncl uded i n thi s uni t i s the l atchi ng, mol ded pl asti c
pi vot bl ock that secures the superstructure to the
wi per arm. Al l of the metal components of the wi per
bl ade have a sati n bl ack fi ni sh appl i ed.
Element - The wi per el ement or squeegee i s the
resi l i ent rubber member of the wi per bl ade that con-
tacts the gl ass.
Flexor - The fl exor i s a ri gi d metal component
runni ng al ong the l ength of each si de of the wi per
el ement where i t i s gri pped by the cl aws of the
superstructure.
Al l model s have a si ngl e 28.00 centi meter (11.00
i nch) rear wi per bl ade wi th a non-repl aceabl e rubber
el ement (squeegee). The wi per bl ade cannot be
adjusted or repai red. I f faul ty, worn, or damaged the
enti re wi per bl ade uni t must be repl aced.
OPERATION
The wi per bl ade i s moved back and forth across the
gl ass by the wi per arm when the wi per system i s i n
operati on. The wi per bl ade superstructure i s the fl ex-
i bl e frame that gri ps the wi per bl ade el ement and
evenl y di stri butes the force of the spri ng-l oaded
wi per arm al ong the l ength of the el ement. The com-
bi nati on of the wi per arm force and the fl exi bi l i ty of
the superstructure makes the el ement conform to
Fig. 11 Rear Wiper Arm Installation
1 - TAILGATE
2 - PARK RAMP
3 - REAR WIPER ARM
4 - INSTALLATION POSITION
5 - REAR WIPER ARM AND BLADE
6 - PARK POSITION
7 - PARK RAMP
8 - TAILGATE
Fig. 12 Rear Wiper Blade
1 - SUPERSTRUCTURE
2 - PIVOT PIN
3 - LATCH RELEASE
4 - PIVOT BLOCK
5 - CLAW
6 - FLEXOR
7 - ELEMENT
REAR WIPER ARM (Continued)
and mai ntai n proper contact wi th the gl ass, even as
the bl ade i s moved over the vari ed curvature found
across the gl ass surface. The wi per el ement fl exor
provi des the cl aws of the bl ade superstructure wi th a
ri gi d, yet fl exi bl e component on the el ement whi ch
can be gri pped. The rubber el ement i s desi gned to be
sti ff enough to mai ntai n an even cl eani ng edge as i t
i s drawn across the gl ass, but resi l i ent enough to
conform to the gl ass surface and fl i p from one cl ean-
i ng edge to the other each ti me the wi per bl ade
changes di recti ons.
REMOVAL
wiper blade that is nearest to the wiper motor out-
put shaft.
(1) Di sengage the rear wi per arm support from the
rear wi per arm park ramp on the ri ght si de of the
tai l gate just bel ow the rear fl i p-up gl ass.
(2) Li ft the rear wi per arm to rai se the wi per bl ade
and el ement off of the tai l gate and the rear fl i p-up
gl ass.
(3) To remove the wi per bl ade from the wi per arm,
careful l y l i ft up the pi vot bl ock l atch rel ease tab on
the top of the wi per arm to unl atch i t from the arm
(Fi g. 13).
(4) Rai se the pi vot bl ock l atch rel ease tab unti l i t
i s perpendi cul ar to the rear wi per bl ade superstruc-
ture (Fi g. 14).
(5) Sl i de the rear wi per bl ade away from the ti p of
the arm towards the pi vot end of the arm far enough
to di sengage the pi vot bl ock from the hook formati on
on the end of the arm.
(6) Extract the hook formati on on the ti p of the
wi per arm from the wi ndow i n the wi per bl ade pi vot
bl ock/l atch uni t.
back against the tailgate or the flip-up glass without
the wiper blade in place or they may be damaged.
(7) Gentl y l ower the wi per arm and pl ace the arm
support i n the park ramp.
INSTALLATION
wiper blade that is nearest to the wiper motor out-
put shaft.
(1) Li ft the rear wi per arm support out of the tai l
gate park ramp.
(2) Posi ti on the rear wi per bl ade near the hook for-
mati on on the ti p of the arm wi th the notched end of
the wi per el ement fl exor ori ented towards the end of
the wi per arm that i s nearest to the wi per motor out-
put shaft.
Fig. 13 Rear Wiper Blade Release
1 - PIVOT BLOCK WINDOW
2 - TIP OF REAR WIPER ARM
3 - SUPERSTRUCTURE
4 - PIVOT BLOCK HINGE PIN
5 - LATCH RELEASE TAB
Fig. 14 Rear Wiper Blade Remove/Install
1 - SUPERSTRUCTURE
2 - HOOK
3 - ELEMENT
4 - LATCH RELEASE
5 - REAR WIPER ARM
REAR WIPER BLADE (Continued)
(3) Rai se the pi vot bl ock l atch rel ease tab unti l i t
i s perpendi cul ar to the rear wi per bl ade superstruc-
ture (Fi g. 14).
(4) I nsert the hook formati on on the ti p of the
wi per arm through the wi ndow i n the wi per bl ade
pi vot bl ock/l atch uni t.
(5) Sl i de the wi per bl ade pi vot bl ock/l atch up i nto
the hook formati on on the ti p of the wi per arm unti l
the hook i s fi rml y seated agai nst the pi vot bl ock.
(6) Press the pi vot bl ock l atch rel ease tab down-
ward unti l i t snaps i nto i ts l ocked posi ti on over the
top of the wi per arm.
(7) Gentl y l ower the wi per arm and pl ace the arm
support i n the tai l gate park ramp.
REAR WIPER MOTOR
DESCRIPTION
The rear wi per motor i s conceal ed wi thi n the tai l -
gate, bel ow the rear fl i p-up gl ass openi ng and behi nd
the tai l gate i nner tri m panel . The end of the motor
output shaft that protrudes through the tai l gate
outer panel to dri ve the rear wi per arm and bl ade i s
the onl y vi si bl e component of the rear wi per motor
(Fi g. 15). A rubber gasket, a bezel , and a nut secure
and seal the motor output shaft to the tai l gate outer
panel . A mol ded pl asti c nut cover snaps onto the
bezel to conceal the nut and i mprove appearance. An
i ntegral connector receptacl e connects the rear wi per
motor to the vehi cl e el ectri cal system through a ded-
i cated take out and connector of the tai l gate wi re
harness. The rear wi per motor consi sts of the fol l ow-
i ng major components:
Bracket - The rear wi per motor bracket consi sts
of a stamped steel mounti ng pl ate for the wi per
motor that i s secured wi th screws through two rub-
ber i nsul ators to the tai l gate i nner panel .
Rear Wiper Module - The rear wi per motor
el ectroni c control s are conceal ed beneath a mol ded
pl asti c cover and i ncl udes the rear wi per system el ec-
troni c l ogi c and rear wi per motor el ectroni c control s.
Motor - The permanent magnet rear wi per
motor i s secured wi th screws to the rear wi per motor
bracket. The wi per motor i ncl udes an i ntegral trans-
mi ssi on, and the motor output shaft.
The rear wi per motor cannot be adjusted or
repai red. I f any component of the motor i s faul ty or
damaged, the enti re rear wi per motor uni t must be
repl aced. The motor output shaft gasket, bezel , nut,
and nut cover are avai l abl e for servi ce repl acement.
OPERATION
The rear wi per motor recei ves non-swi tched bat-
tery current through a fuse i n the Juncti on Bl ock
(JB) on a fused B(+) ci rcui t and i s connected to
ground at al l ti mes. The rear wi per motor operati on
i s control l ed by the vehi cl e operator through battery
current si gnal i nputs recei ved by the rear wi per
motor el ectroni c control modul e from the rear wi per
swi tch ci rcui try that i s i ntegral to the ri ght (wi per)
control stal k of the mul ti -functi on swi tch on the
steeri ng col umn. The modul e al so recei ves an exter-
nal control i nput from the fl i p-up gl ass ajar swi tch
sense ci rcui t. I f the rear wi per modul e senses that
the fl i p-up gl ass i s ajar, i t wi l l not al l ow the rear
wi per motor to operate.
The rear wi per modul e el ectroni c control l ogi c uses
these i nputs, i ts i nternal i nputs, and i ts program-
mi ng to provi de a conti nuous wi pe mode, an i nter-
mi ttent wi pe mode, a wi pe-after-wash mode, and off-
the-gl ass wi per bl ade parki ng. The wi per bl ade
cycl i ng i s control l ed by the i nternal el ectroni c con-
trol s of the modul e. The modul e control s current fl ow
to the wi per motor brushes and provi des an el ec-
troni c speed control that speeds the wi per bl ade near
the center of the gl ass, but sl ows the wi per bl ade
duri ng di recti onal reversal s at each end of the wi pe
pattern and duri ng wi per bl ade off-the-gl ass parki ng
for qui eter operati on. The wi per motor transmi ssi on
converts the rotary output of the wi per motor to the
back and forth wi pi ng moti on of the rear wi per arm
and bl ade on the rear fl i p-up gl ass.
Fig. 15 Rear Wiper Motor
1 - SCREW (2)
2 - INSULATOR (2)
3 - BRACKET
4 - OUTPUT SHAFT
5 - SEAL
7 - COVER
8 - MOTOR
REAR WIPER BLADE (Continued)
REMOVAL
cabl e.
(2) Remove the rear wi per arm from the rear
wi per motor output shaft. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS/REAR WI PER ARM
- REMOVAL).
(3) Usi ng a smal l thi n-bl aded tool , gentl y pry at
the notch i n the base of the rear wi per motor output
shaft bezel to unsnap the nut cover from the bezel
(Fi g. 16). Be certain to take proper precautions
to protect the outer tailgate panel and its paint
finish from damage during this procedure.
(4) Remove the nut that secures the rear wi per
motor output shaft to the outer swi ng gate panel
(Fi g. 16).
(5) Remove the bezel and gasket from the rear
wi per motor output shaft.
(6) Remove the tri m panel from the tai l gate i nner
panel . (Refer to 23 - BODY/SWI NG GATE/TRI M
PANEL - REMOVAL).
(7) Di sconnect the tai l gate wi re harness connector
for the fl i p-up gl ass ajar swi tch from the fl i p-up gl ass
l atch connector receptacl e.
(8) Di sconnect the tai l gate wi re harness connector
for the rear wi per motor from the motor connector
receptacl e (Fi g. 17).
(9) Loosen the two screws that secure the rear
wi per motor mounti ng bracket to the top of the tai l -
gate i nner panel .
(10) Sl i de the rear wi per motor and mounti ng
bracket back far enough to di sengage the two mount-
i ng screws from the keyed sl ots i n the top of the tai l -
gate i nner panel .
(11) Remove the rear wi per motor and mounti ng
bracket from the tai l gate as a uni t.
INSTALLATION
(1) Posi ti on the rear wi per motor and bracket i nto
the tai l gate as a uni t (Fi g. 17).
(2) I nsert the rear wi per motor output shaft
through the hol e i n the tai l gate outer panel and
engage the two mounti ng screws i nto the keyed sl ots
i n the top of tai l gate i nner panel .
(3) From the outsi de of the tai l gate, center the
rear wi per motor output shaft i n the tai l gate outer
panel cl earance hol e and i nstal l the gasket and bezel
over the centered shaft (Fi g. 16).
rear wi per motor output shaft to the outer tai l gate
panel . Ti ghten the nut to 5 Nm (43 i n. l bs.).
(5) From the i nsi de of the tai l gate, ti ghten the two
screws that secure the rear wi per motor mounti ng
bracket to the top of the tai l gate i nner panel . Ti ghten
(6) Reconnect the tai l gate wi re harness connector
for the rear wi per motor to the motor connector
receptacl e.
Fig. 16 Rear Wiper Motor Output Shaft Nut
Remove/Install
1 - BEZEL AND GASKET
2 - OUTPUT SHAFT
3 - TAILGATE OUTER PANEL
4 - NUT
5 - NUT COVER
Fig. 17 Rear Wiper Motor Remove/Install
1 - KEYED SLOT (2)
2 - SWING GATE INNER PANEL
3 - SCREW (2)
4 - REAR WIPER MOTOR ELECTRICAL CONNECTOR
5 - REAR WIPER MOTOR
REAR WIPER MOTOR (Continued)
(7) Reconnect the tai l gate wi re harness connector
for the fl i p-up gl ass ajar swi tch to the fl i p-up gl ass
l atch connector receptacl e.
(8) Rei nstal l the tri m panel onto the tai l gate i nner
panel . (Refer to 23 - BODY/SWI NG GATE/TRI M
PANEL - I NSTALLATI ON).
(9) From the outsi de of the tai l gate, press the nut
cover fi rml y and evenl y over the rear wi per motor
output shaft bezel usi ng hand pressure unti l i t snaps
i nto pl ace.
(10) Rei nstal l the rear wi per arm onto the rear
wi per motor output shaft. (Refer to 8 - ELECTRI -
CAL/REAR WI PERS/WASHERS/REAR WI PER ARM
- I NSTALLATI ON).
REAR WIPER/WASHER
SWITCH
DESCRIPTION
The rear wi per and washer swi tches are i ntegral to
DESCRI PTI ON).
OPERATION
The rear wi per and washer swi tches are i ntegral to
OPERATI ON).
WIPER ARM PARK RAMP
REMOVAL
(1) Di sengage the rear wi per arm support from the
wi per arm park ramp on the ri ght si de of the tai l gate
just bel ow the rear fl i p-up gl ass.
(2) Li ft the wi per arm and bl ade away from the
tai l gate unti l the wi per arm hi nge i s i n i ts over-cen-
ter posi ti on.
Remove the screw that secures the wi per arm park
ramp to the tai l gate outer panel (Fi g. 18).
(3) Remove the wi per arm park ramp from the
tai l gate outer panel .
INSTALLATION
(1) Posi ti on the wi per arm park ramp onto the
tai l gate outer panel (Fi g. 18).
wi per arm park ramp to the tai l gate outer panel .
Ti ghten the screw to 5 Nm (45 i n. l bs.).
(3) Lower the rear wi per arm and bl ade and pl ace
the wi per arm support onto the wi per arm park
ramp.
Fig. 18 Wiper Arm Park Ramp Remove/Install
1 - SCREW (1)
2 - PARK RAMP
3 - RIVET NUT (1)
4 - TAILGATE OUTER PANEL
REAR WIPER MOTOR (Continued)
WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION. . . . . . 8Wa-01-1
COMPONENT INDEX. . . . . . . . . . . . . . . . . 8Wa-02-1
POWER DISTRIBUTION . . . . . . . . . . . . . . 8Wa-10-1
JUNCTION BLOCK. . . . . . . . . . . . . . . . . . . 8Wa-12-1
GROUND DISTRIBUTION . . . . . . . . . . . . . 8Wa-15-1
BUS COMMUNICATIONS . . . . . . . . . . . . . 8Wa-18-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . 8Wa-20-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . 8Wa-21-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . 8Wa-30-1
TRANSMISSION CONTROL SYSTEM . . . . 8Wa-31-1
VEHICLE SPEED CONTROL . . . . . . . . . . . 8Wa-33-1
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . 8Wa-35-1
VEHICLE THEFT SECURITY SYSTEM . . . . 8Wa-39-1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . 8Wa-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . 8Wa-41-1
AIR CONDITIONING-HEATER . . . . . . . . . . 8Wa-42-1
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . 8Wa-43-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . 8Wa-44-1
BODY CONTROL MODULE . . . . . . . . . . . . 8Wa-45-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . 8Wa-47-1
REAR WINDOW DEFOGGER. . . . . . . . . . . 8Wa-48-1
OVERHEAD CONSOLE. . . . . . . . . . . . . . . . 8Wa-49-1
FRONT LIGHTING. . . . . . . . . . . . . . . . . . . 8Wa-50-1
REAR LIGHTING . . . . . . . . . . . . . . . . . . . . 8Wa-51-1
TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . 8Wa-52-1
WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-1
TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . 8Wa-54-1
POWER WINDOWS. . . . . . . . . . . . . . . . . . 8Wa-60-1
POWER DOOR LOCKS . . . . . . . . . . . . . . . 8Wa-61-1
POWER MIRRORS . . . . . . . . . . . . . . . . . . 8Wa-62-1
POWER SEAT . . . . . . . . . . . . . . . . . . . . . . 8Wa-63-1
POWER SUNROOF . . . . . . . . . . . . . . . . . . 8Wa-64-1
SPLICE INFORMATION . . . . . . . . . . . . . . . 8Wa-70-1
CONNECTOR PIN-OUTS . . . . . . . . . . . . . . 8Wa-80-1
CONNECTOR/GROUND/
SPLICE LOCATION . . . . . . . . . . . . . . . . . 8Wa-91-1
KJ WIRING 8Wa - 1
8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - CIRCUIT INFORMATION . . . . 5
DESCRIPTION - CIRCUIT FUNCTIONS . . . . . . 5
DESCRIPTION - SECTION IDENTIFICATION
AND INFORMATION . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - CONNECTOR, GROUND
AND SPLICE INFORMATION . . . . . . . . . . . . . . 6
WARNINGS - GENERAL . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - WIRING
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STANDARD PROCEDURE
STANDARD PROCEDURE -
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL. . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - TESTING FOR
CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND . . . . . . . . . . . . . . . . . . . 9
SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS . . . . . . . . . . . . 9
VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . 10
CONNECTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIODE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
TERMINAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
WIRE
STANDARD PROCEDURE - WIRE SPLICING . . 13
WIRING DIAGRAM
INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS
Dai ml erChrysl er Corporati on wi ri ng di agrams are
desi gned to provi de i nformati on regardi ng the vehi -
cl es wi ri ng content. I n order to effecti vel y use the
wi ri ng di agrams to di agnose and repai r
Dai ml erChrysl er Corporati on vehi cl es, i t i s i mportant
to understand al l of thei r features and characteri s-
ti cs.
Di agrams are arranged such that the power (B+)
si de of the ci rcui t i s pl aced near the top of the page,
and the ground (B-) si de of the ci rcui t i s pl aced near
the bottom of the page (Fi g. 1).
Al l swi tches, components, and modul es are shown
i n the at rest posi ti on wi th the doors cl osed and the
key removed from the i gni ti on (Fi g. 2).
Components are shown two ways. A sol i d l i ne
around a component i ndi cates that the component i s
compl ete. A dashed l i ne around the component i ndi -
cates that the component i s bei ng shown i s not com-
pl ete. I ncompl ete components have a reference
number to i ndi cate the page where the component i s
shown compl ete.
I t i s i mportant to real i ze that no attempt i s made
on the di agrams to represent components and wi ri ng
as they appear on the vehi cl e. For exampl e, a short
pi ece of wi re i s treated the same as a l ong one. I n
addi ti on, swi tches and other components are shown
as si mpl y as possi bl e, wi th regard to functi on onl y.
SYMBOLS
I nternati onal symbol s are used throughout the wi r-
i ng di agrams. These symbol s are consi stent wi th
those bei ng used around the worl d (Fi g. 3).
KJ 8W-01 WIRING DIAGRAM INFORMATION 8Wa - 01 - 1
Fig. 1 WIRING DIAGRAM EXAMPLE 1
8Wa - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION KJ
WIRING DIAGRAM INFORMATION (Continued)
Fig. 2 WIRING DIAGRAM EXAMPLE 2
Fig. 3 WIRING DIAGRAM SYMBOLS
TERMINOLOGY
Thi s i s a l i st of terms and defi ni ti ons used i n the
wi ri ng di agrams.
LHD . . . . . . . . . . . . . . . . . Left Hand Dri ve Vehi cl es
RHD . . . . . . . . . . . . . . . . Ri ght Hand Dri ve Vehi cl es
ATX . . Automati c Transmi ssi ons-Front Wheel Dri ve
MTX . . . . Manual Transmi ssi ons-Front Wheel Dri ve
AT . . . . Automati c Transmi ssi ons-Rear Wheel Dri ve
MT . . . . . Manual Transmi ssi ons-Rear Wheel Dri ve
SOHC . . . . . . . . . . . Si ngl e Over Head Cam Engi ne
DOHC . . . . . . . . . . Doubl e Over Head Cam Engi ne
Bui l t-Up-Export . . . . . . . . Vehi cl es Bui l t For Sal e I n
Markets Other Than North Ameri ca
Except-Bui l t-Up-Export . . Vehi cl es Bui l t For Sal e I n
North Ameri ca
DESCRIPTION - CIRCUIT INFORMATION
Each wi re shown i n the di agrams contai ns a code
whi ch i denti fi es the mai n ci rcui t, part of the mai n
ci rcui t, gage of wi re, and col or (Fi g. 4).
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
COLOR CODE COLOR
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
DESCRIPTION - CIRCUIT FUNCTIONS
Al l ci rcui ts i n the di agrams use an al pha/numeri c
code to i denti fy the wi re and i ts functi on. To i denti fy
whi ch ci rcui t code appl i es to a system, refer to the
Ci rcui t I denti fi cati on Code Chart. Thi s chart shows
the mai n ci rcui ts onl y and does not show the second-
ary codes that may appl y to some model s.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION
CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS
(GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL
MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY
FEED)
Q POWER OPTIONS (IGNITION
FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
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
CIRCUIT FUNCTION
U OPEN
V SPEED CONTROL, WIPER/
WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
DESCRIPTION - SECTION IDENTIFICATION AND
INFORMATION
The wi ri ng di agrams are grouped i nto i ndi vi dual
secti ons. I f a component i s most l i kel y found i n a par-
ti cul ar group, i t wi l l be shown compl ete (al l wi res,
connectors, and pi ns) wi thi n that group. For exam-
pl e, the Auto Shutdown Rel ay i s most l i kel y to be
found i n Group 30, so i t i s shown there compl ete. I t
can, however, be shown parti al l y i n another group i f
i t contai ns some associ ated wi ri ng.
Spl i ce di agrams i n Secti on 8W-70 show the enti re
spl i ce and provi de references to other secti ons the
spl i ces serves. Secti on 8W-70 onl y contai ns spl i ce di a-
grams that are not shown i n thei r enti rety some-
where el se i n the wi ri ng di agrams.
Secti on 8W-80 shows each connector and the ci r-
cui ts i nvol ved wi th that connector. The connectors
are i denti fi ed usi ng the name/number on the di a-
gram pages.
WIRING SECTION CHART
GROUP TOPIC
8Wa-01 thru
8W-09
General information and Diagram
Overview
8Wa-10 thru
8W-19
Main Sources of Power and
Vehicle Grounding
8Wa-20 thru
8W-29
Starting and Charging
8Wa-30 thru
8W-39
Powertrain/Drivetrain Systems
8Wa-40 thru
8W-49
Body Electrical items and A/C
8Wa-50 thru
8W-59
Exterior Lighting, Wipers and
Trailer Tow
8Wa-60 thru
8W-69
Power Accessories
8Wa-70 Splice Information
8Wa-80 Connector Pin Outs
8Wa-91 Connector, Ground and Splice
Locations
DESCRIPTION - CONNECTOR, GROUND AND
SPLICE INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
I n-l i ne connectors are i denti fi ed by a number, as
fol l ows:
I n-l i ne connectors l ocated i n the engi ne compart-
ment are C100 seri es numbers
I n-l i ne connectors l ocated i n the I nstrument
Panel area are C200 seri es numbers.
I n-l i ne connectors l ocated i n the body are C300
seri es numbers.
Jumper harness connectors are C400 seri es
numbers.
Grounds and ground connectors are i denti fi ed
wi th a G and fol l ow the same seri es numberi ng as
the i n-l i ne connectors.
Spl i ces are i denti fi ed wi th an S and fol l ow the
same seri es numberi ng as the i n-l i ne connectors.
Component connectors are i denti fi ed by the com-
ponent name i nstead of a number. Mul ti pl e connec-
tors on a component use a C1, C2, etc. i denti fi er.
LOCATIONS
Secti on 8W-91 contai ns connector/ground/spl i ce
l ocati on i l l ustrati ons. The i l l ustrati ons contai n the
connector name (or number)/ground number/spl i ce
number and component i denti fi cati on. Connector/
ground/spl i ce l ocati on charts i n secti on 8W-91 refer-
ence the fi gure numbers of the i l l ustrati ons.
The abbrevi ati on T/O i s used i n the component
l ocati on secti on to i ndi cate a poi nt i n whi ch the wi r-
i ng harness branches out to a component. The abbre-
vi ati on N/S means Not Shown i n the i l l ustrati ons
WARNINGS - GENERAL
WARNINGS provi de i nformati on to prevent per-
sonal i njury and vehi cl e damage. Bel ow i s a l i st of
general warni ngs that shoul d be fol l owed any ti me a
vehi cl e i s bei ng servi ced.
WARNING:: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
When di agnosi ng a probl em i n an el ectri cal ci rcui t
there are several common tool s necessary. These tool s
are l i sted and expl ai ned bel ow.
Jumper Wi re - Thi s i s a test wi re used to con-
nect two poi nts of a ci rcui t. I t can be used to bypass
an open i n a ci rcui t.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
Vol tmeter - Used to check for vol tage on a ci r-
cui t. Al ways connect the bl ack l ead to a known good
ground and the red l ead to the posi ti ve si de of the
ci rcui t.
CAUTION: Most of the electrical components used
in todays vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
Ohmmeter - Used to check the resi stance
between two poi nts of a ci rcui t. Low or no resi stance
i n a ci rcui t means good conti nui ty.
CAUTION: Most of the electrical components used
in todays vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 -
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicles
electrical system can cause damage to the equip-
ment and provide false readings.
Probi ng Tool s - These tool s are used for probi ng
termi nal s i n connectors (Fi g. 5). Sel ect the proper
si ze tool from Speci al Tool Package 6807, and i nsert
i t i nto the termi nal bei ng tested. Use the other end
of the tool to i nsert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. I t i s al so
possi bl e for a sti cki ng component or rel ay to cause a
probl em. Before condemni ng a component or wi ri ng
assembl y, check the fol l owi ng i tems.
Connectors are ful l y seated
Spread termi nal s, or termi nal push out
Termi nal s i n the wi ri ng assembl y are ful l y
seated i nto the connector/component and l ocked i nto
posi ti on
Di rt or corrosi on on the termi nal s. Any amount
of corrosi on or di rt coul d cause an i ntermi ttent prob-
l em
Damaged connector/component casi ng exposi ng
the i tem to di rt or moi sture
Wi re i nsul ati on that has rubbed through causi ng
a short to ground
Some or al l of the wi ri ng strands broken i nsi de
of the i nsul ati on
Wi ri ng broken i nsi de of the i nsul ati on
Fig. 5 PROBING TOOL
1 - SPECIAL TOOL 6801
2 - PROBING END
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are
si x steps whi ch can ai d i n the procedure. The steps
are l i sted and expl ai ned bel ow. Al ways check for non-
factory i tems added to the vehi cl e before doi ng any
di agnosi s. I f the vehi cl e i s equi pped wi th these i tems,
di sconnect them to veri fy these add-on i tems are not
the cause of the probl em.
(1) Veri fy the probl em.
(2) Veri fy any rel ated symptoms. Do thi s by per-
formi ng operati onal checks on components that are
i n the same ci rcui t. Refer to the wi ri ng di agrams.
(3) Anal yze the symptoms. Use the wi ri ng di a-
grams to determi ne what the ci rcui t i s doi ng, where
the probl em most l i kel y i s occurri ng and where the
di agnosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em area.
(6) Veri fy the proper operati on. For thi s step,
check for proper operati on of al l i tems on the
repai red ci rcui t. Refer to the wi ri ng di agrams.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
Al l ESD sensi ti ve components are sol i d state and a
symbol (Fi g. 6) i s used to i ndi cate thi s. When han-
dl i ng any component wi th thi s symbol , compl y wi th
the fol l owi ng procedures to reduce the possi bi l i ty of
el ectrostati c charge bui l d up on the body and i nad-
vertent di scharge i nto the component. I f i t i s not
known whether the part i s ESD sensi ti ve, assume
that i t i s.
(1) Al ways touch a known good ground before han-
dl i ng the part. Thi s shoul d be repeated whi l e han-
dl i ng the part and more frequentl y after sl i di ng
across a seat, si tti ng down from a standi ng posi ti on,
or wal ki ng a di stance.
(2) Avoi d touchi ng el ectri cal termi nal s of the part,
unl ess i nstructed to do so by a wri tten procedure.
(3) When usi ng a vol tmeter, be sure to connect the
ground l ead fi rst.
(4) Do not remove the part form i ts protecti ve
packi ng unti l i t i s ti me to i nstal l the part.
(5) Before removi ng the part from i ts pakage,
ground the pakage to a known good ground on the
vehi cl e.
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL
(1) Connect the ground l ead of a vol tmeter to a
known good ground (Fi g. 7).
(2) Connect the other l ead of the vol tmeter to the
sel ected test poi nt. The vehi cl e i gni ti on may need to
be turned ON to check vol tage. Refer to the appropri -
ate test procedure.
STANDARD PROCEDURE - TESTING FOR
CONTINUITY
(1) Remove the fuse for the ci rcui t bei ng checked
or, di sconnect the battery.
(2) Connect one l ead of the ohmmeter to one si de
of the ci rcui t bei ng tested (Fi g. 8).
(3) Connect the other l ead to the other end of the
ci rcui t bei ng tested. Low or no resi stance means good
conti nui ty.
Fig. 6 ELECTROSTATIC DISCHARGE SYMBOL
Fig. 7 TESTING FOR VOLTAGE POTENTIAL
SHORT TO GROUND
(1) Remove the fuse and di sconnect al l i tems
i nvol ved wi th the fuse.
(2) Connect a test l i ght or a vol tmeter across the
termi nal s of the fuse.
(3) Starti ng at the fuse bl ock, wi ggl e the wi ri ng
harness about si x to ei ght i nches apart and watch
the vol tmeter/test l amp.
(4) I f the vol tmeter regi sters vol tage or the test
l amp gl ows, there i s a short to ground i n that gen-
eral area of the wi ri ng harness.
SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS
(1) Refer to the wi ri ng di agrams and di sconnect or
i sol ate al l i tems on the suspected fused ci rcui ts.
(2) Repl ace the bl own fuse.
(3) Suppl y power to the fuse by turni ng ON the
i gni ti on swi tch or re-connecti ng the battery.
(4) Start connecti ng or energi zi ng the i tems i n the
fuse ci rcui t one at a ti me. When the fuse bl ows the
ci rcui t wi th the short to ground has been i sol ated.
VOLTAGE DROP
the si de of the ci rcui t cl osest to the battery (Fi g. 9).
(2) Connect the other l ead of the vol tmeter to the
other si de of the swi tch, component or ci rcui t.
(3) Operate the i tem.
(4) The vol tmeter wi l l show the di fference i n vol t-
age between the two poi nts.
Fig. 8 TESTING FOR CONTINUITY
1 - FUSE REMOVED FROM CIRCUIT
Fig. 9 TESTING FOR VOLTAGE DROP
SPECIAL TOOLS
WIRING/TERMINAL
CONNECTOR
REMOVAL
(1) Di sconnect battery.
(2) Rel ease Connector Lock (Fi g. 10).
(3) Di sconnect the connector bei ng repai red from
i ts mati ng hal f/component.
(4) Remove the dress cover (i f appl i cabl e) (Fi g. 10).
(5) Rel ease the Secondary Termi nal Lock, i f
requi red (Fi g. 11).
(6) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper speci al tool . Pul l on
the wi re to remove the termi nal from the connector
(Fi g. 12).
PROBING TOOL PACKAGE 6807
TERMINAL PICK TOOL SET 6680
TERMINAL REMOVING TOOLS 6932 AND 8638
TERMINAL REMOVING TOOL 6934
Fig. 10 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
1 - Secondary Terminal Lock
Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS
CONNECTOR (Continued)
1 - TYPICAL CONNECTOR
2 - PICK FROM SPECIAL TOOL KIT 6680
3 - APEX CONNECTOR
4 - PICK FROM SPECIAL TOOL KIT 6680
5 - AUGAT CONNECTOR
7 - MOLEX CONNECTOR
9 - THOMAS AND BETTS CONNECTOR
11 - TYCO CONNECTOR
Fig. 12 TERMINAL REMOVAL
INSTALLATION
(1) I nsert the removed termi nal i n the same cavi ty
on the repai r connector.
(2) Repeat steps for each termi nal i n the connec-
tor, bei ng sure that al l wi res are i nserted i nto the
proper cavi ti es. For addi ti onal connector pi n-out
i denti fi cati on, refer to the wi ri ng di agrams.
(3) When the connector i s re-assembl ed, the sec-
ondary termi nal l ock must be pl aced i n the l ocked
posi ti on to prevent termi nal push out.
(4) Repl ace dress cover (i f appl i cabl e).
(5) Connect connector to i ts mati ng hal f/compo-
nent.
(6) Connect battery and test al l affected systems.
DIODE
REMOVAL
(1) Di sconnect the battery.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 13).
INSTALLATION
(1) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(2) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary, refer to the
appropri ate wi ri ng di agram for current fl ow (Fi g. 13).
(3) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(4) Tape the di ode to the harness usi ng el ectri cal
tape. Make sure the di ode i s compl etel y seal ed from
the el ements.
(5) Re-connect the battery and test affected sys-
tems.
TERMINAL
REMOVAL
(1) Fol l ow steps for removi ng termi nal s descri bed
i n the connector removal secti on.
(2) Cut the wi re 6 i nches from the back of the con-
nector.
INSTALLATION
(1) Sel ect a wi re from the termi nal repai r ki t that
best matches the col or and gage of the wi re bei ng
repai red.
(2) Cut the repai r wi re to the proper l ength and
remove onehal f (1/2) i nch of i nsul ati on.
(3) Spl i ce the repai r wi re to the wi re harness (see
wi re spl i ci ng procedure).
(4) I nsert the repai red wi re i nto the connector.
(5) I nstal l the connector l ocki ng wedge, i f requi red,
and reconnect the connector to i ts mati ng hal f/compo-
nent.
(6) Re-tape the wi re harness starti ng at 11/2
i nches behi nd the connector and 2 i nches past the
repai r.
(7) Connect battery and test al l affected systems.
WIRE
STANDARD PROCEDURE - WIRE SPLICING
When spl i ci ng a wi re, i t i s i mportant that the cor-
rect gage be used as shown i n the wi ri ng di agrams.
(1) Remove one-hal f (1/2) i nch of i nsul ati on from
each wi re that needs to be spl i ced.
(2) Pl ace a pi ece of adhesi ve l i ned heat shri nk tub-
i ng on one si de of the wi re. Make sure the tubi ng wi l l
be l ong enough to cover and seal the enti re repai r
area.
Fig. 13 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
(3) Pl ace the strands of wi re overl appi ng each
other i nsi de of the spl i ce cl i p (Fi g. 14).
(4) Usi ng cri mpi ng tool , Mopar p/n 05019912AA,
cri mp the spl i ce cl i p and wi res together (Fi g. 15).
type sol der onl y (Fi g. 16).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shri nk tubi ng over the joi nt
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng (Fi g. 17).
Fig. 14 SPLICE BAND
1 - SPLICE BAND
Fig. 15 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 16 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 17 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
WIRE (Continued)
8W-02 COMPONENT INDEX
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . 8Wa-42
A/C Compressor Cl utch . . . . . . . . . . . . . . . . 8Wa-42
A/C-Heater Control . . . . . . . . . . . . . . . . . . . 8Wa-42
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . . 8Wa-42
A/C Low Pressure Swi tch . . . . . . . . . . . . . . . 8Wa-42
A/C Pressure Transducer . . . . . . . . . . . . . . . 8Wa-42
Accel erator Pedal Posi ti on Sensor . . . . . . . . 8Wa-30
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . 8Wa-43
Ambi ent Temperature Sensor . . . . . . . . . . . . 8Wa-45
Antenna Modul e . . . . . . . . . . . . . . . . . . . . . . 8Wa-47
Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . 8Wa-44
Auto Shut Down Rel ay . . . . . . . . . . . . . . . . . 8Wa-30
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . 8Wa-31
Battery Temperature Sensor . . . . . . . . . 8Wa-20, 30
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-20
Bl end Door Actuator . . . . . . . . . . . . . . . . . . . 8Wa-42
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . . 8Wa-42
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . . 8Wa-42
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42
Body Control Modul e . . . . . . . . . . . . . . . . . . 8Wa-45
Boost Pressure Sensor . . . . . . . . . . . . . . . . . 8Wa-30
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . 8Wa-33
Brake Pressure Swi tch . . . . . . . . . . . . . . . . . 8Wa-35
Cabi n Heater Rel ay . . . . . . . . . . . . . . . . . . . 8Wa-42
Cabi n Heater . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . 8Wa-30
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-44
CD Changer . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47
Center Hi gh Mounted Stop Lamp . . . . . . . . 8Wa-51
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41
Ci rcui t Breakers . . . . . . . . . . . . . . . . . . . . . . 8Wa-12
Cl ockspri ng . . . . . . . . . . . . . . . . . 8Wa-33, 41, 43, 47
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . . 8Wa-21
Cl utch Swi tch Overri de Rel ay . . . . . . . . . . . 8Wa-21
Coi l On Pl ugs . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30
Coi l Rai l . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30
Compass Mi ni -Tri p Computer . . . . . . . . . . . 8Wa-49
Control l er Anti l ock Brake . . . . . . . . . . . . . . 8Wa-35
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . 8Wa-44
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . 8Wa-30
Curtai n Ai rbags . . . . . . . . . . . . . . . . . . . . . . 8Wa-43
Cyl i nder Lock Swi tches . . . . . . . . . . . . . . . . 8Wa-61
Data Li nk Connector . . . . . . . . . . . . . . . . . . 8Wa-18
Dayti me Runni ng Lamp Rel ay . . . . . . . . . . . 8Wa-50
Defogger Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8Wa-48
Di agnosti c Juncti on Port . . . . . . . . . . . . . . . 8Wa-18
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-44
Door Ajar Swi tches . . . . . . . . . . . . . . . . . . . . 8Wa-45
Door Lock Motor/Ajar Swi tches . . . . . . . . . . 8Wa-61
Door Lock Rel ay . . . . . . . . . . . . . . . . . . . . . . 8Wa-61
Component Page
Door Lock Swi tches . . . . . . . . . . . . . . . . . . . 8Wa-61
Door Speakers . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47
Dri ver Ai rbag Squi b 1 . . . . . . . . . . . . . . . . . 8Wa-43
Dri ver Ai rbag Squi b 2 . . . . . . . . . . . . . . . . . 8Wa-43
Dri ver Door Unl ock Rel ay . . . . . . . . . . . . . . 8Wa-61
Dri ver Seat Bel t Swi tch . . . . . . . . . . . . . . . . 8Wa-40
Dri ver Seat Bel t Tensi oner . . . . . . . . . . . . . . 8Wa-43
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30
El ectri c Brake Provi si on . . . . . . . . . . . . . . . . 8Wa-54
Engi ne Control Modul e . . . . . . . . . . . . . . . . 8Wa-30
Engi ne Cool ant Level Sensor . . . . . . . . . . . . 8Wa-40
Engi ne Cool ant Temperature Sensor . . . . . . 8Wa-30
Engi ne Oi l Pressure Sensor . . . . . . . . . . . . . 8Wa-30
EVAP/Purge Sol enoi d . . . . . . . . . . . . . . . . . . 8Wa-30
Fl i p-Up Gl ass Rel ease Motor . . . . . . . . . . . . 8Wa-61
Fl i p-Up Gl ass Rel ease Swi tch . . . . . . . . . . . 8Wa-61
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50
Front Fog Lamp Rel ay . . . . . . . . . . . . . . . . . 8Wa-50
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . 8Wa-53
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . 8Wa-30
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30
Fuel Pressure Sensor . . . . . . . . . . . . . . . . . . 8Wa-30
Fuel Pressure Sol enoi d . . . . . . . . . . . . . . . . . 8Wa-30
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . 8Wa-30
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . 8Wa-30
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10, 12
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-20
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-20
Gl ow Pl ugs . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30
Hazard Swi tch/Combi nati on Fl asher . . . . . . 8Wa-52
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . 8Wa-50
Headl amps . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50
Heated Seats . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-63
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . . . . 8Wa-50
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . . . 8Wa-45
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . 8Wa-30
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10
I mpact Sensors . . . . . . . . . . . . . . . . . . . . . . . 8Wa-43
I nput Speed Sensor . . . . . . . . . . . . . . . . . . . 8Wa-31
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8Wa-40
I nstrument Panel Speakers . . . . . . . . . . . . . 8Wa-47
I ntake Ai r Temperature Sensor . . . . . . . . . . 8Wa-30
I ntrusi on Sensor . . . . . . . . . . . . . . . . . . . . . 8Wa-49
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30
Leak Detecti on Pump . . . . . . . . . . . . . . . . . . 8Wa-30
Level i ng Motors . . . . . . . . . . . . . . . . . . . . . . 8Wa-50
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-51
Li ne Pressure Sensor . . . . . . . . . . . . . . . . . . 8Wa-31
KJ 8W-02 COMPONENT INDEX 8Wa - 02 - 1
Component Page
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . . 8Wa-50
Mani fol d Absol ute Pressure Sensor . . . . . . . 8Wa-30
Mul ti -Functi on Swi tch . . . . . . . . . . . 8Wa-50, 52, 53
Output Speed Sensor . . . . . . . . . . . . . . . . . . 8Wa-31
Overhead Map/Readi ng Lamp . . . . . . . . . . . 8Wa-44
Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . 8Wa-30
Oxygen Sensor Downstream Rel ay . . . . . . . . 8Wa-30
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . 8Wa-40
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8Wa-50
Park/Turn Si gnal Lamps . . . . . . . . . . . . 8Wa-50, 52
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . . . 8Wa-43
Passenger Door Unl ock Rel ay . . . . . . . . . . . 8Wa-61
Passenger Seat Bel t Swi tch . . . . . . . . . . . . . 8Wa-40
Posi ti on Lamps . . . . . . . . . . . . . . . . . . . . . . 8Wa-50
Power Di stri buti on Center . . . . . . . . . . . . . . 8Wa-10
Power Mi rrors . . . . . . . . . . . . . . . . . . . . . . . 8Wa-62
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41
Power Seats . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-63
Power Steeri ng Pressure Swi tch . . . . . . . . . 8Wa-30
Power Wi ndows . . . . . . . . . . . . . . . . . . . . . . 8Wa-60
Powertrai n Control Modul e . . . . . . . . . . . . . 8Wa-30
Radi ator Fans . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30
Radi o Choke . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . . 8Wa-51
Rear Power Outl et . . . . . . . . . . . . . . . . . . . . 8Wa-41
Rear Power Wi ndow Swi tch . . . . . . . . . . . . . 8Wa-60
Rear Wheel Speed Sensor . . . . . . . . . . . . . . 8Wa-35
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . 8Wa-48
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . 8Wa-53
Red Brake Warni ng I ndi cator Swi tch . . . . . . 8Wa-40
Component Page
Remote Keyl ess Entry Modul e . . . . . . . . . . . 8Wa-45
Remote Radi o Swi tches . . . . . . . . . . . . . . . . 8Wa-47
Spl i ces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . 8Wa-39
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . . . 8Wa-31
Si de I mpact Ai rbag Control Modul es . . . . . . 8Wa-43
Si de Marker Lamps . . . . . . . . . . . . . . . . 8Wa-50, 52
Si de Repeater Lamps . . . . . . . . . . . . . . . 8Wa-50, 52
Si ren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-49
Speed Control Servo . . . . . . . . . . . . . . . . . . . 8Wa-33
Speed Control Swi tches . . . . . . . . . . . . . . . . 8Wa-33
Starter Motor Rel ay . . . . . . . . . . . . . . . . . . . 8Wa-21
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-21
Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-64
Tai l /Stop Lamps . . . . . . . . . . . . . . . . . . . . . . 8Wa-51
Tai l gate Cyl i nder Lock Swi tch . . . . . . . . . . . 8Wa-61
Tai l gate Fl i p-Up Ajar Swi tch . . . . . . . . . . . . 8Wa-61
Tai l gate Lock Motor/Ajar Swi tch . . . . . . . . . 8Wa-61
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . . 8Wa-30
Trai l er Tow . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-54
Transfer Case Posi ti on Sensor . . . . . . . . 8Wa-30, 31
Transmi ssi on Control Modul e . . . . . . . . . . . 8Wa-31
Transmi ssi on Control Rel ay . . . . . . . . . . . . . 8Wa-31
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . 8Wa-31
Vi sor/Vani ty Lamps . . . . . . . . . . . . . . . . . . . 8Wa-44
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . 8Wa-53
Washer Pump . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53
Water I n Fuel Sensor . . . . . . . . . . . . . . . . . . 8Wa-30
Wheel Speed Sensors . . . . . . . . . . . . . . . . . . 8Wa-35
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . . . . . 8Wa-53
KJ 8W-02 COMPONENT INDEX 8Wa - 02 - 1
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Cl utch Rel ay . . . 8Wa-10-11, 13, 22,
26
A/C Compressor Cl utch . . . . . . . . . . . . . . 8Wa-10-26
Auto Shut Down Rel ay . . . . . . 8Wa-10-10, 12, 19, 22
Battery . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12
Bl ower Motor Rel ay . . . . . . . . . . . 8Wa-10-10, 12, 14
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . 8Wa-10-14
Body Control Modul e . . . . . . . . . . . . . . . . 8Wa-10-23
Cabi n Heater Rel ay . . . . . . . . . . . 8Wa-10-13, 22, 26
Cabi n Heater . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-26
Camshaft Posi ti on Sensor . . . . . . . . . . . . 8Wa-10-22
Capaci tor . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-19, 21
Ci rcui t Breaker No. 1 . . . . . . . . . . . . . . . 8Wa-10-16
Ci rcui t Breaker No. 3 (JB) . . . . . . . . . . . 8Wa-10-27
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . 8Wa-10-28
Cl utch Swi tch Overri de Rel ay . . . . . . . . . 8Wa-10-28
Coi l On Pl ug No. 1 . . . . . . . . . . . . . . . . . 8Wa-10-21
Coi l On Pl ug No. 2 . . . . . . . . . . . . . . . . . 8Wa-10-21
Coi l On Pl ug No. 3 . . . . . . . . . . . . . . . . . 8Wa-10-21
Coi l On Pl ug No. 4 . . . . . . . . . . . . . . . . . 8Wa-10-21
Coi l On Pl ug No. 5 . . . . . . . . . . . . . . . . . 8Wa-10-21
Coi l On Pl ug No. 6 . . . . . . . . . . . . . . . . . 8Wa-10-21
Coi l Rai l . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-19
Control l er Anti l ock Brake . 8Wa-10-10, 11, 12, 13, 14
Dayti me Runni ng Lamp Rel ay . . . . . . . . 8Wa-10-16
Defogger Rel ay . . . . . . . . . . . . . . . . . . . . 8Wa-10-24
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . 8Wa-10-22
Engi ne Control Modul e . . . . . . . . . . . . . . 8Wa-10-22
Fuel Heater Rel ay . . . . . . . . . . . . . . . 8Wa-10-13, 18
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-18
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . 8Wa-10-20
Fuel Pressure Sol enoi d . . . . . . . . . . . . . . 8Wa-10-22
Fuel Pump Modul e . . . . . . . . . . . . . . . . . 8Wa-10-26
Fuel Pump Rel ay . . . . . . . . . . . . . . . . 8Wa-10-11, 26
Fuse 1 . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12, 14, 25
Fuse 2 . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12, 14, 15
Fuse 3 . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12, 16, 25
Fuse 4 . . . . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12, 14
Fuse 5 . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12, 17, 18
Fuse 6 . . . . . . . . . . . . . . . 8Wa-10-10, 12, 19, 22, 24
Fuse 7 . . . . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12, 15
Fuse 8 . . . . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12, 23
Fuse 9 . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12, 13, 24
Fuse 10 . . . . . . . . . . . . . . 8Wa-10-10, 12, 13, 15, 18
Fuse 11 . . . . . . . . . . . . . . . . . . . . 8Wa-10-13, 15, 18
Fuse 12 . . . . . . . . . . . . 8Wa-10-10, 11, 13, 15, 17, 18
Fuse 13 . . . . . . . . . . . . . . . 8Wa-10-10, 11, 13, 23, 27
Fuse 14 . . . . . . . . . . . . . . . . . . . . 8Wa-10-11, 13, 23
Fuse 15 . . . . . . . . . . . . . . . . . 8Wa-10-11, 13, 25, 27
Component Page
Fuse 16 . . . . . . . . . . . . . . . . . 8Wa-10-19, 20, 22, 24
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-24
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-24
Fuse 19 . . . . . . . . . . . . . . . . . . . . 8Wa-10-11, 13, 24
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-27
Fuse 21 . . . . . . . . . . . . . . . . . . . . 8Wa-10-11, 13, 26
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-27
Fuse 24 . . . . . . . . . . . . . . . . . . . . 8Wa-10-11, 26, 29
Fuse 25 . . . . . . . . . . . . . . . . . 8Wa-10-11, 13, 14, 29
Fuse 26 . . . . . . . . . . . . . . . . . 8Wa-10-12, 19, 20, 22
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-28
Fuse 29 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-15
Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-24
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-27
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-27
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-16
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-15
Fuse 36 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-27
Fuse 37 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-29
Fuse 38 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-29
Fuse 39 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-29
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-23
Generator . . . . . . . . . . . . . . . . . . 8Wa-10-10, 12, 22
Gl ow Pl ug Assembl y . . . . . . . . . . . . . . . . 8Wa-10-18
Gl ow Pl ug Rel ay No. 1 . . . . . . . . . 8Wa-10-13, 18, 22
Gl ow Pl ug Rel ay No. 2 . . . . . . . . . 8Wa-10-13, 18, 22
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . 8Wa-10-16
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-25
I gni ti on Swi tch . . . 8Wa-10-10, 11, 12, 13, 23, 27, 29
Juncti on Bl ock . . . 8Wa-10-10, 11, 12, 13, 15, 16, 24,
25, 27, 29
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . 8Wa-10-25
Oxygen Sensor 1/1 Upstream . . . . . . . . . 8Wa-10-19
Oxygen Sensor 1/2 Downstream . . . . 8Wa-10-19, 20
Oxygen Sensor 2/2 Downstream . . . . . . . 8Wa-10-20
Oxygen Sensor Downstream Rel ay . . 8Wa-10-19, 20
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . 8Wa-10-16
Power Di stri buti on Center . 8Wa-10-2, 3, 10, 11, 12,
13, 14, 15, 16, 17, 18, 19, 22, 23, 24, 25, 26, 27, 28
Power Wi ndow Master Swi tch . . . . . . . . . 8Wa-10-29
Powertrai n Control Modul e . . 8Wa-10-11, 19, 26, 28
Radi ator Fan Rel ay . . . . . . . . . . . . . . 8Wa-10-10, 14
Starter Motor Rel ay . . . . . . . . . . . . . . 8Wa-10-23, 28
Starter Motor . . . . . . . . . . . . . . . . . . . . . 8Wa-10-23
Trai l er Tow Ci rcui t Breaker . . . . . 8Wa-10-10, 12, 15
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . 8Wa-10-15
Trai l er Tow Connector . . . . . . . . . . . . . . . 8Wa-10-15
Trai l er Tow Rel ay . . . . . . . . . . . . . . . . . . 8Wa-10-15
Transmi ssi on Control Modul e . . . 8Wa-10-10, 17, 28
Transmi ssi on Control Rel ay . . . . . . . . 8Wa-10-10, 17
Transmi ssi on Sol enoi d/TRS Assembl y . . . 8Wa-10-17
KJ 8W-10 POWER DISTRIBUTION 8Wa - 10 - 1
8W-12 J UNCTION BLOCK
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . . . . 8Wa-12-19
A/C-Heater Control . . . . . . . . . . . . . . . . . 8Wa-12-26, 28, 35
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . 8Wa-12-18, 25
Antenna Modul e . . . . . . . . . . . . . . . . . . . . . 8Wa-12-23, 24
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-35
Auto Shut Down Rel ay . . . . . . . . . . . . . . . . . . . 8Wa-12-19
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8Wa-12-28
Bl end Door Actuator . . . . . . . . . . . . . . . . . . . . . 8Wa-12-26
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . . . . 8Wa-12-25
Body Control Modul e . 8Wa-12-9, 10, 11, 13, 14, 15, 18, 21 22, 23
, 24, 27, 28, 30, 31, 32, 33, 34
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . 8Wa-12-16
Brake Pressure Swi tch . . . . . . . . . . . . . . . . . . . . 8Wa-12-25
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-30, 34
Center Hi gh Mounted Stop Lamp . . . . . . . . . . . . . 8Wa-12-16
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-23, 24
Ci rcui t Breaker No. 1 . . . . . . . . . . . . . . . . . . . . 8Wa-12-29
Ci rcui t Breaker No. 3 (JB) . . . . . . . . . . . . . . . 8Wa-12-23, 24
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-9
Compass Mi ni -Tri p Computer . . . . . . . . . . . . . 8Wa-12-18, 30
Control l er Anti l ock Brake . . . . . . . . . . . . . . . 8Wa-12-16, 25
Data Li nk Connector . . . . . . . . . . . . . . . . . . . . . 8Wa-12-29
Dayti me Runni ng Lamp Rel ay . . . . . . . . . . . . . . . 8Wa-12-27
Defogger Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-28
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-30, 34
Door Lock Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-11
Dri ver Door Unl ock Rel ay . . . . . . . . . . . . . . . . . . 8Wa-12-11
Engi ne Control Modul e . . . . . . . . . . . . . . . . . . . 8Wa-12-20
EVAP/Purge Sol enoi d . . . . . . . . . . . . . . . . . . . . 8Wa-12-19
Front Fog Lamp Rel ay . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-32
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-19
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-9
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-10
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-9
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-10
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-10
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-11
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-16
Fuse 9 . . . . . . . . . . . . . . . . . . . . 8Wa-12-13, 14, 15, 21, 22
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-17
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-16
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-18
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-19, 20
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-23, 24
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-23, 24
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-13, 14, 15
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-25
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-26
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-27
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-27
Fuse 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-17
Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-28
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-23, 24
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-23, 24
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-29
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-30
Fuse 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-18
Fuse 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-25
Fuse 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-25
Fuse 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-28
G202 . . . . . . . . . . . . . . . . . . . 8Wa-12-11, 13, 14, 15, 27, 32
Hazard Swi tch/Combi nati on Fl asher . . . . . . 8Wa-12-17, 28, 35
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . . 8Wa-12-14, 15
Heated Seat Modul e . . . . . . . . . . . . . . . . . . . . . 8Wa-12-17
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-27
Component Page
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-9
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-9
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-9
I nstrument Cl uster . . . . . . . . . . 8Wa-12-13, 14, 15, 18, 30, 35
I ntrusi on Sensor . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-30
Juncti on Bl ock . 8Wa-12-2, 3, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18,
19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 30, 31, 32, 33, 34, 35,
Left Courtesy Lamp . . . . . . . . . . . . . . . . . . . 8Wa-12-30, 34
Left Cyl i nder Lock Swi tch . . . . . . . . . . . . . . . . . 8Wa-12-33
Left Door Lock Swi tch . . . . . . . . . . . . . 8Wa-12-23, 24, 31, 33
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
Left Front Door Lock Motor/Ajar Swi tch . . . . . . . 8Wa-12-11, 12
Left Front Park/Turn Si gnal Lamp . . . . . . . . . . . . 8Wa-12-13
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-10, 27
Left Heated Seat Swi tch . . . . . . . . . . . . . . . . . . . 8Wa-12-26
Left Posi ti on Lamp . . . . . . . . . . . . . . . . . . . . 8Wa-12-14, 15
Left Power Mi rror . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-28
Left Power Seat Swi tch . . . . . . . . . . . . . . . . . . . 8Wa-12-29
Left Rear Door Lock Motor/Ajar Swi tch . . . . . . . . . 8Wa-12-12
Left Si de I mpact Ai rbag Control Modul e . . . . . . . . . 8Wa-12-18
Left Si de Marker Lamp . . . . . . . . . . . . . . . . . . . 8Wa-12-13
Left Tai l /Stop Lamp . . . . . . . . . . . . . . 8Wa-12-13, 14, 15, 16
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . . . . 8Wa-12-30
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . . . . 8Wa-12-31
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . 8Wa-12-13, 14, 15
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-10
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-9
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . 8Wa-12-23, 24, 27
Overhead Map/Readi ng Lamp . . . . . . . . . . . 8Wa-12-30, 31, 34
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . 8Wa-12-13, 14, 15
Passenger Door Unl ock Rel ay . . . . . . . . . . . . . . . 8Wa-12-11
Power Di stri buti on Center . . . . . . . . 8Wa-12-16, 21, 22, 31, 32
Power Mi rror Swi tch . . . . . . . . . . . . . . . . . . . . . 8Wa-12-26
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-9
Powertrai n Control Modul e . . . . . . . . . . . . . . . . . 8Wa-12-19
Radi o Choke . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
Radi o . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-23, 24, 30, 35
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8Wa-12-10
Rear Power Outl et . . . . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . . . 8Wa-12-28
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . . . 8Wa-12-30, 34
Ri ght Cyl i nder Lock Swi tch . . . . . . . . . . . . . . . . . 8Wa-12-33
Ri ght Door Lock Swi tch . . . . . . . . . . . . 8Wa-12-23, 24, 31 33
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
Ri ght Front Door Lock Motor/Ajar Swi tch . . . . . . 8Wa-12-11, 12
Ri ght Front Park/Turn Si gnal Lamp . . . . . . . . . . . 8Wa-12-13
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . 8Wa-12-10, 27
Ri ght Heated Seat Swi tch . . . . . . . . . . . . . . . . . . 8Wa-12-26
Ri ght Posi ti on Lamp . . . . . . . . . . . . . . . . . . . 8Wa-12-14, 15
Ri ght Power Mi rror . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-28
Ri ght Power Seat Swi tch . . . . . . . . . . . . . . . . . . 8Wa-12-29
Ri ght Rear Door Lock Motor/Ajar Swi tch . . . . . . . . 8Wa-12-12
Ri ght Si de I mpact Ai rbag Control Modul e . . . . . . . . 8Wa-12-18
Ri ght Si de Marker Lamp . . . . . . . . . . . . . . . . . . 8Wa-12-13
Ri ght Tai l /Stop Lamp . . . . . . . . . . . 8Wa-12-10, 13, 14, 15, 16
Ri ght Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . 8Wa-12-30, 31
Sentry Key I mmobi l i zer Modul e . . . . . . . . . 8Wa-12-19, 20, 29
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . . . 8Wa-12-25, 35
Si ren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-30
Sunroof Motor . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-23, 24
Tai l gate Lock Motor/Ajar Swi tch . . . . . . . . . . . . . . 8Wa-12-32
Trai l er Tow Brake Lamp Rel ay . . . . . . . . . . 8Wa-12-16, 21, 22
Trai l er Tow Connector . . . . . . . . . . . . . . . 8Wa-12-13, 14, 15
Trai l er Tow Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-26
Transmi ssi on Control Modul e . . . . . . . . . . . . . . . 8Wa-12-19
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . . . . . . 8Wa-12-28
Wi per On/Off Rel ay . . . . . . . . . . . . . . . 8Wa-12-23, 24, 31, 32
KJ 8W-12 JUNCTION BLOCK 8Wa - 12 - 1
8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . . . 8Wa-15-6
A/C Low Pressure Swi tch . . . . . . . . . . . . . . . . . 8Wa-15-3
A/C- Heater Control . . . . . . . . . . . . . . . . . . . 8Wa-15-7, 8
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . . 8Wa-15-7
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-2
Bl end Door Actuator . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . . . . 8Wa-15-4
Body Control Modul e . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
Cabi n Heater . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-6
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-2
Center Hi gh Mounted Stop Lamp . . . . . . . . . . . 8Wa-15-14
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
Compass Mi ni -Tri p Computer . . . . . . . . . . . . . . 8Wa-15-14
Control l er Anti l ock Brake . . . . . . . . . . . . . . . . . 8Wa-15-2
Data Li nk Connector . . . . . . . . . . . . . . . . . . . . 8Wa-15-2
Engi ne Control Modul e . . . . . . . . . . . . . . . . . . . 8Wa-15-7
Engi ne Cool ant Level Sensor . . . . . . . . . . . . . . . 8Wa-15-6
Fl i p-Up Gl ass Rel ease Motor . . . . . . . . . . . . . . 8Wa-15-14
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-6
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-4
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . 8Wa-15-15
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-2, 7
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-6
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-2
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-6
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-7
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-2
G110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-2
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3, 4
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-7
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-7
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-9, 11
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-9, 10
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-9, 12
G310 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-13, 14, 15
G311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-14
G312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-14
G320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-15
Hazard Swi tch/Combi nati on Fl asher . . . . . . . . . . 8Wa-15-8
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . . . 8Wa-15-8
Heated Seat Modul e . . . . . . . . . . . . . . . . . . . . 8Wa-15-10
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-4
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
I ntrusi on Sensor . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-14
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
Left Door Lock Swi tch . . . . . . . . . . . . . . . . . . . 8Wa-15-11
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-5
Left Front Door Ajar Swi tch . . . . . . . . . . . . . . . 8Wa-15-11
Left Front Door Lock Motor/Ajar Swi tch . . . . . . . 8Wa-15-11
Left Front Door Speaker . . . . . . . . . . . . . . . . . . 8Wa-15-7
Left Front Park/Turn Si gnal Lamp . . . . . . . . . . . 8Wa-15-5
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
Left Heated Seat Assembl y . . . . . . . . . . . . . . . 8Wa-15-10
Left Heated Seat Swi tch . . . . . . . . . . . . . . . . . 8Wa-15-10
Component Page
Left Level i ng Motor . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
Left Posi ti on Lamp . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
Left Power Mi rror . . . . . . . . . . . . . . . . . . . . . 8Wa-15-11
Left Power Seat Swi tch . . . . . . . . . . . . . . . . . . 8Wa-15-10
Left Rear Door Ajar Swi tch . . . . . . . . . . . . . . . 8Wa-15-11
Left Rear Door Lock Motor/Ajar Swi tch . . . . . . . 8Wa-15-11
Left Si de I mpact Ai rbag Control Modul e . . . . . . . . 8Wa-15-9
Left Si de Repeater Lamp . . . . . . . . . . . . . . . . . . 8Wa-15-5
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . 8Wa-15-15
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-15
Li ne Pressure Sensor . . . . . . . . . . . . . . . . . . . . 8Wa-15-2
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
Mul ti - Functi on Swi tch . . . . . . . . . . . . . . . . . . . 8Wa-15-8
Oxygen Sensor 1/2 Downstream . . . . . . . . . . . . . 8Wa-15-6
Oxygen Sensor 2/2 Downstream . . . . . . . . . . . . . 8Wa-15-6
Power Mi rror Swi tch . . . . . . . . . . . . . . . . . 8Wa-15-11, 12
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
Power Steeri ng Pressure Swi tch . . . . . . . . . . . . . 8Wa-15-6
Power Wi ndow Master Swi tch . . . . . . . . . . . . . 8Wa-15-10
Powertrai n Control Modul e . . . . . . . . . . . . . . . . 8Wa-15-2
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-7
Radi o Choke . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-9
Rear Power Outl et . . . . . . . . . . . . . . . . . . . . . 8Wa-15-15
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . . 8Wa-15-14
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . 8Wa-15-14
Red Brake Warni ng I ndi cator Swi tch . . . . . . . . . . 8Wa-15-4
Ri ght Door Lock Swi tch . . . . . . . . . . . . . . . . . . 8Wa-15-12
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-5
Ri ght Front Door Ajar Swi tch . . . . . . . . . . . . . . 8Wa-15-12
Ri ght Front Door Lock Motor/Ajar Swi tch . . . . . . 8Wa-15-12
Ri ght Front Door Speaker . . . . . . . . . . . . . . . . . 8Wa-15-7
Ri ght Front Park/Turn Si gnal Lamp . . . . . . . . . . 8Wa-15-5
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-4
Ri ght Heated Seat Assembl y . . . . . . . . . . . . . . 8Wa-15-10
Ri ght Heated Seat Swi tch . . . . . . . . . . . . . . . . 8Wa-15-10
Ri ght Level i ng Motor . . . . . . . . . . . . . . . . . . . . 8Wa-15-4
Ri ght Posi ti on Lamp . . . . . . . . . . . . . . . . . . . . 8Wa-15-4
Ri ght Power Mi rror . . . . . . . . . . . . . . . . . . . . 8Wa-15-12
Ri ght Power Seat Swi tch . . . . . . . . . . . . . . . . . 8Wa-15-10
Ri ght Rear Door Ajar Swi tch . . . . . . . . . . . . . . 8Wa-15-12
Ri ght Rear Door Lock Motor/Ajar Swi tch . . . . . . 8Wa-15-12
Ri ght Si de I mpact Ai rbag Control Modul e . . . . . . . 8Wa-15-9
Ri ght Si de Repeater Lamp . . . . . . . . . . . . . . . . . 8Wa-15-5
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . 8Wa-15-15
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . . . . 8Wa-15-8
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-9
Si ren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-4
Speed Control Servo . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
Starter Motor Rel ay . . . . . . . . . . . . . . . . . . . . . 8Wa-15-4
Sunroof Motor . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-14
Tai l gate Fl i p-Up Ajar Swi tch . . . . . . . . . . . . . . 8Wa-15-14
Trai l er Tow Brake Lamp Rel ay . . . . . . . . . . . . . 8Wa-15-13
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . . 8Wa-15-13
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . . . . . 8Wa-15-13
Trai l er Tow Rel ay . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-13
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . . . . 8Wa-15-13
Transmi ssi on Control Modul e . . . . . . . . . . . . . . . 8Wa-15-2
Transmi ssi on Control Rel ay . . . . . . . . . . . . . . . . 8Wa-15-4
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . . . . 8Wa-15-3
KJ 8W-15 GROUND DISTRIBUTION 8Wa - 15 - 1
8W-18 BUS COMMUNICATIONS
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . . 8Wa-18-2
Body Control Modul e . . . . . . . . . . . . . 8Wa-18-2, 5, 6
Compass Mi ni -Tri p Computer . . . . . . . . . . 8Wa-18-2
Control l er Anti l ock Brake . . . . . . . 8Wa-18-3, 4, 5, 6
Data Li nk Connector . . . . . . . . . . . . . 8Wa-18-2, 5, 6
Di agnosti c Juncti on Port . . . . . . . . 8Wa-18-2, 4, 5, 6
Engi ne Control Modul e . . . . . . . . . . . . . 8Wa-18-4, 6
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-18-5, 6
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-18-5, 6
Component Page
I nstrument Cl uster . . . . . . . . . . . . . . . . . . 8Wa-18-2
I ntrusi on Sensor . . . . . . . . . . . . . . . . . . . . 8Wa-18-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8Wa-18-5, 6
Left Si de I mpact Ai rbag Control Modul e . . 8Wa-18-2
Powertrai n Control Modul e . . . . . . . . . . 8Wa-18-2, 5
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-18-2
Ri ght Si de I mpact Ai rbag Control Modul e . 8Wa-18-2
Sentry Key I mmobi l i zer Modul e . . . . . . 8Wa-18-2, 4
Transmi ssi on Control Modul e . . . . . . . . 8Wa-18-3, 5
KJ 8W-18 BUS COMMUNICATIONS 8Wa - 18 - 1
8W-20 CHARGING SYSTEM
Component Page
Auto Shut Down Rel ay . . . . . . . . . . . . . 8Wa-20-2, 3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-20-2, 3
Battery Temperature Sensor . . . . . . . . . 8Wa-20-2, 3
Engi ne Control Modul e . . . . . . . . . . . . . . . 8Wa-20-3
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-20-2, 3
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-20-3
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-20-2
Component Page
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . 8Wa-20-2, 3
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-20-2, 3
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-20-2, 3
Generator . . . . . . . . . . . . . . . . . . . . . . . 8Wa-20-2, 3
Power Di stri buti on Center . . . . . . . . . . 8Wa-20-2, 3
Powertrai n Control Modul e . . . . . . . . . . . . 8Wa-20-2
Starter Motor . . . . . . . . . . . . . . . . . . . . 8Wa-20-2, 3
KJ 8W-20 CHARGING SYSTEM 8Wa - 20 - 1
8W-21 STARTING SYSTEM
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . 8Wa-21-2, 4, 6
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . 8Wa-21-3, 5
Cl utch Swi tch Overri de Rel ay . . . . 8Wa-21-3, 4, 5, 6
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-21-2, 4, 6
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-21-2, 3, 5
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-21-4, 6
Component Page
I gni ti on Swi tch . . . . . . . . . . . . . . . . . 8Wa-21-2, 3, 5
Power Di stri buti on Center . . . . . 8Wa-21-2, 3, 4, 5, 6
Starter Motor . . . . . . . . . . . . . . . . . . 8Wa-21-2, 4, 6
Starter Motor Rel ay . . . . . . . . . . 8Wa-21-2, 3, 4, 5, 6
Transmi ssi on Control Modul e . . . . . . . . . . 8Wa-21-2
Transmi ssi on Sol enoi d/Trs Assembl y . . . . . 8Wa-21-2
KJ 8W-21 STARTING SYSTEM 8Wa - 21 - 1
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . 8Wa-30-34
A/C Compressor Cl utch Rel ay . . . . . 8Wa-30-34, 2, 3
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . 8Wa-30-29
A/C Low Pressure Swi tch . . . . . . . . . . 8Wa-30-8, 29
A/C Pressure Transducer . . . . . . . 8Wa-30-11, 23, 12
Accel erator Pedal Posi ti on Sensor . . . . . . 8Wa-30-27
Auto Shut Down Rel ay . . 8Wa-30-13, 14, 15, 24, 28,
31, 16, 17, 2
Battery Temperature Sensor . . . . . . . . 8Wa-30-30, 7
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . 8Wa-30-31
Body Control Modul e . . . . . . . . . . . . . . 8Wa-30-8, 33
Boost Pressure Sensor . . . . . . . . . . . . 8Wa-30-26, 28
Brake Lamp Swi tch . . . . . . . . . . . . 8Wa-30-8, 32, 33
Cabi n Heater . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-34
Cabi n Heater Rel ay . . . . . . . . . . . . . . . . . 8Wa-30-34
Camshaft Posi ti on Sensor . . . . . . . 8Wa-30-10, 9, 28
Capaci tor . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-19, 17
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . 8Wa-30-33, 7
Cl utch Swi tch Overri de Rel ay . . . . 8Wa-30-13, 8, 32
Coi l On Pl ug No. 1 . . . . . . . . . . . . . . . . . 8Wa-30-19
Coi l On Pl ug No. 2 . . . . . . . . . . . . . . . . . 8Wa-30-20
Coi l On Pl ug No. 3 . . . . . . . . . . . . . . . . . 8Wa-30-19
Coi l On Pl ug No. 4 . . . . . . . . . . . . . . . . . 8Wa-30-20
Coi l On Pl ug No. 5 . . . . . . . . . . . . . . . . . 8Wa-30-19
Coi l On Pl ug No. 6 . . . . . . . . . . . . . . . . . 8Wa-30-20
Coi l Rai l . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-17
Control l er Anti l ock Brake . . . . . . . . . . . . 8Wa-30-33
Crankshaft Posi ti on Sensor . . . . . . 8Wa-30-10, 9, 27
Data Li nk Connector . . . . . . . . . . . . . . 8Wa-30-25, 6
Di agnosti c Juncti on Port . . . . . . . . . . . 8Wa-30-25, 6
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . 8Wa-30-30
Engi ne Control Modul e . . 8Wa-30-24, 25, 26, 27, 28,
29, 30, 31, 32, 33, 34, 35, 36
Engi ne Cool ant Temperature Sensor . 8Wa-30-11, 28,
12
Engi ne Oi l Pressure Sensor . . . . . 8Wa-30-11, 28, 12
Evap/Purge Sol enoi d . . . . . . . . . . . . . . . . . 8Wa-30-2
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-31
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . 8Wa-30-31
Fuel I njector No. 1 . . . . . . . . . . . . . . . 8Wa-30-18, 36
Fuel Pressure Sensor . . . . . . . . . . . . . . . 8Wa-30-36
Fuel Pressure Sol enoi d . . . . . . . . . . . . . . 8Wa-30-31
Fuel Pump Modul e . . . . . . . . . . . . . 8Wa-30-30, 4, 5
Fuel Pump Rel ay . . . . . . . . . . . . . . 8Wa-30-4, 2, 3, 5
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-23
Fuse 6 . . . . . . . . . . . . . . . . . . . 8Wa-30-24, 28, 31, 2
Component Page
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-35
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-35
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-31, 33
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-25, 2, 3
Fuse 16 . . . . . . 8Wa-30-13, 14, 15, 24, 30, 34, 35, 16
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-34
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-31, 2, 3
Fuse 26 . . . . . . . . . . . . . . . . . . 8Wa-30-18, 24, 17, 2
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-13
G100 . . . . . . . . . . . . . . . . . . . . 8Wa-30-19, 27, 17, 3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-23
G103 . . . . . . . . . . . . . . . . . 8Wa-30-15, 23, 31, 34, 16
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-27
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-31
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-8, 23
G320 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-4, 5
Generator . . . . . . . . . . . . . . . . . . 8Wa-30-24, 4, 3, 5
Gl ow Pl ug Assembl y . . . . . . . . . . . . . . . . 8Wa-30-35
Gl ow Pl ug Rel ay No. 1 . . . . . . . . . . . . . . 8Wa-30-35
Gl ow Pl ug Rel ay No. 2 . . . . . . . . . . . . . . 8Wa-30-35
I dl e Ai r Control Motor . . . . . . . . . . . . 8Wa-30-21, 22
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . 8Wa-30-32
I ntake Ai r Temperature Sensor . . . . . 8Wa-30-11, 12
Juncti on Bl ock . . . . . . . . . . . 8Wa-30-25, 31, 33, 2, 3
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-8
Leak Detecti on Pump . . . . . . . . . . . . . . 8Wa-30-4, 5
Left Speed Control Swi tch . . . . . . . . . . 8Wa-30-33, 7
Mani fol d Absol ute Pressure Sensor . . 8Wa-30-11, 12
Oxygen Sensor 1/1 Upstream . . . . . . 8Wa-30-14, 15
Oxygen Sensor 1/2 Downstream . 8Wa-30-13, 14, 15
Oxygen Sensor 2/2 Downstream . . . . 8Wa-30-13, 16
Oxygen Sensor Downstream Rel ay . . 8Wa-30-13, 15,
16
Power Di stri buti on Center . . 8Wa-30-13, 14, 15, 23,
24, 28, 30, 31, 34, 35, 16, 17, 2, 3
Power Steeri ng Pressure Swi tch . . . . . . . 8Wa-30-23
Powertrai n Control Modul e . . . 8Wa-30-10, 13, 20, 8,
11, 14, 15, 18, 19, 21, 9, 23, 4, 12, 16, 17, 2, 22, 3,
6, 7, 5
Radi ator Fan Motor . . . . . . . . . . . . . . . . . 8Wa-30-23
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . 8Wa-30-23
Ri ght Speed Control Swi tch . . . . . . . . . 8Wa-30-33, 7
Shi fter Assembl y . . . . . . . . . . . . . . . . . 8Wa-30-8, 32
Speed Control Servo . . . . . . . . . . . . . . . . . 8Wa-30-8
Starter Motor Rel ay . . . . . . . . . . . . . . . . 8Wa-30-13
Throttl e Posi ti on Sensor . . . . . . . . . . 8Wa-30-21, 22
Transfer Case Posi ti on Sensor . . . . 8Wa-30-9, 23, 32
Transmi ssi on Control Modul e . . 8Wa-30-10, 8, 22, 6
Transmi ssi on Sol enoi d/Trs Assembl y . . . . 8Wa-30-10
Water I n Fuel Sensor . . . . . . . . . . . . . . . 8Wa-30-29
KJ 8W-30 FUEL/IGNITION SYSTEM 8Wa - 30 - 1
8W-31 TRANSMISSION CONTROL SYSTEM
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . 8Wa-31-3
Auto Shut Down Rel ay . . . . . . . . . . . . . . . 8Wa-31-3
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . 8Wa-31-4
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . 8Wa-31-5
Crankshaft Posi ti on Sensor . . . . . . . . . . . . 8Wa-31-6
Data Li nk Connector . . . . . . . . . . . . . . . . . 8Wa-31-6
Di agnosti c Juncti on Port . . . . . . . . . . . . . . 8Wa-31-3
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . 8Wa-31-3
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-2
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-3
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-3
Fuse 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-5
Fuse 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-4
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-7, 9
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-2
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-5
I nput Speed Sensor . . . . . . . . . . . . . . . . . . 8Wa-31-9
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . 8Wa-31-3, 4, 5
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . 8Wa-31-4
Li ne Pressure Sensor . . . . . . . . . . . . . . . . 8Wa-31-9
Output Speed Sensor . . . . . . . . . . . . . . . . 8Wa-31-9
Powertrai n Control Modul e . . . . . . . . 8Wa-31-3, 5, 6
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . 8Wa-31-4
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . . 8Wa-31-5
Starter Motor Rel ay . . . . . . . . . . . . . . . . . 8Wa-31-8
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . 8Wa-31-5
Trai l er Tow Connector . . . . . . . . . . . . . . . . 8Wa-31-4
Transfer Case Posi ti on Sensor . . . . . . . . . . 8Wa-31-5
Transmi ssi on Control Modul e . . 8Wa-31-2, 3, 5, 6, 7,
8, 9
Transmi ssi on Control Rel ay . . . . . . . 8Wa-31-2, 7, 8
Transmi ssi on Sol enoi d/Trs Assembl y . . 8Wa-31-2, 4,
7, 8, 9
KJ 8W-31 TRANSMISSION CONTROL SYSTEM 8Wa - 31 - 1
8W-33 VEHICLE SPEED CONTROL
Component Page
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . 8Wa-33-3, 4, 5
Control l er Anti l ock Brake . . . . . . . . . . . . . 8Wa-33-2
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-33-2
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-33-2
Component Page
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-33-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . 8Wa-33-2
Left Speed Control Swi tch . . . . . . . . . . . . . 8Wa-33-4
Ri ght Speed Control Swi tch . . . . . . . . . . . 8Wa-33-4
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . . 8Wa-33-2
KJ 8W-33 VEHICLE SPEED CONTROL 8Wa - 33 - 1
8W-35 ANTILOCK BRAKES
Component Page
Brake Pressure Swi tch . . . . . . . . . . . . . . . 8Wa-35-2
Control l er Anti l ock Brake . . . . . . . . . 8Wa-35-2, 3, 4
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-35-2
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-35-3
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-35-2
Fuse 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-35-2
Component Page
G110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-35-2
Left Front Wheel Speed Sensor . . . . . . . . . 8Wa-35-4
Power Di stri buti on Center . . . . . . . . . . . . 8Wa-35-2
Rear Wheel Speed Sensor . . . . . . . . . . . . . 8Wa-35-4
Ri ght Front Wheel Speed Sensor . . . . . . . 8Wa-35-4
Shi fter Assembl y . . . . . . . . . . . . . . . . . . 8Wa-35-2, 3
KJ 8W-35 ANTILOCK BRAKES 8Wa - 35 - 1
8W-39 VEHICLE THEFT SECURITY SYSTEM
Component Page
Body Control Modul e . . . . . . . . . 8Wa-39-2, 3, 4, 5, 9
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-5
Cl utch Swi tch Overri de Rel ay . . . . . . . . . . 8Wa-39-2
Compass Mi ni -Tri p Computer . . . . . . . . . . 8Wa-39-8
Di agnosti c Juncti on Port . . . . . . . . . . . . 8Wa-39-6, 8
Fl i p-Up Gl ass Rel ease Swi tch . . . . . . . . . . 8Wa-39-4
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-5
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-2
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-2, 8
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-2
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-6
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-2
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-2
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-6
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-2, 7, 8
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-5, 7
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-6
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-3
G311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-8
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . 8Wa-39-5
Component Page
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . 8Wa-39-5
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-5
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-5
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8Wa-39-2
I ntrusi on Sensor . . . . . . . . . . . . . . . . . . 8Wa-39-7, 8
Juncti on Bl ock . . . . . . . . . . . . 8Wa-39-2, 5, 6, 7, 8, 9
Left Cyl i nder Lock Swi tch . . . . . . . . . . . . . 8Wa-39-9
Left Door Lock Swi tch . . . . . . . . . . . . . . . . 8Wa-39-9
Left Front Door Lock Motor/Ajar Swi tch . . 8Wa-39-3
Left Rear Door Lock Motor/Ajar Swi tch . . 8Wa-39-3
Low Note Horn . . . . . . . . . . . . . . . . . . . . . 8Wa-39-5
Ri ght Cyl i nder Lock Swi tch . . . . . . . . . . . 8Wa-39-9
Ri ght Door Lock Swi tch . . . . . . . . . . . . . . 8Wa-39-9
Ri ght Front Door Lock Motor/Ajar Swi tch . 8Wa-39-3
Ri ght Rear Door Lock Motor/Ajar Swi tch . 8Wa-39-3
Sentry Key I mmobi l i zer Modul e . . . . . . . . 8Wa-39-6
Si ren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-39-7
Starter Motor Rel ay . . . . . . . . . . . . . . . . . 8Wa-39-2
Tai l gate Cyl i nder Lock Swi tch . . . . . . . . . 8Wa-39-4
Tai l gate Lock Motor/Ajar Swi tch . . . . . . . . 8Wa-39-4
KJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8Wa - 39 - 1
8W-40 INSTRUMENT CLUSTER
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . 8Wa-40-4, 8
Body Control Modul e . . . . . . . . . . . 8Wa-40-3, 4, 5, 8
Di agnosti c Juncti on Port . . . . . . 8Wa-40-4, 5, 6, 7, 8
Dri ver Seat Bel t Swi tch . . . . . . . . . . . . . . 8Wa-40-8
Engi ne Cool ant Level Sensor . . . . . . . . . . 8Wa-40-3
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-40-3
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-40-2
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-40-2
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-40-3
Component Page
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-40-3
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-40-2, 3
Hazard Swi tch/Combi nati on Fl asher . . . . . 8Wa-40-3
I nstrument Cl uster . . . . . . . . 8Wa-40-2, 3, 4, 5, 7, 8
Park Brake Swi tch . . . . . . . . . . . . . . . . . . 8Wa-40-5
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . 8Wa-40-3
Passenger Seat Bel t Swi tch . . . . . . . . . . . . 8Wa-40-8
Red Brake Warni ng I ndi cator Swi tch . . . . 8Wa-40-3
Transmi ssi on Control Modul e . . . . . . . . . . 8Wa-40-6
Washer Fl ui d Level Swi tch . . . . . . . . . . . . 8Wa-40-2
KJ 8W-40 INSTRUMENT CLUSTER 8Wa - 40 - 1
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
Component Page
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-2
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-3
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-2
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-3
Fuse 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-3
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-2
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-3
Component Page
G310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-3
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . 8Wa-41-2
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-2
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-2
Low Note Horn . . . . . . . . . . . . . . . . . . . . . 8Wa-41-2
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-3
Rear Power Outl et . . . . . . . . . . . . . . . . . . 8Wa-41-3
KJ 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8Wa - 41 - 1
8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . 8Wa-42-5, 7
A/C Compressor Cl utch Rel ay . . . . . . . . 8Wa-42-5, 7
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . 8Wa-42-6
A/C Low Pressure Swi tch . . . . . . . . . . . 8Wa-42-3, 6
A/C Pressure Transducer . . . . . . . . . . . . . 8Wa-42-5
A/C- Heater Control . . . . . . . . . . . . . . . 8Wa-42-2, 4
Auto Shut Down Rel ay . . . . . . . . . . . . . . . 8Wa-42-5
Bl end Door Actuator . . . . . . . . . . . . . . . . . 8Wa-42-2
Bl ower Motor . . . . . . . . . . . . . . . . . . . 8Wa-42-3, 4, 6
Bl ower Motor Rel ay . . . . . . . . . . . . . . 8Wa-42-3, 4, 6
Bl ower Motor Resi stor Bl ock . . . . . . . 8Wa-42-3, 4, 6
Cabi n Heater . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-7
Cabi n Heater Rel ay . . . . . . . . . . . . . . . . . . 8Wa-42-7
Defogger Rel ay . . . . . . . . . . . . . . . . . . . . . 8Wa-42-2
Engi ne Control Modul e . . . . . . . . . . . . . 8Wa-42-6, 7
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . 8Wa-42-3, 6
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . 8Wa-42-5
Component Page
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-3, 6
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-5
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-7
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-6
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-5, 7
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-3
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-2
Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-5
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-5, 7
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-3, 6
G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-3, 6
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-4
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-42-2
Juncti on Bl ock . . . . . . . . . . . . . . 8Wa-42-2, 3, 4, 5, 6
Power Di stri buti on Center . . . . . . . 8Wa-42-3, 5, 6, 7
KJ 8W-42 AIR CONDITIONING-HEATER 8Wa - 42 - 1
8W-43 AIRBAG SYSTEM
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . 8Wa-43-2, 3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-43-2
Dri ver Ai rbag Squi b 1 . . . . . . . . . . . . . . . . 8Wa-43-2
Dri ver Ai rbag Squi b 2 . . . . . . . . . . . . . . . . 8Wa-43-2
Dri ver Seat Bel t Swi tch . . . . . . . . . . . . . . 8Wa-43-3
Dri ver Seat Bel t Tensi oner . . . . . . . . . . . . 8Wa-43-3
Fuse 36 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-43-2, 4
Fuse 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-43-2
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-43-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-43-4
Component Page
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-43-4
Left Curtai n Ai rbag . . . . . . . . . . . . . . . . . . 8Wa-43-4
Left Front I mpact Sensor . . . . . . . . . . . . . 8Wa-43-3
Left Si de I mpact Ai rbag Control Modul e . . 8Wa-43-4
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . 8Wa-43-2
Passenger Seat Bel t Swi tch . . . . . . . . . . . . 8Wa-43-3
Ri ght Curtai n Ai rbag . . . . . . . . . . . . . . . . 8Wa-43-4
Ri ght Front I mpact Sensor . . . . . . . . . . . . 8Wa-43-3
Ri ght Si de I mpact Ai rbag Control Modul e . 8Wa-43-4
KJ 8W-43 AIRBAG SYSTEM 8Wa - 43 - 1
8W-44 INTERIOR LIGHTING
Component Page
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . 8Wa-44-2
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . 8Wa-44-4
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-44-2
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-44-2, 3, 4
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-44-2
Component Page
Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8Wa-44-2
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . 8Wa-44-3
Overhead Map/Readi ng Lamp . . . . . . . . . . 8Wa-44-4
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . 8Wa-44-2
Ri ght Vi sor/Vani ty Lamp . . . . . . . . . . . . . . 8Wa-44-3
KJ 8W-44 INTERIOR LIGHTING 8Wa - 44 - 1
8W-45 BODY CONTROL MODULE
Component Page
A/C- Heater Control . . . . . . . . . . . . . . . . . 8Wa-45-5
Ambi ent Temperature Sensor . . . . . . . . . . 8Wa-45-7
Body Control Modul e . 8Wa-45-10, 11, 2, 3, 4, 5, 6, 7,
8, 9
Cargo Lamp . . . . . . . . . . . . . . . . . . . . . 8Wa-45-4, 8
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-5
Data Li nk Connector . . . . . . . . . . . . . 8Wa-45-10, 11
Door Lock Rel ay . . . . . . . . . . . . . . . . . . . . 8Wa-45-4
Dri ver Door Unl ock Rel ay . . . . . . . . . . . . . 8Wa-45-3
Fl i p-Up Gl ass Rel ease Motor . . . . . . . . . . . 8Wa-45-8
Front Fog Lamp Rel ay . . . . . . . . . . . . . . . 8Wa-45-4
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-7
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-3
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-2
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-2
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-2
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-7
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-2, 6
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-9
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-9
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . . . . 8Wa-45-3
Hood Ajar Swi tch . . . . . . . . . . . . . . . . . . . 8Wa-45-7
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-7
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . 8Wa-45-2, 3, 4, 7, 8
Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8Wa-45-4
Left Cyl i nder Lock Swi tch . . . . . . . 8Wa-45-10, 11, 4
Left Door Lock Swi tch . . . . . . . . . . . . . . 8Wa-45-4, 7
Left Front Door Ajar Swi tch . . . . . . . . . . . 8Wa-45-9
Left Front Door Lock Motor/Ajar
Swi tch . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-10, 11
Left Rear Door Ajar Swi tch . . . . . . . . . . . . 8Wa-45-9
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . 8Wa-45-3
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . 8Wa-45-3
Mul ti - Functi on Swi tch . . . . . . . . . . . 8Wa-45-3, 5, 6
Overhead Map/Readi ng Lamp . . . . . . . . 8Wa-45-3, 4
Passenger Door Unl ock Rel ay . . . . . . . . . . 8Wa-45-3
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . 8Wa-45-2
Rear Wi per Motor . . . . . . . . . . . . . . . . . 8Wa-45-6, 8
Remote Keyl ess Entry Modul e . . . . . . . . . 8Wa-45-8
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . 8Wa-45-4
Ri ght Cyl i nder Lock Swi tch . . . . . . 8Wa-45-10, 11, 4
Ri ght Door Lock Swi tch . . . . . . . . . . . . 8Wa-45-4, 7
Ri ght Front Door Ajar Swi tch . . . . . . . . . . 8Wa-45-9
Ri ght Front Door Lock Motor/Ajar
Swi tch . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-10, 11
Ri ght Rear Door Ajar Swi tch . . . . . . . . . . . 8Wa-45-9
Ri ght Remote Radi o Swi tch . . . . . . . . . . . . 8Wa-45-5
Ri ght Vi sor/Vani ty Lamp . . . . . . . . . . . . . . 8Wa-45-3
Tai l gate Cyl i nder Lock Swi tch . . . . 8Wa-45-10, 11, 8
Tai l gate Lock Motor/Ajar Swi tch . . . . . . 8Wa-45-7, 8
Washer Pump . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-6
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . . . 8Wa-45-4
Wi per On/Off Rel ay . . . . . . . . . . . . . . . . . . 8Wa-45-4
KJ 8W-45 BODY CONTROL MODULE 8Wa - 45 - 1
8W-47 AUDIO SYSTEM
Component Page
Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-2
Antenna Modul e . . . . . . . . . . . . . . . . . . . . 8Wa-47-2
Cd Changer . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-5
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-9
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-6
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-2
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-2
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-7
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-6
Component Page
Left Front Door Speaker . . . . . . . . . . 8Wa-47-3, 7, 8
Left I nstrument Panel Speaker . . . . . . . 8Wa-47-3, 7
Left Rear Door Speaker . . . . . . . . . . . . . 8Wa-47-4, 8
Left Remote Radi o Swi tch . . . . . . . . . . . . . 8Wa-47-9
Radi o . . . . . . . . . . . . . . . 8Wa-47-2, 3, 4, 5, 6, 7, 8, 9
Radi o Choke . . . . . . . . . . . . . . . . . . . 8Wa-47-2, 6, 7
Ri ght Front Door Speaker . . . . . . . . . 8Wa-47-3, 7, 8
Ri ght I nstrument Panel Speaker . . . . . . 8Wa-47-3, 7
Ri ght Rear Door Speaker . . . . . . . . . . . 8Wa-47-4, 8
Ri ght Remote Radi o Swi tch . . . . . . . . . . . . 8Wa-47-9
KJ 8W-47 AUDIO SYSTEM 8Wa - 47 - 1
8W-48 REAR WINDOW DEFOGGER
Component Page
A/C- Heater Control . . . . . . . . . . . . . . . . . 8Wa-48-2
Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-48-2
Fuse 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-48-2
Fuse 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-48-2
Component Page
G310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-48-2
G312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-48-2
Rear Wi ndow Defogger . . . . . . . . . . . . . . . 8Wa-48-2
KJ 8W-48 REAR WINDOW DEFOGGER 8Wa - 48 - 1
8W-49 OVERHEAD CONSOLE
Component Page
Compass Mi ni -Tri p Computer . . . . . . . . 8Wa-49-2, 4
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-49-4
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-49-2, 4
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-49-2, 3, 4
Component Page
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-49-3
G311 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-49-2, 4
I ntrusi on Sensor . . . . . . . . . . . . . . . . . . 8Wa-49-2, 3
Si ren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-49-3
KJ 8W-49 OVERHEAD CONSOLE 8Wa - 49 - 1
8W-50 FRONT LIGHTING
Component Page
Body Control Modul e . . . . . . . . . . 8Wa-50-14, 2, 7, 8
Dayti me Runni ng Lamp Rel ay . . . . 8Wa-50-14, 2, 8
Front Fog Lamp Rel ay . . . . . . . . . . . . . . . 8Wa-50-8
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-8
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-2
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-2
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-6, 7, 8
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-8
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-6, 7
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-2, 8
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-2, 8
G111 . . . . . . . . . . . . 8Wa-50-10, 11, 12, 13, 3, 4, 5, 9
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-6
Headl amp Level i ng Swi tch . . . . . . . . . . . . 8Wa-50-6
Hi gh Beam Rel ay . . . . . . . . . . . . . . . . 8Wa-50-14, 2
Juncti on Bl ock . 8Wa-50-10, 11, 12, 13, 14, 2, 3, 4, 5,
6, 7, 8, 9
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . 8Wa-50-8, 9
Component Page
Left Front Park/Turn Si gnal Lamp . . . 8Wa-50-11, 9
Left Headl amp . . . . . . . . . . . . . . . . . . . 8Wa-50-3, 4
Left Level i ng Motor . . . . . . . . . . . . . . . . 8Wa-50-4, 5
Left Posi ti on Lamp . . . . . . . . . . . . . . . . . . 8Wa-50-4
Left Si de Marker Lamp . . . . . . . . . . . . . . . 8Wa-50-9
Left Si de Repeater Lamp . . . . . . . . . . . . . 8Wa-50-11
Low Beam Rel ay . . . . . . . . . . . . . . . . . . . . 8Wa-50-2
Mul ti - Functi on Swi tch . . . . . . . . . . . . 8Wa-50-14, 2
Park Lamp Rel ay . . . . . . . . . . . . . . . . . 8Wa-50-6, 7
Ri ght Fog Lamp . . . . . . . . . . . . 8Wa-50-10, 12, 13, 8
Ri ght Front Park/Turn Si gnal Lamp . 8Wa-50-10, 11,
12, 13
Ri ght Headl amp . . . . . . . . . . . . . . . . . . 8Wa-50-3, 5
Ri ght Level i ng Motor . . . . . . . . . . . . . . 8Wa-50-4, 5
Ri ght Posi ti on Lamp . . . . . . . . . . . . . . . . . 8Wa-50-5
Ri ght Si de Marker Lamp . . . . . . . . . . . . . 8Wa-50-10
Ri ght Si de Repeater Lamp . . . . . . 8Wa-50-11, 12, 13
KJ 8W-50 FRONT LIGHTING 8Wa - 50 - 1
8W-51 REAR LIGHTING
Component Page
Body Control Modul e . . . . . . . . . . . . . . . 8Wa-51-2, 5
Center Hi gh Mounted Stop Lamp . . . . . . . 8Wa-51-4
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-51-5
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-51-2
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-51-2
Fuse 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-51-3
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-51-2
G310 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-51-2, 3, 4, 5
Component Page
G312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-51-4
Juncti on Bl ock . . . . . . . . . . . . . . . . 8Wa-51-2, 3, 4, 5
Left Tai l /Stop Lamp . . . . . . . . . . . . . 8Wa-51-3, 4, 5
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . 8Wa-51-3
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . 8Wa-51-5
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . 8Wa-51-2, 4, 5
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . 8Wa-51-4
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . 8Wa-51-4
KJ 8W-51 REAR LIGHTING 8Wa - 51 - 1
8W-52 TURN SIGNALS
Component Page
Body Control Modul e . . . . . . . . . . . . . . . 8Wa-52-2, 3
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-3
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-2
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-3
Fuse 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-2
G111 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-4, 5, 6, 7
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-2, 3
G310 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-4, 5, 6, 7
Hazard Swi tch/Combi nati on Fl asher . . 8Wa-52-2, 4,
5, 6, 7
I nstrument Cl uster . . . . . . . . . . 8Wa-52-2, 4, 5, 6, 7
Component Page
Left Front Park/Turn Si gnal Lamp . . . . 8Wa-52-6, 7
Left Si de Marker Lamp . . . . . . . . . . . . . . . 8Wa-52-6
Left Si de Repeater Lamp . . . . . . . . . . . . . 8Wa-52-7
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . 8Wa-52-6, 7
Mul ti - Functi on Swi tch . . . . . . . . . . . . . . . 8Wa-52-2
Ri ght Front Park/Turn Si gnal Lamp . . . 8Wa-52-4, 5
Ri ght Si de Marker Lamp . . . . . . . . . . . . . 8Wa-52-4
Ri ght Si de Repeater Lamp . . . . . . . . . . . . 8Wa-52-5
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . 8Wa-52-4, 5
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . 8Wa-52-6
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . 8Wa-52-4
KJ 8W-52 TURN SIGNALS 8Wa - 52 - 1
8W-53 WIPERS
Component Page
Ci rcui t Breaker No. 3 (JB) . . . . . . . . . . . . 8Wa-53-4
Front Wi per Motor . . . . . . . . . . . . . . . . 8Wa-53-4, 5
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-3
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-3
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-2
G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-5
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-2
G311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-3
G312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-3
Component Page
Mul ti - Functi on Swi tch . . . . . . . . . . . 8Wa-53-2, 3, 4
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . 8Wa-53-3
Tai l gate Fl i p-Up Ajar Swi tch . . . . . . . . . . . 8Wa-53-3
Washer Fl ui d Level Swi tch . . . . . . . . . . . . 8Wa-53-5
Washer Pump . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-2
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . 8Wa-53-4, 5
Wi per On/Off Rel ay . . . . . . . . . . . . . . . . 8Wa-53-4, 5
KJ 8W-53 WIPERS 8Wa - 53 - 1
8W-54 TRAILER TOW
Component Page
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . . 8Wa-54-6
El ectri c Brake Provi si on . . . . . . . . . . . . . . 8Wa-54-3
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-54-6
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-54-2
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-54-6
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-54-4
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-54-6
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-54-2
Component Page
G310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-54-5
Trai l er Tow Brake Lamp Rel ay . . . . . . . 8Wa-54-4, 5
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . . 8Wa-54-6
Trai l er Tow Connector . . . . . . . . . . 8Wa-54-2, 3, 5, 6
Trai l er Tow Left Turn Rel ay . . . . . . . . . 8Wa-54-4, 5
Trai l er Tow Rel ay . . . . . . . . . . . . . . . . . 8Wa-54-5, 6
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . 8Wa-54-4, 5
KJ 8W-54 TRAILER TOW 8Wa - 54 - 1
8W-60 POWER WINDOWS
Component Page
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-60-2
Left Front Power Wi ndow Motor . . . . . . . . 8Wa-60-2
Left Rear Power Wi ndow Motor . . . . . . . . 8Wa-60-3
Component Page
Power Wi ndow Master Swi tch . . . . . . . . 8Wa-60-2, 3
Rear Power Wi ndow Swi tch . . . . . . . . . . . 8Wa-60-3
Ri ght Front Power Wi ndow Motor . . . . . . . 8Wa-60-2
Ri ght Rear Power Wi ndow Motor . . . . . . . 8Wa-60-3
KJ 8W-60 POWER WINDOWS 8Wa - 60 - 1
8W-61 POWER DOOR LOCKS
Component Page
Body Control Modul e . . . . . 8Wa-61-2, 3, 4, 5, 6, 7, 8
Door Lock Rel ay . . . . . . . . . . . . . . . . . . 8Wa-61-3, 7
Dri ver Door Unl ock Rel ay . . . . . . . . . . . 8Wa-61-2, 6
Fl i p-Up Gl ass Rel ease Motor . . . . . . . . . . . 8Wa-61-5
Fuse 32 . . . . . . . . . . . . . . . . . . . . . 8Wa-61-2, 4, 6, 8
G300 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-61-2, 4, 7, 8
G302 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-61-3, 4, 6, 7
G311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-61-5
G312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-61-5
Juncti on Bl ock . . . . . . . . . . 8Wa-61-2, 3, 4, 5, 6, 7, 8
Left Cyl i nder Lock Swi tch . . . . . . . . . . . 8Wa-61-2, 8
Left Door Lock Swi tch . . . . . . . . . . . . . . 8Wa-61-2, 8
Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-61-2, 7
Component Page
Left Power Mi rror . . . . . . . . . . . . . . . . . . . 8Wa-61-2
Left Rear Door Lock Motor/Ajar
Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-61-4, 8
Passenger Door Unl ock Rel ay . . . . . . . . 8Wa-61-3, 7
Power Mi rror Swi tch . . . . . . . . . . . . . . . . . 8Wa-61-2
Ri ght Cyl i nder Lock Swi tch . . . . . . . . . 8Wa-61-4, 6
Ri ght Door Lock Swi tch . . . . . . . . . . . . 8Wa-61-4, 6
Ri ght Front Door Lock Motor/Ajar
Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-61-3, 6
Ri ght Rear Door Lock Motor/Ajar
Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-61-3, 7
Tai l gate Fl i p-Up Ajar Swi tch . . . . . . . . . . . 8Wa-61-5
Tai l gate Lock Motor/Ajar Swi tch . . . . . . . . 8Wa-61-5
KJ 8W-61 POWER DOOR LOCKS 8Wa - 61 - 1
8W-62 POWER MIRRORS
Component Page
Defogger Rel ay . . . . . . . . . . . . . . . . . . . 8Wa-62-2, 4
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-62-2, 4
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-62-2, 4
Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-62-2, 4
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-62-3, 5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-62-3, 5
Component Page
Left Power Mi rror . . . . . . . . . . . . . 8Wa-62-2, 3, 4, 5
Power Mi rror Swi tch . . . . . . . . . . . 8Wa-62-2, 3, 4, 5
Ri ght Power Mi rror . . . . . . . . . . . . 8Wa-62-2, 3, 4, 5
KJ 8W-62 POWER MIRRORS 8Wa - 62 - 1
8W-63 POWER SEAT
Component Page
Ci rcui t Breaker No. 1 . . . . . . . . . . . . . . 8Wa-63-2, 3
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-63-4
Fuse 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-63-5
G301 . . . . . . . . . . . . . . . . . . . . . . . 8Wa-63-2, 3, 4, 5
Heated Seat Modul e . . . . . . . . . . . . . . . 8Wa-63-4, 5
Left Heated Seat Assembl y . . . . . . . . . . 8Wa-63-4, 5
Component Page
Left Heated Seat Swi tch . . . . . . . . . . . . . . 8Wa-63-5
Left Power Seat Motors . . . . . . . . . . . . . . . 8Wa-63-2
Left Power Seat Swi tch . . . . . . . . . . . . . . . 8Wa-63-2
Ri ght Heated Seat Assembl y . . . . . . . . . . . 8Wa-63-4
Ri ght Heated Seat Swi tch . . . . . . . . . . . . . 8Wa-63-4
Ri ght Power Seat Motor . . . . . . . . . . . . . . 8Wa-63-3
Ri ght Power Seat Swi tch . . . . . . . . . . . . . . 8Wa-63-3
KJ 8W-63 POWER SEAT 8Wa - 63 - 1
8W-64 POWER SUNROOF
Component Page
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-64-2
G311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-64-2
Component Page
Sunroof Motor . . . . . . . . . . . . . . . . . . . . . . 8Wa-64-2
Sunroof Swi tch . . . . . . . . . . . . . . . . . . . . . 8Wa-64-2
KJ 8W-64 POWER SUNROOF 8Wa - 64 - 1
8W-70 SPLICE INFORMATION
Component Page
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-23
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-6
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-70-2, 4, 6
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-33
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-9
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-41-2
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-4
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-18-3, 4
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-28
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-4, 5
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-22
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-5
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-19
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-25
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-19
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-25
S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-24
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-3
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-4
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-5
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-13
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-6, 7
S143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-5
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-21, 22
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-4, 5
S146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-13
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-4
S148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-5
S149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-50-4, 5
S151 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-19, 21, 22
S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-21
S153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-70-2, 4, 6
S154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-70-3, 4, 6
S155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-70-3
S156 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-11, 12, 28
S157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-70-5
S158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-22
S159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-10
S160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-19
S161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-20
S163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-9
S164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-17
S165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-21-2
S167 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-2
S168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-6
S169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-6
S170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-19
S175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-36
S177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-7
S177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-27
S178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-20
S180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-2
S181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-31
S184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-28
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-18-2, 4
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-28
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-70-2, 4, 6
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-2
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-5
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-6
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-27
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-4, 5
S213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-6, 7
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-8
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-30-32
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-5
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-14, 15
Component Page
S217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-3
S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-3
S219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-13, 25
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-10-24
S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-33-4
S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-33-4
S223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-9
S224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-9
S300 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-13, 14, 15
S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-30
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-16
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-29
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-15
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-15
S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-23, 24
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-31-4
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-13, 14, 15
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-13
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-4, 5
S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-26
S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-63-4
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-7
S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-12
S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-12
S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-7
S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-45-9
S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-61-3, 7
S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-10
S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-63-4
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-17
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-10
S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-9
S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-10
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-11
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-12
S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-18-2
S338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-23, 24
S340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-3
S341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-3
S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-3
S344 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-3
S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-52-6
S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-51-4
S348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-16
S349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-13
S350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-10
S351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-14
S352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-28
S352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-48-2
S356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-14
S360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-11
S361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-62-3, 5
S362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-33
S363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-3
S364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-3
S370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-12
S371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-33
S372 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-3
S373 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-47-3
S377 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-62-5
S378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-62-5
S380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-14
S381 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-61-5
S382 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-53-3
S390 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-30
S391 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-34
S392 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-12-31
S393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-18-2
S394 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-15-14
KJ 8W-70 SPLICE INFORMATION 8Wa - 70 - 1
8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . .8Wa-80-5
A/C Hi gh Pressure Swi tch (Di esel ) . . . . . . 8Wa-80-5
A/C Low Pressure Swi tch . . . . . . . . . . . . . 8Wa-80-5
A/C Pressure Transducer (Gas) . . . . . . . . . 8Wa-80-5
A/C-Heater Control C1 . . . . . . . . . . . . . . . 8Wa-80-5
A/C-Heater Control C2 . . . . . . . . . . . . . . . 8Wa-80-6
Accel erator Pedal Posi ti on Sensor
(Di esel ) . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-6
Ai rbag Control Modul e C1 (ORC C1) . . . . 8Wa-80-6
Ai rbag Control Modul e C2 (ORC C2) . . . . 8Wa-80-7
Ambi ent Temperature Sensor . . . . . . . . . . 8Wa-80-7
Antenna (Except Bui l t-Up-Export) . . . . . . 8Wa-80-7
Antenna Modul e C1 (Bui l t-Up-Export) . . . 8Wa-80-8
Antenna Modul e C2 (Bui l t-Up-Export) . . . 8Wa-80-8
Ash Recei ver Lamp . . . . . . . . . . . . . . . . . . 8Wa-80-8
Back-Up Lamp Swi tch (M/T) . . . . . . . . . . . 8Wa-80-8
Battery Temperature Sensor . . . . . . . . . . . 8Wa-80-8
Bl end Door Actuator . . . . . . . . . . . . . . . . . 8Wa-80-9
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-9
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . 8Wa-80-9
Body Control Modul e C1 . . . . . . . . . . . . . . 8Wa-80-9
Body Control Modul e C2 . . . . . . . . . . . . . 8Wa-80-10
Body Control Modul e C3 (Premi um) . . . . 8Wa-80-10
Boost Pressure Sensor (Di esel ) . . . . . . . . 8Wa-80-11
Brake Pressure Swi tch (ABS) . . . . . . . . . 8Wa-80-11
C100 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-11
C100 (LHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-13
C100 (LHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-14
C100 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-16
C101 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-17
C101 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-18
C102 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-18
C102 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-18
C103 (Gas) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-19
C103 (Gas) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-19
C104 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-19
C104 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-20
C104 (Gas) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-20
C104 (Gas) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-20
C105 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-21
C105 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-21
C105 (Gas) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-22
C105 (Gas) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-22
C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-22
C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-23
C107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-23
C107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-23
C108 (Gas) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-24
C108 (Gas) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-24
C110 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-24
C110 (2.4L) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-25
Component Page
C111 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-25
C111 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-25
C112 (Gas) . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-26
C112 (Gas) . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-26
C113 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-26
C113 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-26
C114 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-27
C114 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-27
C201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-27
C201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-28
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-29
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-29
C300 (LHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-29
C300 (LHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-30
C300 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-30
C300 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-31
C301 (LHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-31
C301 (LHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-32
C301 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-32
C301 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-33
C302 (LHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-33
C302 (LHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-34
C302 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-34
C302 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-35
C303 (LHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-35
C303 (LHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-36
C303 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-36
C303 (RHD) . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-37
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-37
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-37
C305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-38
C305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-38
C306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-39
C306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-40
C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-40
C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-41
C308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-41
C308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-41
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-42
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-42
C310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-43
C310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-43
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-43
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-44
C312 (Hi ghl i ne) . . . . . . . . . . . . . . . . . . . . 8Wa-80-44
C312 (Hi ghl i ne) . . . . . . . . . . . . . . . . . . . . 8Wa-80-44
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-44
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-45
C314 (Hi ghl i ne) . . . . . . . . . . . . . . . . . . . . 8Wa-80-45
C314 (Hi ghl i ne) . . . . . . . . . . . . . . . . . . . . 8Wa-80-45
C315 (Mi dl i ne/Hi ghl i ne) . . . . . . . . . . . . . 8Wa-80-46
C315 (Mi dl i ne/Hi ghl i ne) . . . . . . . . . . . . . 8Wa-80-46
KJ 8W-80 CONNECTOR PIN-OUTS 8Wa - 80 - 1
Component Page
C316 (Bui l t-Up-Export) . . . . . . . . . . . . . . 8Wa-80-46
C316 (Bui l t-Up-Export) . . . . . . . . . . . . . . 8Wa-80-46
C317 (Except Bui l t-Up-Export) . . . . . . . . 8Wa-80-47
C317 (Except Bui l t-Up-Export) . . . . . . . . 8Wa-80-47
Cabi n Heater (Di esel ) . . . . . . . . . . . . . . . 8Wa-80-47
Camshaft Posi ti on Sensor (2.4L) . . . . . . . 8Wa-80-47
Camshaft Posi ti on Sensor (3.7L) . . . . . . . 8Wa-80-47
Camshaft Posi ti on Sensor (Di esel ) . . . . . . 8Wa-80-48
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-48
Cargo Lamp (Except Base) . . . . . . . . . . . 8Wa-80-48
CD Changer . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-48
Center Hi gh Mounted Stop Lamp . . . . . . 8Wa-80-49
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . 8Wa-80-49
Cl ockspri ng C1 . . . . . . . . . . . . . . . . . . . . 8Wa-80-49
Cl ockspri ng C2 . . . . . . . . . . . . . . . . . . . . 8Wa-80-49
Cl ockspri ng C3 . . . . . . . . . . . . . . . . . . . . 8Wa-80-49
Cl utch I nterl ock Swi tch (M/T) . . . . . . . . . 8Wa-80-50
Coi l On Pl ug No. 1 (3.7L) . . . . . . . . . . . . 8Wa-80-50
Coi l Rai l (2.4L) . . . . . . . . . . . . . . . . . . . . 8Wa-80-51
Compass Mi ni -Tri p Computer
(Premi um) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-51
Control l er Anti l ock Brake . . . . . . . . . . . . 8Wa-80-52
Crankshaft Posi ti on Sensor (2.4L) . . . . . . 8Wa-80-52
Crankshaft Posi ti on Sensor (3.7L) . . . . . . 8Wa-80-52
Crankshaft Posi ti on Sensor (Di esel ) . . . . 8Wa-80-53
Data Li nk Connector . . . . . . . . . . . . . . . . 8Wa-80-53
Di agnosti c Juncti on Port . . . . . . . . . . . . . 8Wa-80-53
Dome Lamp (Base) . . . . . . . . . . . . . . . . . 8Wa-80-54
Dri ver Ai rbag Squi b 1 . . . . . . . . . . . . . . . 8Wa-80-54
Dri ver Ai rbag Squi b 2 . . . . . . . . . . . . . . . 8Wa-80-54
Dri ver Seat Bel t Swi tch . . . . . . . . . . . . . 8Wa-80-54
Dri ver Seat Bel t Tensi oner . . . . . . . . . . . 8Wa-80-54
EGR Sol enoi d (Di esel ) . . . . . . . . . . . . . . . 8Wa-80-55
Engi ne Control Modul e C1 . . . . . . . . . . . 8Wa-80-55
Engi ne Control Modul e C2 . . . . . . . . . . . 8Wa-80-56
Engi ne Cool ant Level Sensor (Di esel ) . . . 8Wa-80-57
Engi ne Cool ant Temp Sensor (Di esel ) . . . 8Wa-80-57
Engi ne Cool ant Temperature
Sensor (Gas) . . . . . . . . . . . . . . . . . . . . 8Wa-80-58
Engi ne Oi l Pressure Sensor . . . . . . . . . . . 8Wa-80-58
Evap/Purge Sol enoi d . . . . . . . . . . . . . . . . 8Wa-80-58
Fl i p-Up Gl ass Rel ease Motor . . . . . . . . . . 8Wa-80-58
Fl i p-Up Gl ass Rel ease Swi tch . . . . . . . . . 8Wa-80-58
Front Wi per Motor . . . . . . . . . . . . . . . . . 8Wa-80-59
Fuel Heater (Di esel ) . . . . . . . . . . . . . . . . 8Wa-80-59
Fuel I njector No. 1 (Di esel ) . . . . . . . . . . . 8Wa-80-59
Fuel I njector No. 1 (Gas) . . . . . . . . . . . . . 8Wa-80-59
Component Page
Fuel I njector No. 5 (3.7L) . . . . . . . . . . . . 8Wa-80-61
Fuel I njector No. 6 (3.7L) . . . . . . . . . . . . 8Wa-80-61
Fuel Pressure Sensor (Di esel ) . . . . . . . . . 8Wa-80-61
Fuel Pressure Sol enoi d (Di esel ) . . . . . . . . 8Wa-80-61
Fuel Pump Modul e . . . . . . . . . . . . . . . . . 8Wa-80-61
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-61
Generator . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-62
Gl ow Pl ug Assembl y (Di esel ) . . . . . . . . . . 8Wa-80-62
Hazard Swi tch/Combi nati on Fl asher . . . . 8Wa-80-62
Headl amp Level i ng Swi tch
(Bui l t-Up-Export) . . . . . . . . . . . . . . . . 8Wa-80-63
Heated Seat Modul e (Hi ghl i ne) . . . . . . . . 8Wa-80-63
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . 8Wa-80-63
Hood Ajar Swi tch (Except Base) . . . . . . . 8Wa-80-63
I dl e Ai r Control Motor . . . . . . . . . . . . . . . 8Wa-80-64
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . 8Wa-80-64
I nput Speed Sensor (3.7L) . . . . . . . . . . . . 8Wa-80-64
I nstrument Cl uster . . . . . . . . . . . . . . . . . 8Wa-80-64
I ntake Ai r Temperature Sensor (Gas) . . . 8Wa-80-65
I ntrusi on Sensor (Bui l t-Up-Export) . . . . . 8Wa-80-65
Juncti on Bl ock Body Control Modul e-JB . 8Wa-80-65
Juncti on Bl ock C1 . . . . . . . . . . . . . . . . . . 8Wa-80-66
Knock Sensor (3.7L) . . . . . . . . . . . . . . . . 8Wa-80-69
Leak Detecti on Pump . . . . . . . . . . . . . . . 8Wa-80-69
Left Courtesy Lamp . . . . . . . . . . . . . . . . 8Wa-80-69
Left Curtai n Ai rbag . . . . . . . . . . . . . . . . . 8Wa-80-69
Left Cyl i nder Lock Swi tch (Except Base). 8Wa-80-69
Left Door Lock Swi tch (Except Base) . . . 8Wa-80-70
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8Wa-80-70
Left Front Door Ajar Swi tch (Base) . . . . . 8Wa-80-70
Left Front Door Lock Motor/Ajar Swi tch
(Except Base) . . . . . . . . . . . . . . . . . . . 8Wa-80-70
Left Front Door Speaker (Base) . . . . . . . . 8Wa-80-70
Left Front Door Speaker (Premi um) . . . . 8Wa-80-71
Left Front I mpact Sensor . . . . . . . . . . . . 8Wa-80-71
Left Front Park/Turn Si gnal Lamp . . . . . 8Wa-80-71
Left Front Power Wi ndow Motor
(Mi dl i ne/Hi ghl i ne) . . . . . . . . . . . . . . . . 8Wa-80-71
Left Front Wheel Speed Sensor (ABS) . . . 8Wa-80-72
Left Headl amp (Bui l t-Up-Export) . . . . . . 8Wa-80-72
Left Headl amp (Except Bui l t-Up-Export). 8Wa-80-72
Left Heated Seat Assembl y (Hi ghl i ne) . . . 8Wa-80-72
Left Heated Seat Swi tch (Hi ghl i ne) . . . . . 8Wa-80-72
Left I nstrument Panel Speaker . . . . . . . . 8Wa-80-73
Left Level i ng Motor (Bui l t-Up-Export) . . 8Wa-80-73
Left Posi ti on Lamp (Bui l t-Up-Export) . . . 8Wa-80-73
Left Power Mi rror (Except Base) . . . . . . . 8Wa-80-73
8Wa - 80 - 2 8W-80 CONNECTOR PIN-OUTS KJ
Component Page
Left Power Seat Motors
Left Power Seat Swi tch
Left Rear Door Ajar Swi tch (Base) . . . . . 8Wa-80-74
Left Rear Door Lock Motor/Ajar Swi tch
(Except Base) . . . . . . . . . . . . . . . . . . . 8Wa-80-74
Left Rear Door Speaker . . . . . . . . . . . . . . 8Wa-80-75
Left Rear Power Wi ndow Motor
Left Remote Radi o Swi tch (Premi um) . . . 8Wa-80-75
Left Si de I mpact Ai rbag Control
Modul e (LSI ACM) . . . . . . . . . . . . . . . . 8Wa-80-75
Left Si de Marker Lamp (Except
Bui l t-Up-Export) . . . . . . . . . . . . . . . . . 8Wa-80-76
Left Si de Repeater Lamp
Left Speed Control Swi tch (Except Base). 8Wa-80-76
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . 8Wa-80-76
Left Vi sor/Vani ty Lamp (Except Base) . . . 8Wa-80-76
Li cense Lamp (Bui l t-Up-Export) . . . . . . . 8Wa-80-77
Li cense Lamp (Except Bui l t-Up-Export) . 8Wa-80-77
Li ne Pressure Sensor (3.7L) . . . . . . . . . . 8Wa-80-77
Low Note Horn . . . . . . . . . . . . . . . . . . . . 8Wa-80-77
Mani fol d ABSol ute Pressure Sensor . . . . 8Wa-80-77
Mul ti -Functi on Swi tch C1 . . . . . . . . . . . . 8Wa-80-78
Mul ti -Functi on Swi tch C2 . . . . . . . . . . . . 8Wa-80-78
Output Speed Sensor (3.7L) . . . . . . . . . . 8Wa-80-78
Overhead Map/Readi ng Lamp
(Except Base) . . . . . . . . . . . . . . . . . . . 8Wa-80-78
Oxygen Sensor 1/2 Downstream . . . . . . . 8Wa-80-79
Oxygen Sensor 2/1 Upstream (3.7L) . . . . 8Wa-80-79
Oxygen Sensor 2/2 Downstream (3.7L) . . 8Wa-80-79
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . 8Wa-80-79
Passenger Seat Bel t Swi tch . . . . . . . . . . . 8Wa-80-80
Power Mi rror Swi tch (Except Base) . . . . . 8Wa-80-80
Power Outl et . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-80
Power Steeri ng Pressure Swi tch . . . . . . . 8Wa-80-80
Power Wi ndow Master Swi tch
Powertrai n Control Modul e-C1 (2.4L) . . . 8Wa-80-81
Powertrai n Control Modul e-C1 (3.7L) . . . 8Wa-80-82
Powertrai n Control Modul e-C2 (Gas) . . . 8Wa-80-82
Powertrai n Control Modul e-C3 (Gas) . . . 8Wa-80-83
Radi ator Fan Motor . . . . . . . . . . . . . . . . . 8Wa-80-84
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . 8Wa-80-84
Radi o C1 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-84
Radi o C2 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-85
Radi o C3 . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-85
Radi o Choke (Premi um) . . . . . . . . . . . . . 8Wa-80-85
Rear Power Outl et . . . . . . . . . . . . . . . . . . 8Wa-80-85
Rear Power Wi ndow Swi tch
Rear Wheel Speed Sensor . . . . . . . . . . . . 8Wa-80-86
Component Page
Rear Wi per Motor . . . . . . . . . . . . . . . . . . 8Wa-80-86
Red Brake Warni ng I ndi cator Swi tch . . . 8Wa-80-86
Remote Keyl ess Entry Modul e
(Except Base) . . . . . . . . . . . . . . . . . . . 8Wa-80-86
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . 8Wa-80-87
Ri ght Curtai n Ai rbag . . . . . . . . . . . . . . . . 8Wa-80-87
Ri ght Cyl i nder Lock Swi tch
(Except Base) . . . . . . . . . . . . . . . . . . . 8Wa-80-87
Ri ght Door Lock Swi tch (Except Base) . . 8Wa-80-87
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . 8Wa-80-87
Ri ght Front Door Ajar Swi tch (Base) . . . . 8Wa-80-88
Ri ght Front Door Lock Motor/Ajar Swi tch
(Except Base) . . . . . . . . . . . . . . . . . . . 8Wa-80-88
Ri ght Front Door Speaker (Base) . . . . . . 8Wa-80-88
Ri ght Front Door Speaker (Premi um) . . . 8Wa-80-88
Ri ght Front I mpact Sensor . . . . . . . . . . . 8Wa-80-88
Ri ght Front Park/Turn Si gnal Lamp . . . 8Wa-80-89
Ri ght Front Power Wi ndow Motor
Ri ght Front Wheel Speed Sensor (ABS) . 8Wa-80-89
Ri ght Headl amp (Bui l t-Up-Export) . . . . . 8Wa-80-89
Ri ght Headl amp (Except Bui l t-Up-Export) . 8Wa-80-89
Ri ght Heated Seat Assembl y (Hi ghl i ne) . 8Wa-80-90
Ri ght Heated Seat Swi tch (Hi ghl i ne) . . . 8Wa-80-90
Ri ght I nstrument Panel Speaker . . . . . . . 8Wa-80-90
Ri ght Level i ng Motor (Bui l t-Up-Export) . 8Wa-80-90
Ri ght Posi ti on Lamp (Bui l t-Up-Export) . . 8Wa-80-91
Ri ght Power Mi rror (Except Base) . . . . . . 8Wa-80-91
Ri ght Power Seat Motors
Ri ght Power Seat Swi tch
Ri ght Rear Door Ajar Swi tch (Base) . . . . 8Wa-80-92
Ri ght Rear Door Lock Motor/Ajar Swi tch
(Except Base) . . . . . . . . . . . . . . . . . . . 8Wa-80-92
Ri ght Rear Door Speaker . . . . . . . . . . . . 8Wa-80-92
Ri ght Rear Power Wi ndow Motor
Ri ght Remote Radi o Swi tch (Premi um) . . 8Wa-80-92
Ri ght Si de I mpact Ai rbag Control Modul e
(RSI ACM) . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-93
Ri ght Si de Marker Lamp
(Except Bui l t-Up-Export) . . . . . . . . . . . 8Wa-80-93
Ri ght Si de Repeater Lamp
Ri ght Speed Control Swi tch
(Except Base) . . . . . . . . . . . . . . . . . . . 8Wa-80-93
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . 8Wa-80-93
Ri ght Vi sor/Vani ty Lamp (Except Base) . 8Wa-80-94
Sentry Key I mmobi l i zer Modul e
(Except Base) . . . . . . . . . . . . . . . . . . . 8Wa-80-94
Shi fter Assembl y . . . . . . . . . . . . . . . . . . . 8Wa-80-94
Si ren (Bui l t-Up-Export) . . . . . . . . . . . . . . 8Wa-80-94
Speed Control Servo . . . . . . . . . . . . . . . . 8Wa-80-94
Sunroof Motor . . . . . . . . . . . . . . . . . . . . . 8Wa-80-95
Component Page
Sunroof Swi tch . . . . . . . . . . . . . . . . . . . . 8Wa-80-95
Tai l gate Fl i p-Up Ajar Swi tch . . . . . . . . . . 8Wa-80-95
Tai l gate Lock Motor/Ajar Swi tch . . . . . . . 8Wa-80-95
Throttl e Posi ti on Sensor . . . . . . . . . . . . . 8Wa-80-96
Trai l er Tow Brake Lamp Rel ay . . . . . . . . 8Wa-80-96
Trai l er Tow Ci rcui t Breaker . . . . . . . . . . 8Wa-80-96
Trai l er Tow Connector . . . . . . . . . . . . . . . 8Wa-80-96
Trai l er Tow Left Turn Rel ay . . . . . . . . . . 8Wa-80-97
Component Page
Trai l er Tow Rel ay . . . . . . . . . . . . . . . . . . 8Wa-80-97
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . 8Wa-80-97
Transfer Case Posi ti on Sensor . . . . . . . . . 8Wa-80-97
Transmi ssi on Control Modul e (3.7L) . . . . 8Wa-80-98
Transmi ssi on Sol enoi d/TRS Assembl y
(3.7L) . . . . . . . . . . . . . . . . . . . . . . . . . . 8Wa-80-99
Washer Fl ui d Level Swi tch . . . . . . . . . . . 8Wa-80-99
Washer Pump . . . . . . . . . . . . . . . . . . . . 8Wa-80-100
Water I n Fuel Sensor (Di esel ) . . . . . . . . 8Wa-80-100
A/C COMPRESSOR CLUTCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 C3 18DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z246 18BK/GY GROUND
A/C HIGH PRESSURE SWITCH (DIESEL) - GRAY 2 WAY
1 C18 20DB A/C PRESSURE SIGNAL
2 C21 18DB/OR A/C SWITCH SENSE
A/C LOW PRESSURE SWITCH - GRAY 2 WAY
2 Z142 18BK/WT (RHD) GROUND
2 Z212 18BK/OR (LHD) GROUND
A/C PRESSURE TRANSDUCER (GAS) - BLACK 4 WAY
1 K4 18BK/LB SENSOR GROUND
2 K6 18VT/WT 5 VOLT SUPPLY
4 - -
A/C-HEATER CONTROL C1 - BLACK 7 WAY
1 Z8 12BK/VT GROUND
2 C7 12BK/TN BLOWER MOTOR HIGH DRIVER
3 C6 12LB BLOWER MOTOR M2 DRIVER
4 C5 14LG BLOWER MOTOR M1 DRIVER
5 C4 14TN BLOWER MOTOR LOW DRIVER
6 C19 18BR A/C ON/OFF CONTROL
7 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
A/C-HEATER CONTROL C2 - BLACK 12 WAY
1 C35 20DG/YL MODE DOOR DRIVER (A)
2 V23 20BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
3 - -
4 - -
5 - -
6 C79 20VT/BK REAR WINDOW DEFOGGER CONTROL
7 - -
8 Z12 20BK/TN GROUND
9 - -
10 - -
11 - -
12 C16 20LB/YL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY
1 - -
2 - -
3 - -
5 K151 20WT LOW IDLE POSITION SWITCH SENSE
6 - -
7 K81 20VT/TN ACCELERATOR PEDAL POSITION SENSOR SIGNAL
8 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR GROUND
9 - -
10 K852 20VT/WT ACCELERATOR PEDAL POSITION SENSOR 5 VOLT
SUPPLY
AIRBAG CONTROL MODULE C1 (ORC C1) - YELLOW 23 WAY
1 R45 18DG/LB DRIVER SQUIB 1 LINE 2
2 R43 18BK/LB DRIVER SQUIB 1 LINE 1
3 - -
4 - -
5 R53 18OR/YL DRIVER SEAT BELT TENSIONER LINE 2
6 R55 18OR/BK DRIVER SEAT BELT TENSIONER LINE 1
7 R61 18OR/LB DRIVER SQUIB 2 LINE 1
8 R63 18TN/LB DRIVER SQUIB 2 LINE 2
9 R62 18OR/YL PASSENGER SQUIB 2 LINE 2
10 R64 18TN/YL PASSENGER SQUIB 2 LINE 1
11 R42 18BK/YL PASSENGER SQUIB 1 LINE 1
12 R44 18DG/YL PASSENGER SQUIB 1 LINE 2
13 - -
14 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
15 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
16 Z6 18BK/PK GROUND
AIRBAG CONTROL MODULE C1 (ORC C1) - YELLOW 23 WAY
17 - -
18 - -
19 - -
20 - -
21 D25 18YL/VT/OR PCI BUS
22 - -
23 - -
AIRBAG CONTROL MODULE C2 (ORC C2) - BLACK 12 WAY
1 - -
2 R59 20LB DRIVER SEAT BELT SWITCH GROUND
3 R57 20DG DRIVER SEAT BELT SWITCH SENSE
4 - -
5 R60 20VT PASSENGER SEAT BELT SWITCH GROUND
6 R58 20GY PASSENGER SEAT BELT SWITCH SENSE
7 R48 20TN RIGHT FRONT IMPACT SENSOR SIGNAL
8 R46 20BR/LB RIGHT FRONT IMPACT SENSOR GROUND
9 - -
10 - -
11 R47 20DB/LB LEFT FRONT IMPACT SENSOR GROUND
12 R49 20LB/OR LEFT FRONT IMPACT SENSOR SIGNAL
AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY
1 G31 18VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G32 18DB/OR AMBIENT TEMPERATURE SENSOR RETURN
ANTENNA (EXCEPT BUILT-UP-EXPORT) - 2 WAY
1 X30 BK RADIO ANTENNA CORE
2 X31 BK RADIO ANTENNA SHIELD
ANTENNA MODULE C1 (BUILT-UP-EXPORT) - 2 WAY
1 F85 16VT/WT FUSED IGNITION SWITCH OUTPUT (RUN--ACC)
2 - -
ANTENNA MODULE C2 (BUILT-UP-EXPORT) - 2 WAY
ASH RECEIVER LAMP - 2 WAY
BACK-UP LAMP SWITCH (M/T) - BLACK 2 WAY
1 F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
2 L10 18BR/LG BACK-UP LAMP FEED
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY
1 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
BLEND DOOR ACTUATOR - WHITE 4 WAY
2 C35 20DG/YL MODE DOOR DRIVER (A)
4 - -
BLOWER MOTOR - BLACK 2 WAY
2 A111 12RD/LB BLOWER MOTOR RELAY OUTPUT
BLOWER MOTOR RESISTOR BLOCK - BLACK 10 WAY
3 C6 12LB BLOWER MOTOR M2 DRIVER
4 C5 14LG BLOWER MOTOR M1 DRIVER
5 C4 14TN BLOWER MOTOR LOW DRIVER
6 - -
7 - -
8 - -
9 - -
10 - -
BODY CONTROL MODULE C1 - GRAY 26 WAY
1 Z103 16BK/OR GROUND
2 V22 20BR/YL REAR WIPER INTERMITTENT DRIVER
3 Y98 20GY/DB INSTRUMENT CLUSTER WAKE UP SIGNAL
4 G75 20TN DRIVER DOOR AJ AR SWITCH SENSE
5 G74 20TN/WT PASSENGER DOOR AJ AR SWITCH SENSE
6 G70 20BR/TN (EXCEPT BASE) HOOD AJ AR SWITCH SENSE
7 G78 20TN/BK TAILGATE AJ AR SWITCH SENSE
8 G26 20LB KEY-IN IGNITION SWITCH SENSE
9 G80 20YL/WT FLIP-UP GLASS AJ AR SWITCH SENSE
10 M3 20PK/DB REAR COURTESY LAMP CONTROL
11 V10 18BR WASHER PUMP DRIVER
12 L91 20DB/PK HAZARD LAMP CONTROL
13 V21 20DB/RD REAR WIPER ON DRIVER
14 Z231 16BK/WT SIGNAL GROUND
15 D25 18YL/VT/WT PCI BUS
16 D19 20VT/OR BODY CONTROL MODULE FLASH ENABLE
17 P101 20OR/PK FLIP-UP GLASS RELEASE SWITCH SENSE
18 - -
19 - -
20 B22 18LG/YL VEHICLE SPEED OUTPUT
21 G69 20BK/OR VTSS INDICATOR DRIVER
22 - -
23 C79 20VT/BK REAR WINDOW DEFOGGER CONTROL
24 C19 18BR A/C ON/OFF CONTROL
26 P100 18OR/BR FLIP-UP GLASS RELEASE MOTOR DRIVER
1 Y66 20GY (EXCEPT BASE) RKE ANTENNA
2 G910 20VT/BR TAILGATE SWITCH GROUND
3 - -
4 L80 20WT/DG HEADLAMP SWITCH RETURN
5 L307 20LG/OR HEADLAMP SWITCH MUX
6 G72 18DG/OR (LHD PREMIUM) RIGHT CYLINDER LOCK SWITCH MUX
6 G73 18LG/OR (RHD) RIGHT CYLINDER LOCK SWITCH MUX
7 L27 20WT/TN (EXCEPT BASE) FRONT FOG LAMP SWITCH SENSE
8 E21 20OR/RD PANEL LAMPS DIMMER SWITCH MUX
9 G72 18DG/OR (RHD) LEFT CYLINDER LOCK SWITCH MUX
9 G73 18LG/OR (LHD PREMIUM) LEFT CYLINDER LOCK SWITCH MUX
10 V52 20DG/RD FRONT WIPER SWITCH MUX
11 X10 20RD/DB (EXCEPT BASE) RADIO CONTROL MUX RETURN
12 Y66 20GY (EXCEPT BASE) RKE ANTENNA
13 - -
14 - -
15 G32 20DB/OR (EXCEPT BASE) AMBIENT TEMPERATURE SENSOR RETURN
16 - -
17 G71 18VT/YL TAILGATE CYLINDER LOCK SWITCH MUX
18 G31 20VT/LG (EXCEPT BASE) AMBIENT TEMPERATURE SENSOR SIGNAL
19 L324 20WT/LG HIGH BEAM SWITCH SENSE
20 F512 18PK/OR VEHICLE SPEED SENSOR SUPPLY
21 B12 18DG/OR VEHICLE SPEED SIGNAL
22 X20 20RD/BK (EXCEPT BASE) RADIO CONTROL MUX
BODY CONTROL MODULE C3 (PREMIUM) - 6 WAY
1 Y60 RKE DATA
2 Y62 RKE SUPPLY
3 Y61 RKE PROGRAM
4 Y63 RKE GROUND
5 Y64 RKE ANTENNA (+)
6 Y65 RKE ANTENNA (-)
BOOST PRESSURE SENSOR (DIESEL) - 4 WAY
2 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
3 K6 18VT/WT SENSOR REFERENCE VOLTAGE B
4 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
BRAKE LAMP SWITCH - BLACK 6 WAY
1 F32 18PK/DB FUSED B(+)
2 L50 18WT/TN (GAS) BRAKE LAMP SWITCH OUTPUT
2 L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
3 V30 18DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
4 V32 18YL/RD SPEED CONTROL SUPPLY
5 Z3 18BK/OR GROUND
6 K29 18WT/PK (GAS) BRAKE SWITCH SENSE
6 K29 18WT/PK (DIESEL) SECONDARY BRAKE SWITCH SIGNAL
BRAKE PRESSURE SWITCH (ABS) - BLACK 2 WAY
1 F22 18DB/PK FUSED IGNITION SWITCH OUTPUT (RUN)
2 S43 18LB/YL FLUID PRESSURE SWITCH SIGNAL
C100 (RHD) - GRAY (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
1 L43 18VT
2 F1 20DB
3 M1 18PK
4 B22 18LG/YL
5 L44 18VT/RD
6 V16 18VT/YL
7 V55 16TN/RD
8 G32 20DB/OR
9 D20 20LG
10 D25 18YL/VT/BR
11 V14 18RD/VT
12 L13 18BR/YL
13 G70 20BR/TN
14 G11 20WT/BK
15 K4 20BK/LB
16 L50 18WT/TN
17 L62 18BR/RD
C100 (RHD) - GRAY (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
18 L62 18DG/RD
19 V30 18DB/RD
20 D32 20LG/DG
21 V32 18YL/RD
22 G29 20BK/TN
23 X2 18DG/RD
24 F15 18DB/WT
25 G18 20PK/BK
26 D24 18WT/DG
27 B12 18DG/OR
28 R46 20BR/LB
29 R48 20TN
30 R47 20DB/LB
31 R49 20LB/OR
32 -
33 -
34 -
35 F512 18PK/OR
36 -
37 Z252 18BK/GY
38 Z252 18BK/GY
39 V10 18BR
40 -
41 T6 20VT/WT
42 V37 20RD/LG
43 V20 18BK/WT
44 K29 18WT/PK
45 D25 18YL/VT/GY
46 -
47 X75 18DG
48 L10 18BR/LG
49 D21 20PK/RD
50 F22 18DB/PK
51 L33 18LG/BR
52 L39 18LB
53 L78 18DG/YL
54 F20 18WT
55 V6 14DB/YL
56 G31 20VT/LG
57 -
58 L34 18RD/OR
59 L77 18BK/YL
60 -
61 A41 12YL
62 A21 12RD/DB
63 A1 12RD
64 A111 12RD/LB
65 A12 10RD/TN
66 A13 10PK/WT
67 A18 10PK
68 A7 10RD/BK
69 A2 12PK/BK
70 A25 12DB
71 A4 12BK/PK
72 A99 14RD/VT
C100 (LHD) - GRAY (HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
1 B1 18YL/DB
2 B2 18YL
3 K226 18DB/WT
4 B22 18DG/YL
5 K106 18WT/DG (GAS)
6 K107 18OR (GAS)
7 K125 18WT/DB (GAS)
8 G32 18DB/OR
9 D20 18LG (GAS)
10 D25 18YL/VT
11 -
12 L13 18BR/YL (BUILT-UP-EXPORT)
13 G70 18BR/TN (BUILT-UP-EXPORT)
14 G11 18WT/BK
15 K4 18BK/LB
16 -
17 L62 18BR/RD
18 L63 18DG/RD
19 V30 18DB/RD (GAS)
20 D32 18LG (GAS)
21 V32 18YL/RD (GAS)
22 G29 18BK/TN
23 -
24 F15 18DB/WT
25 G18 18PK/BK (DIESEL)
26 D24 18WT/DG (ABS)
27 B12 18DG/OR (ABS)
27 B1 18YL/DB (EXCEPT ABS)
28 R46 18BR/LB
29 R48 18TN
30 R47 18DB/LB
31 R49 18LB
32 -
33 -
34 -
35 B2 18YL (EXCEPT ABS)
36 -
37 Z252 18BK/GY
38 Z252 18BK/GY
39 V10 18BR
40 T138 18GY/LB (DIESEL)(M/T)
41 T6 18VT/WT (GAS)
42 V37 18RD/LG
43 V20 18BK/WT
44 K29 18WT/PK
45 D25 18YL/VT
46 -
47 X75 18DG (BUILT-UP-EXPORT)
48 L10 18BR/LG
49 D21 18PK
50 -
51 -
52 -
C100 (LHD) - GRAY (HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
53 -
54 -
55 -
56 G31 18VT/LG
57 -
58 -
59 -
60 A32 14RD/DB (A/T)
61 A41 12YL
62 A21 12RD/DB (M/T)
63 A1 12RD
64 A111 12RD/LB
65 A99 14RD/VT
66 -
67 -
68 -
69 A2 12PK/BK
70 A25 12DB
71 -
72 A141 16DG/WT (GAS)
C100 (LHD) - GRAY (INSTRUMENT PANEL
SIDE)
CAV CIRCUIT
1 B1 18YL/DB
2 B2 18YL
3 K226 18DB/WT
4 B22 18LG/YL
5 K106 18WT/DG
6 K107 18OR
7 K125 18WT/DB
8 G32 20DB/OR (EXCEPT BASE)
9 D20 20LG
10 D25 18YL/VT/BR
11 -
12 L13 18BR/YL (BUILT-UP-EXPORT)
13 G70 20BR/TN (EXCEPT BASE)
14 G11 20WT/BK
15 K4 18BK/LB
16 -
17 L62 18BR/RD
18 L63 18DG/RD
19 V30 18DB/RD
20 D32 20LG/DG
21 V32 18YL/RD
22 G29 20BK/TN
23 -
24 F15 18DB/WT
25 G18 20PK/BK
26 D24 18WT/DG
27 B12 18DG/OR
C100 (LHD) - GRAY (INSTRUMENT PANEL
SIDE)
CAV CIRCUIT
28 R46 20BR/LB
29 R48 20TN
30 R47 20DB/LB
31 R49 20LB/OR
32 -
33 -
34 -
35 F512 18PK/OR
36 -
37 Z252 18BK/GY
38 Z252 18BK/GY
39 V10 18BR
40 -
41 T6 20VT/WT
42 V37 20RD/LG
43 V20 18BK/WT
44 K29 18WT/PK
45 D25 18YL/VT/GY
46 -
47 X75 18 DG (EXCEPT BASE)
48 L10 18BR/LG
49 D21 20PK/RD
50 -
51 -
52 -
53 -
54 -
55 -
56 G31 20VT/LG (EXCEPT BASE)
57 -
58 -
59 --
60 -
61 A41 12YL
62 A21 12 RD/DB
63 A1 12RD
64 A111 12RD/LB
65 A99 14RD/VT
66 -
67 -
68 -
69 A2 12PK/BK
70 A25 12DB
71 -
72 A141 16DG/WT
C100 (RHD) - GRAY (HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
1 L43 18VT
2 F1 18DB
3 M1 18PK
4 B22 18DG/YL
5 L44 18VT/RD
6 V16 18VT/YL
7 V55 16TN/RD
8 G32 18DB/OR
9 D20 18LG
10 D25 18YL/VT
11 V14 18RD/VT
12 L13 18BR/YL
13 G70 18BR/TN
14 G11 18WT/BK
15 K4 18BK/LB
16 L50 18WT/TN (ABS)
17 L62 18BR/RD
18 L63 18DG/RD
19 V30 18DB/RD
20 D32 18LG
21 V32 18YL/RD
22 G29 18BK/TN
23 X2 18DG/RD
24 F15 18DB/WT
25 -
26 D24 18WT/DG (ABS)
27 B1 18YL/DB (EXCEPT ABS)
27 B12 18DG/OR (ABS)
28 R46 18BR/LB
29 R48 18TN
30 R47 18DB/LB
31 R49 18LB
32 -
33 -
34 -
35 B2 18YL (EXCEPT ABS)
35 F512 18PK/OR (ABS)
36 -
37 Z252 18BK/GY
38 Z252 18BK/GY
39 V10 18BR
40 -
41 T6 18VT/WT
42 V37 18RD/LG
43 V20 18BK/WT
44 K29 18WT/PK
45 D25 18YL/VT (ABS)
45 D25 18YL/VT (EXCEPT ABS)
46 -
47 X75 18DG
48 L10 18BR/LG
49 D21 18PK
50 F22 18DB/PK (ABS)
SIDE)
CAV CIRCUIT
51 L33 18LG/BR
52 L39 18LB
53 L78 18DG/YL
54 F20 18WT
55 V6 16DB/YL
56 G31 18VT/LG
57 -
58 L34 18RD/OR
59 L77 18BK/YL
60 A32 14RD/DB (A/T)
61 A41 12YL
62 A21 12RD/DB (M/T)
63 A1 12RD
64 A111 12RD/LB
65 A12 10RD/TN
66 A13 10PK/WT
67 A18 10PK
68 A7 10RD/BK
69 A2 12PK/BK
70 A25 12DB
71 A4 12BK/PK
72 A99 14RD/VT
C101 (2.4L) - BLACK (ENGINE TO HEADLAMP
AND DASH SIDE)
CAV CIRCUIT
1 K59 18VT/BK
2 K40 18BR/WT
3 K60 18YL/BK
4 K39 18GY/RD
5 K21 18BK/RD
6 K2 18TN/BK
7 K1 18DG/RD
8 K22 18OR/DB
9 K6 18VT/WT
10 G60 18GY/YL
11 K24 18GY/BK
12 K7 18OR
13 -
14 -
C101 (2.4L) - BLACK (ENGINE TO FUEL INJ EC-
TOR SIDE)
CAV CIRCUIT
1 K59 18VT/BK
2 K40 18BR/WT
3 K60 18YL/BK
4 K39 18GY/RD
5 K21 18BK/RD
6 K2 18TN/BK
7 K1 18DG/RD
8 K22 18OR/DB
9 K6 18VT/WT
10 G60 18GY/YL
11 K24 18GY/BK
12 K7 18OR
13 -
14 -
SIDE)
CAV CIRCUIT
1 K226 18DB/WT
2 K512 18PK/OR
3 A141 16DG/WT (GAS)
4 B1 18YL/DB
5 B2 18YL
6 K4 18BK/LB
7 B12 18DG/OR
9 K107 18OR (GAS)
10 K106 18WT/DG (GAS)
C102 (RHD) - GRAY (FRONT BODY SIDE)
CAV CIRCUIT
1 K226 18DB/WT
2 F512 18PK/OR
3 A141 16DG/WT
4 B1 18YL/DB
5 B2 18YL
6 K4 18BK/LB
7 B12 18DG/OR
8 K125 18WT/DB
9 K107 18OR
10 K105 18WT/DG
C103 (GAS) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 F142 18OR/DG
2 -
3 K299 18BR/WT
4 -
5 K173 18LG
6 -
7 -
8 -
9 K99 18BR/OR
10 -
C103 (GAS) - BLACK (HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
1 F142 18OR/DG
2 -
3 K299 18BR/WT
4 -
5 K173 18LG
6 -
7 -
8 -
9 K99 18BR/OR
10 -
C104 (DIESEL) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 K90 20TN
2 K132 20DG/LB
3 K152 20WT
4 C3 18DB/BK
5 -
6 -
7 D21 20PK
8 D25 20VT/YL
9 F15 18DB/WT
10 -
11 F1 20DB
12 L50 20WT/TN
13 -
14 -
C104 (DIESEL) - BLACK (HEADLAMP AND
DASH SIDE)
CAV CIRCUIT
1 K90 18TN
2 K132 18DG/LB
3 K152 18WT
4 C3 18DB/BK
5 -
6 -
7 -
8 -
9 F15 18DB/WT
10 -
11 F1 18DB
12 L50 18WT/TN
13 -
14 -
CAV CIRCUIT
1 A14 16RD/WT
2 F18 18LG/BK (3.7L)
3 -
4 C3 18DB/BK
5 -
6 D20 18LG (A/T)
7 D21 18PK (A/T)
8 D25 18VT/YL (A/T)
9 F15 18DB/WT
10 F45 18YL/BR (A/T)
11 F1 18DB
12 T10 18YL/DG (A/T)
13 K20 18DG
14 T6 18OR/WT (A/T)
SIDE)
CAV CIRCUIT
1 A14 16RD/WT (GAS)
2 F18 18LG/BK (GAS)
3 -
4 C3 18DB/BK
5 -
6 D20 18LG
7 D21 18PK
8 D25 18YL/VT
9 F15 18DB/WT
SIDE)
CAV CIRCUIT
10 F45 18YL/BR
11 F1 18DB
12 T10 18YL/DG
13 K20 18DG
14 T6 18VT/WT
C105 (DIESEL) - GRAY (ENGINE SIDE)
CAV CIRCUIT
1 B22 20DG/YL
2 K4 18BK/LB
3 L10 18BR/LG
4 C21 18DB/OR
5 A71 18DG/RD
6 -
7 -
8 -
9 A142 14DG/OR
10 -
11 -
12 A93 16RD/BK
13 Z252 18BK/GY
14 Z252 18BK/GY
C105 (DIESEL) - GRAY (HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
1 B22 18DG/YL
2 K4 18BK/LB
3 L10 18BR/LG
4 C21 18DB/OR
5 A71 18DG/RD
6 -
7 -
8 -
9 A142 16DG/OR
10 T138 18GY/LB
11 -
12 A93 16RD/BK
13 Z252 18BK/GY
14 Z252 18BK/GY
C105 (GAS) - GRAY (ENGINE SIDE)
CAV CIRCUIT
1 -
2 K4 18BK/LB
3 L10 18BR/LG
4 -
5 A71 18DG/RD
6 T16 14RD (A/T)
7 T41 18BK/WT (A/T)
8 K30 18PK (A/T)
9 -
10 T141 18YL/RD (M/T)
11 -
12 A30 14RD/WT (A/T)
13 -
14 -
C105 (GAS) - GRAY (HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
1 -
2 K4 18BK/LB
3 L10 18BR/LG
4 -
5 A71 18DG/RD
6 T16 14RD (A/T)
7 T41 18BK/WT (A/T)
8 K30 18PK (A/T)
9 -
10 T141 18YL/RD (M/T)
11 -
12 A30 14RD/WT (A/T)
13 -
14 -
C106 - BLACK (HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 G31 18VT/LG
2 G32 18DB/OR
3 L33 18LG/BR
4 L43 18VT
5 L63 18DG/RD
6 L39 18LB
7 L78 18DG/YL
8 Z141 18BK
9 L13 18BR/YL (BUILT-UP-EXPORT))
10 L34 18RD/OR
CAV CIRCUIT
11 L44 18VT/RD
12 L62 18BR/RD
13 L77 18BK/YL
14 Z142 18BK/WT
C106 - BLACK (FRONT END LIGHTING SIDE)
CAV CIRCUIT
1 G31 18VT/LG
2 G32 18DB/OR
3 L33 18LG/BR
4 L43 18VT
5 L63 18DG/RD
6 L39 18LB
7 L78 18DG/YL
8 Z141 18BK
9 -
10 L34 18RD/OR
11 L44 18VT/RD
12 L62 18BR/RD
13 L77 18BK/YL
14 Z142 18BK/WT
CAV CIRCUIT
1 Z141 18BK
2 L77 18BK/YL
3 -
4 L78 18DG/YL
5 Z142 18BK/WT
6 L62 18BR/RD
7 -
8 L39 18LB
9 -
10 L63 18DG/RD
CAV CIRCUIT
1 Z141 18BK
2 L77 18BK/YL
3 -
4 L78 18DG/YL
5 Z142 18BK/WT
CAV CIRCUIT
6 L62 18BR/RD
7 -
8 L39 18LB (FOG LAMPS)
9 -
10 L63 18DG/RD
C108 (GAS) - GRAY (BATTERY SIDE)
CAV CIRCUIT
1 K52 18PK/BK
2 K20 18DG
3 K125 18WT/DB
4 T40 12BR
5 F1 18DB
6 -
C108 (GAS) - GRAY (HEADLAMP AND DASH
SIDE)
CAV CIRCUIT
1 K52 18PK/BK
2 K20 18DG
3 K125 18WT/DB
4 T40 12BR
5 F1 18DB
6 -
C110 (2.4L) - BLACK (ENGINE TO HEADLAMP
AND DASH SIDE)
CAV CIRCUIT
1 F142 18OR/DG
2 C3 18DB/BK
3 Z246 18BK/GY
4 K11 18WT/DB
5 K12 18TN
6 K13 18YL/WT
7 K14 18LB/BR
8 K44 18TN/YL
9 K4 18BK/LB
10 -
C110 (2.4L) - BLACK (ENGINE TO FUEL INJ EC-
TORS SIDE)
CAV CIRCUIT
1 F142 18OR/DG
2 C3 18DB/BK
3 Z246 18BK/GY
4 K11 18WT/DB
5 K12 18TN
6 K13 18YL/WT
7 K14 18LB/BR
8 K44 18TN/YL
9 K4 18BK/LB
10 -
C111 (DIESEL) - LT. GRAY (ENGINE SIDE)
CAV CIRCUIT
1 K51 20DB/YL
2 K118 20PK/YL
3 C13 20DG
4 -
5 K226 20DB/WT
6 V37 20RD/LG
7 K35 20GY/YL
8 G18 18PK/BK
9 K29 20WT/PK
10 K236 20GY/PK
11 C151 18DB/WT
12 T40 12BR
13 F92 20YL/BR
14 -
C111 (DIESEL) - LT. GRAY (HEADLAMP AND
DASH SIDE)
CAV CIRCUIT
1 K51 18DB/YL
2 K118 18PK/YL
3 C13 18DG
4 -
5 K226 18DB/WT
6 V37 18RD/LG
7 K35 18GY/YL
8 G18 18PK/BK
9 K29 18WT/PK
10 K236 18GY/PK
11 C151 18DB/WT
12 T40 12BR
13 F92 18YL/BR
14 T141 14YL/RD
CAV CIRCUIT
1 K42 18DB/LB (3.7L)
2 K4 18BK/LB (3.7L)
3 Z252 18BK/GY
4 K142 18GY/BK (3.7L)
5 K4 18BK/LB (3.7L)
6 Z252 18BK/GY
7 -
8 -
9 -
10 A142 14DG/OR
SIDE)
CAV CIRCUIT
1 K42 18DB/LB
2 K4 18BK/LB
3 Z252 18BK/GY
4 K142 18GY/BK
5 K4 18BK/LB
6 Z252 18BK/GY
7 -
8 -
9 -
10 A142 14DG/OR
C113 (DIESEL) - LT.GRAY (GLOW PLUG SIDE)
CAV CIRCUIT
1 K154 10GY
2 K104 10RD/WT
C113 (DIESEL) - LT.GRAY (BATTERY SIDE)
CAV CIRCUIT
1 K154 10GY
2 K104 10RD/WT
C114 (DIESEL) - LT. GRAY (BATTERY SIDE)
CAV CIRCUIT
1 K154 10GY
2 K104 10RD/WT
C114 (DIESEL) - LT. GRAY (GLOW PLUG SIDE)
CAV CIRCUIT
1 K154 10GY
2 K104 10RD/WT
C201 - BLACK (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
1 R57 20DG
2 R59 20LB
3 X75 18DG (EXCEPT BASE)
4 A99 14RD/VT
5 B12 18DG/OR
6 F81 12TN
7 V21 20DB/RD
8 V22 20BR/YL
9 R58 20GY
10 R60 20VT
11 K226 18DB/WT (LHD)
12 G74 20TN/WT
13 G71 18VT/YL
14 T6 20VT/WT
15 G9 20GY/BK
16 B1 18YL/DB (LHD)
17 K29 18WT/PK
18 L62 18BR/RD
19 M3 20PK/DB
20 K125 18WT/DB (LHD)
21 -
22 -
23 K4 18BK/LB (LHD)
24 G910 20VT/BR
25 G78 20TN/BK
26 P101 20OR/PK
27 G80 20YL/WT
28 B2 18YL (LHD)
29 Z9 16BK
30 L63 18DG/RD
31 K106 18WT/DG (LHD)
32 K107 18OR (LHD)
33 D25 18YL/VT/DB
34 G75 20TN
35 G72 18DG/OR (PREMIUM)
C201 - BLACK (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
36 G73 18LG/OR (PREMIUM)
37 F512 18PK/OR
38 A141 16DG/WT (LHD)
39 L10 18BR/LG
40 P100 18OR/BR
C201 - BLACK (BODY SIDE)
CAV CIRCUIT
1 R57 18DG
2 R59 18LB
3 X75 18DG (HIGHLINE)
4 A99 14RD/VT (MIDLINE/HIGHLINE)
5 B12 18DG/OR (RHD)
6 F81 12TN (MIDLINE/HIGHLINE)
7 V21 20DB/RD
8 V22 20BR/YL
9 R58 18GY
10 R60 18VT
11 K226 18DB/WT (LHD)
12 G74 20TN/WT
13 G71 18VT/YL
14 T6 20VT/WT
15 G9 20GY/BK
16 B1 18YL/DB (LHD)
17 K29 20WT/PK
18 L62 18BR/RD
19 M3 20PK/DB
20 K125 18WT/DB (LHD)
21 -
22 -
23 K4 18BK/LB (LHD)
24 G910 20VT/BR
25 G78 20TN/BK
26 P101 20OR/PK
27 G80 20YL/WT
28 B2 18YL (LHD)
29 Z9 16BK
30 L63 18DG/RD
31 K106 18WT/DG (LHD)
32 K107 18OR (LHD)
33 D25 18YL/VT
34 G75 20TN
35 G72 18DG/OR (MIDLINE/HIGHLINE)
36 G73 18LG/OR (MIDLINE/HIGHLINE)
37 F512 18PK/OR (RHD)
38 A141 16DG/WT (LHD)
39 L10 18BR/LG
40 P100 18OR/BR
C202 - YELLOW (INSTRUMENT PANEL SIDE)
CAV CIRCUIT
1 -
2 -
3 R53 18OR/YL
4 R55 18OR/BK
C202 - YELLOW (MAIN BODY SIDE)
CAV CIRCUIT
1 -
2 -
3 R53 18OR/YL
4 R55 18OR/BK
C300 (LHD) - ORANGE (MAIN BODY SIDE)
CAV CIRCUIT
1 X57 18BR/LB (MIDLINE/HIGHLINE)
2 X91 18WT/BK (MIDLINE/HIGHLINE)
3 X81 18YL/BK (MIDLINE/HIGHLINE)
4 X13 16BK/RD (MIDLINE/HIGHLINE)
5 -
6 -
7 X51 18BR/YL (MIDLINE/HIGHLINE)
8 X93 18WT/RD (MIDLINE/HIGHLINE)
9 X83 18YL/RD (MIDLINE/HIGHLINE)
10 -
11 -
12 -
13 -
14 Z9 16BK (MIDLINE/HIGHLINE)
C300 (LHD) - ORANGE (DRIVER DOOR SIDE)
CAV CIRCUIT
1 X57 18BR/LB
2 X57 18BR/LB (BASE)
2 X91 18WT/BK (PREMIUM)
3 X55 18BR/RD (BASE)
3 X81 18YL/BK (PREMIUM)
4 X13 16BK/RD (PREMIUM)
5 -
6 -
7 X51 18BR/YL
8 X93 18WT/RD (PREMIUM)
8 X51 18BR/YL (BASE)
9 X53 18DG (BASE)
9 X83 18YL/RD (PREMIUM)
10 -
11 -
12 -
13 -
14 Z9 16BK (PREMIUM)
C300 (RHD) - ORANGE (MAIN BODY SIDE)
CAV CIRCUIT
1 X58 18DB/OR
2 X92 18TN/BK
3 X86 18OR/RD
4 X13 16BK/RD
5 -
6 -
7 X52 18DB/WT
8 X94 18TN/VT
9 X84 18TN/BK
10 -
11 P99 18GY
12 P110 18YL
13 -
14 Z9 16BK
C300 (RHD) - ORANGE (DRIVER DOOR SIDE)
CAV CIRCUIT
1 X58 18DB/OR
2 X58 18DB/OR (BASE)
2 X92 18TN/BK (PREMIUM)
3 X56 18DB/RD (BASE)
3 X86 18OR/RD (PREMIUM)
5 -
6 -
7 X52 18DB/WT
8 X94 18TN/VT (PREMIUM)
8 X52 18DB/WT (BASE)
9 X54 18VT (BASE)
10 -
11 P99 18GY
12 P110 18YL
13 -
CAV CIRCUIT
1 Q11 14LB (MIDLINE/HIGHLINE)
2 F89 18OR/RD (EXCEPT BASE)
3 P33 18OR/BK (EXCEPT BASE)
4 C16 18LB/YL (EXCEPT BASE)
5 P72 18YL/BK (EXCEPT BASE)
6 -
7 G73 18LG/OR (MIDLINE/HIGHLINE)
8 P37 20LG (EXCEPT BASE)
9 X55 18BR/RD
10 Q21 14WT (MIDLINE/HIGHLINE)
11 V23 20BR/PK (EXCEPT BASE)
12 P34 18PK/BK (EXCEPT BASE)
13 P74 18DB (EXCEPT BASE)
14 P76 18OR/YL (EXCEPT BASE)
15 G75 20TN
16 Z21 20BK/LG (MIDLINE/HIGHLINE)
17 Z350 20BK/LG
18 -
19 P36 20PK/VT (EXCEPT BASE)
20 X53 18DG
C301 (LHD) - ORANGE (DRIVER DOOR SIDE)
CAV CIRCUIT
1 Q11 16LB (POWER WINDOWS)
6 -
7 G73 18LG/OR (EXCEPT BASE)
9 X55 18BR/RD
10 Q21 16WT (POWER WINDOWS)
12 P34 18PK/BK (EXCEPT BASE)
15 G75 20TN
16 -
17 Z350 20BK/LG
18 -
20 X53 18DG
CAV CIRCUIT
1 Q12 14BR
2 F89 18OR/RD
3 P33 18OR/BK
4 C16 18LB/YL
5 P71 18YL/DG
6 -
7 G73 18LG/OR
8 P37 20LG
9 X56 18DB/RD
10 Q22 14VT/WT
11 V23 20BR/PK
12 P34 18PK/BK
13 P75 18LB/WT
14 P76 18OR/YL
15 G75 20TN
16 -
17 Z351 18BK/LG
18 -
19 P36 20PK/VT
20 X54 18VT
C301 (RHD) - ORANGE (DRIVER DOOR SIDE)
CAV CIRCUIT
1 Q12 16BR
2 F89 20OR/RD
3 P33 18OR/BK
4 C16 20LB/YL
5 P71 20YL/DG
6 -
7 G73 18LG/OR
8 P37 18LG
9 X56 18BR/RD
10 Q22 16VT/WT
11 V23 20BR/PK
12 P34 18PK/BK
13 P75 20LB/WT
14 P76 18OR/YL
15 G75 20TN
16 -
17 Z351 18BK/LG
18 -
19 P36 20PK/VT
20 X54 18VT
CAV CIRCUIT
1 X58 18DB/OR (MIDLINE/HIGHLINE)
2 X92 18TN/BK (MIDLINE/HIGHLINE)
3 X86 18OR/RD (MIDLINE/HIGHLINE)
4 X13 16BK/RD (MIDLINE/HIGHLINE))
5 -
6 -
7 X52 18DB/WT (MIDLINE/HIGHLINE)
8 X94 18TN/VT (MIDLINE/HIGHLINE)
10 -
11 -
12 -
13 -
14 Z9 16BK (MIDLINE/HIGHLINE)
C302 (LHD) - ORANGE (PASSENGER DOOR
SIDE)
CAV CIRCUIT
1 X58 18DB/OR
3 X56 18DB/RD (BASE)
3 X86 18OR/RD (PREMIUM)
5 -
6 -
7 X52 18DB/WT
9 X54 18VT (BASE)
10 -
11 -
12 -
13 -
CAV CIRCUIT
1 X57 18BR/LB
2 X91 18WT/BK
3 X81 18YL/BK
4 X13 16BK/RD
5 -
6 -
7 X51 18BR/YL
8 X93 18WT/RD
9 X83 18YL/RD
10 -
11 P99 18GY
12 P110 18YL
13 -
14 Z9 16BK
C302 (RHD) - ORANGE (PASSENGER DOOR
SIDE)
CAV CIRCUIT
1 X57 18BR/LB
2 X57 18BR/LB (BASE)
2 X91 18WT/BK (PREMIUM)
3 X55 18BR/RD (BASE)
3 X81 18YL/BK (PREMIUM)
5 -
6 -
7 X51 18BR/YL
8 X93 18WT/RD (PREMIUM)
8 X51 18BR/YL (BASE)
9 X53 18DG (BASE)
9 X83 18YL/RD (PREMIUM)
10 -
11 P99 20GY
12 P110 20YL
13 -
CAV CIRCUIT
1 Q12 14BR (MIDLINE/HIGHLINE)
6 -
7 G72 18DG/OR (MIDLINE/HIGHLINE)
9 X56 18DB/RD
10 Q22 14VT/WT (MIDLINE/HIGHLINE)
11 -
12 P35 18OR/VT (EXCEPT BASE)
15 G74 20TN/WT
16 -
17 Z351 18BK/LG
18 -
20 X54 18VT
C303 (LHD) - ORANGE (PASSENGER DOOR
SIDE)
CAV CIRCUIT
1 Q12 16BR (POWER WINDOWS)
6 -
7 G72 18DG/OR (EXCEPT BASE)
9 X56 18DB/RD
10 Q22 16VT/WT (POWER WINDOWS)
11 -
15 G74 20TN/WT
16 -
17 Z351 18BK/LG
18 -
20 X54 18VT
CAV CIRCUIT
1 Q11 14LB
2 F89 18OR/RD
3 P33 18OR/BK
4 C16 18LB/YL
5 P71 18YL/DG
6 -
7 G72 18DG/OR
8 P37 20LG
9 X55 18BR/RD
10 Q21 14WT
11 -
12 P35 18OR/VT
13 P75 18LB/WT
14 P76 18OR/YL
15 G74 20TN/WT
16 Z21 20BK/LG
17 Z350 18BK/LG
18 -
19 P36 20PK/VT
20 X53 18DG
C303 (RHD) - ORANGE (PASSENGER DOOR
SIDE)
CAV CIRCUIT
1 Q11 16LB
2 F89 20OR/RD
3 P33 18OR/BK
4 C16 20LB/YL
5 P71 20YL/DG
6 -
7 G72 18DG/OR
8 P37 18LG
9 X55 18BR/RD
10 Q21 16WT
11 -
12 P35 18OR/VT
13 P75 20LB/WT
14 P76 20OR/YL
15 G74 20TN/WT
16 -
17 Z350 18BK/LB
18 -
19 P36 20PK/VT
20 X53 18DG
C304 - BLUE (MAIN BODY SIDE)
CAV CIRCUIT
1 Q14 14GY (MIDLINE/HIGHLINE)
3 -
4 -
5 -
6 X58 18DB/OR (BASE/LOWLINE)
7 Q24 14DG (MIDLINE/HIGHLINE)
9 -
10 Z351 20BK/LG
11 -
12 G74 20TN/WT
13 -
14 X94 18TN/VT (MIDLINE/HIGHLINE)
14 X52 18DB/WT (BASE/LOWLINE)
C304 - BLUE (RIGHT REAR DOOR SIDE)
CAV CIRCUIT
1 Q14 16GY (MIDLINE II/HIGHLINE)
3 -
4 -
C304 - BLUE (RIGHT REAR DOOR SIDE)
CAV CIRCUIT
5 -
7 Q24 16DG (MIDLINE II/HIGHLINE)
9 -
10 Z351 20BK/LG
11 -
12 G74 20TN/WT
13 -
C305 - BLUE (MAIN BODY SIDE)
CAV CIRCUIT
1 Q13 14DB (MIDLINE/HIGHLINE)
3 -
4 -
5 -
6 X91 18WT/BK (MIDLINE/HIGHLINE)
6 X57 18BR/LB (BASE/LOWLINE)
7 Q23 14RD/WT (MIDLINE/HIGHLINE)
9 -
10 Z350 20BK/LG (RHD)
10 Z350 18BK/LG (LHD)
11 -
12 G74 20TN/WT
13 -
14 X93 18WT/RD (MIDLINE/HIGHLINE)
14 X51 18BR/YL (BASE/LOWLINE)
C305 - BLUE (LEFT REAR DOOR SIDE)
CAV CIRCUIT
1 Q13 16GY (MIDLINE II/HIGHLINE)
3 -
4 -
5 -
7 Q23 16DG (MIDLINE II/HIGHLINE)
9 -
10 Z350 20BK/LG
11 -
C305 - BLUE (LEFT REAR DOOR SIDE)
CAV CIRCUIT
12 G74 20TN/WT
13 -
C306 - WHITE (MAIN BODY SIDE)
CAV CIRCUIT
1 A6 16RD/BK (MIDLINE/HIGHLINE)
2 -
3 F85 16VT/WT (MIDLINE/HIGHLINE)
4 F70 18PK/BK
5 F41 16PK/VT
6 A99 14RD/VT (MIDLINE/HIGHLINE)
7 -
8 F87 20WT/BK (EXCEPT BASE)
9 L77 18BK/YL
10 V23 20BR/PK (MIDLINE/HIGHLINE)
11 L10 18BR/LG
12 M3 20PK/DB
13 L50 18WT/TN
14 -
15 L63 18DG/RD
16 L78 18DG/YL
17 V21 20DB/RD
18 -
19 -
20 M1 20PK
21 M2 18YL
22 M20 20BR
23 P30 16OR/WT
24 P31 16PK/WT
25 -
26 -
27 P100 18OR/BR
28 L38 18BR/WT (HIGHLINE)
29 X75 18DG (HIGHLINE)
30 P101 20OR/PK
31 G80 20YL/WT
32 G910 20VT/BR
33 -
34 X13 16BK/RD (HIGHLINE)
35 L62 18BR/RD
36 -
37 G78 20TN/BK
38 G71 18VT/YL
39 D25 18YL/VT (MIDLINE/HIGHLINE)
40 -
41 C15 12BK/WT
42 V22 20BR/YL
43 B40 14LB (MIDLINE/HIGHLINE)
C306 - WHITE (REAR BODY SIDE)
CAV CIRCUIT
1 A6 16RD/BK (EXCEPT BASE)
2 -
3 F85 16VT/WT (EXCEPT BASE)
4 F70 18PK/BK
5 F41 16PK/VT
6 A99 14RD/VT (EXCEPT BASE)
7 -
9 L77 18BK/YL
11 L10 18BR/LG
12 M3 20PK/DB
13 L50 18WT/TN
14 -
15 L63 18DG/RD
16 L78 18DG/YL
17 V21 20DB/RD
18 -
19 -
20 M1 20PK
21 M2 18YL
22 M20 20BR
23 P30 16OR/WT
24 P31 16PK/WT
25 -
26 -
27 P100 18OR/BR
28 L38 18BR/WT (BUILT-UP-EXPORT)
30 P101 20OR/PK
31 G80 20YL/WT
32 G910 20VT/BR
33 -
34 -
35 L62 18BR/RD
36 -
37 G78 20TN/BK
38 G71 18VT/YL
39 D25 18YL/VT (EXCEPT BASE)
40 -
41 C15 12BK/WT
42 V22 20BR/YL
43 B40 14LB (EXCEPT BASE)
C307 - LT. GRAY (MAIN BODY SIDE)
CAV CIRCUIT
1 K226 18DB/WT
2 F512 18PK/OR (RHD)
3 A141 16DG/WT
CAV CIRCUIT
4 B1 18YL/DB
5 B2 18YL
6 K4 18BK/LB
7 B12 18DG/OR (RHD)
8 K125 18WT/DB
9 K107 18OR
10 K106 18WT/DG
C307 - LT. GRAY (FUEL TANK SIDE)
CAV CIRCUIT
1 K226 18DB/WT
2 -
3 A141 16DG/WT (GAS)
4 B1 18YL/DB
5 B2 18YL
6 K4 18BK/LB
7 -
9 K107 18OR (GAS)
10 K106 18WT/DG (GAS)
C308 - LT. GRAY (OVERHEAD SIDE)
CAV CIRCUIT
1 F85 16VT/WT (SUNROOF)
2 -
3 M1 20PK
4 M3 20PK/DB (EXCEPT BASE)
5 Z111 16BK (SUNROOF)
6 -
7 X75 20GY/LG (BUILT-UP-EXPORT)
8 F87 20WT/BK (HIGHLINE)
9 -
10 M20 20BR (EXCEPT BASE)
11 M2 20YL
12 Z2 20BK/LG (HIGHLINE)
13 -
14 D25 20YL/VT (HIGHLINE)
C308 - LT. GRAY (REAR BODY SIDE)
CAV CIRCUIT
1 F85 16VT/WT (EXCEPT BASE)
2 -
3 M1 20PK
4 M3 20PK/DB
CAV CIRCUIT
5 Z111 16BK (EXCEPT BASE)
6 -
9 -
10 M20 20BR
11 M2 18YL
12 Z2 18BK/LG (EXCEPT BASE)
13 -
14 D25 18YL/VT (EXCEPT BASE)
C309 - BLUE (REAR BODY SIDE)
CAV CIRCUIT
1 V21 20DB/RD
2 P31 16PK/WT
3 F70 18PK/BK
4 P100 18OR/BR
5 P101 20OR/PK
6 G71 18VT/YL
7 V22 20BR/YL
8 P30 16OR/WT
9 L77 18BK/YL
10 -
11 G80 20YL/WT
12 Z235 16BK
13 G78 20TN/BK
14 G910 20VT/BR
C309 - BLUE (SPLITGATE SIDE)
CAV CIRCUIT
1 V21 20DB/RD
2 P31 16PK/WT
3 F70 18PK/BK
4 P100 18OR/BR
5 P101 20OR/PK
6 G71 18VT/YL
7 V22 20BR/YL
8 P30 16OR/WT
9 L77 18BK/YL (BUILT-UP-EXPORT)
10 -
11 G80 20YL/WT
12 Z235 16BK
13 G78 20TN/BK
14 G910 20VT/BR
CAV CIRCUIT
1 A6 16RD/BK (BUILT-UP-EXPORT)
2 L10 18BR/LG
3 L77 18BK/YL
4 L63 18DG/RD
6 L50 18WT/TN
7 A99 14RD/VT (BUILT-UP-EXPORT)
8 V23 20BR/PK (BUILT-UP-EXPORT)
9 Z151 16BK/WT (LHD)
9 Z151 18BK/WT (RHD)
10 Z151 18BK/WT (RHD)
10 Z151 16BK/WT (LHD)
11 L78 18DG/YL
12 L62 18BR/RD
13 -
14 B40 14LB (BUILT-UP-EXPORT)
C310 - LT. GRAY (REAR LIGHTING SIDE)
CAV CIRCUIT
1 -
2 L10 18BR/LG
3 L77 18BK/YL
4 L63 18DG/RD
6 L50 18WT/TN
7 -
8 -
9 Z151 18BK/WT
10 Z151 18BK/WT
11 L78 18DG/YL
12 L62 18BR/RD
13 -
14 -
CAV CIRCUIT
1 F37 14RD/LB (MIDLINE/HIGHLINE)
2 R58 18GY (RHD)
2 R57 18DG (LHD)
3 Z238 14BK/WT (MIDLINE/HIGHLINE)
4 R60 18VT (RHD)
4 R59 18LB (LHD)
C311 - LT. GRAY (LEFT FRONT SEAT SIDE)
CAV CIRCUIT
1 F37 18RD/LB (EXCEPT BASE)
2 R58 18GY (RHD)
2 R57 18DG (LHD)
3 Z238 14BK/WT (EXCEPT BASE)
4 R60 18VT (RHD)
4 R59 18LB (LHD)
C312 (HIGHLINE) - LT. GRAY (MAIN BODY
SIDE)
CAV CIRCUIT
1 -
2 P86 20PK/BK
3 F98 14RD/WT
4 V23 20BR/PK
5 A3 16RD/WT
6 P142 20TN/DB
7 P134 20TN/LG
8 P138 20VT/LG
9 P140 20VT/BK
10 Z238 14BK/WT
C312 (HIGHLINE) - LT. GRAY (LEFT FRONT
SEAT SIDE)
CAV CIRCUIT
1 P141 20TN/LB
2 P86 20PK/BK
3 F98 16RD/WT
4 V23 1BR/PK
5 A3 20RD/WT
6 P142 20TN/DB
7 P134 20TN/LG
8 P138 20VT/LG
9 P140 20VT/BK
10 Z238 14BK/WT
CAV CIRCUIT
1 F37 14RD/LB (HIGHLINE)
2 R57 18DG (RHD)
2 R58 18GY (LHD)
3 Z238 14BK/WT (HIGHLINE)
4 R59 18LB (RHD)
4 R60 18VT (LHD)
C313 - LT. GRAY (RIGHT FRONT SEAT SIDE)
CAV CIRCUIT
1 F34 14RD/LB (HIGHLINE)
2 R58 18DG (LHD BASE)
2 R57 DG (RHD)
2 R58 18GY (LHD EXCEPT BASE)
3 Z238 14BK/WT (HIGHLINE)
4 R60 18LB (LHD BASE)
4 R59 18LB (RHD)
4 R60 18VT (LHD EXCEPT BASE))
C314 (HIGHLINE) - LT. GRAY (MAIN BODY
SIDE)
CAV CIRCUIT
1 F98 14RD/WT
2 Z238 14BK/WT
3 P86 18PK/BK
4 P142 20TN/DB
5 V23 20BR/PK
6 P134 20TN/LG
7 P140 20VT/BK
8 P138 20VT/LG
9 -
10 -
C314 (HIGHLINE) - LT. GRAY (RIGHT FRONT
SEAT SIDE)
CAV CIRCUIT
1 F98 16RD/WT
2 Z238 14BK/WT
3 P86 20PK/BK
4 P142 20TN/DB
5 V23 20BR/PK
6 P134 20TN/LG
7 P140 20VT/BK
8 P138 20VT/LG
9 -
10 -
C315 (MIDLINE/HIGHLINE) - LT. GRAY (RIGHT
SIDE)
CAV CIRCUIT
1 Q12 14BR (LHD)
1 Q11 14LB (RHD)
2 Q22 14VT/WT (LHD)
2 Q21 14WT (RHD)
3 Q14 14GY (LHD)
3 Q13 14DB (RHD)
4 Q24 14DG (LHD)
4 Q23 14RD/WT (RHD)
C315 (MIDLINE/HIGHLINE) - LT. GRAY (LEFT
SIDE)
CAV CIRCUIT
1 Q12 14BR (LHD)
1 Q11 14LB (RHD)
2 Q22 14VT/WT (LHD)
2 Q21 14WT (RHD)
3 Q14 14GY (LHD)
3 Q13 14DB (RHD)
4 Q24 14DG (LHD)
4 Q23 14RD/WT (RHD)
C316 (BUILT-UP-EXPORT) - (MAIN BODY SIDE)
CAV CIRCUIT
1 X30 10BK
2 X31 10BK
C316 (BUILT-UP-EXPORT) - (REAR BODY SIDE)
CAV CIRCUIT
1 X30 BK
2 X31 BK
C317 (EXCEPT BUILT-UP-EXPORT) - LT. GRAY
(REAR LIGHTING SIDE)
CAV CIRCUIT
1 L77 18BK/YL
2 Z151 18BK/WT
C317 (EXCEPT BUILT-UP-EXPORT) - LT. GRAY
(LICENSE LAMP SIDE)
CAV CIRCUIT
1 L77 18BR/YL
2 Z151 18BK/WT
CABIN HEATER (DIESEL) - BLACK 2 WAY
1 C151 18DB/WT CABIN HEATER RELAY OUTPUT
CAMSHAFT POSITION SENSOR (2.4L) - BLACK 3 WAY
1 K7 18OR 5 VOLT SUPPLY
3 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
CAMSHAFT POSITION SENSOR (3.7L) - LT. GRAY 3 WAY
CAMSHAFT POSITION SENSOR (DIESEL) - 3 WAY
1 K944 20BK/LB CAMSHAFT POSITION SENSOR GROUND
3 A142 14DG/OR AUTO SHUT DOWN RELAY OUTPUT
CAPACITOR - BLACK 2 WAY
2 Z55 14BK/WT GROUND
CARGO LAMP (EXCEPT BASE) - BLACK 3 WAY
1 M1 20PK FUSED B(+)
2 M3 20PK/DB REAR COURTESY LAMP CONTROL
3 M2 20YL COURTESY LAMP DRIVER
CD CHANGER - GREEN 12 WAY
1 X41 20WT/DG AUDIO OUT LEFT
2 - -
3 - -
4 Z17 20BK GROUND
5 X112 20RD IGNITION SWITCH OUTPUT
6 X160 20YL B(+)
7 X40 20WT/RD AUDIO OUT RIGHT
8 Z30 20WT/BK GROUND
9 - -
10 - -
11 Z9 20BK/DB GROUND
12 D25 20YL/VT PCI BUS
CENTER HIGH MOUNTED STOP LAMP - WHITE 2 WAY
1 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
2 Z309 18BK GROUND
CIGAR LIGHTER - RED 3 WAY
1 F30 16RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 - -
3 Z3 16BK/OR GROUND
CLOCKSPRING C1 - WHITE 6 WAY
1 - -
2 X3 20BK/RD HORN RELAY CONTROL
3 X20 20RD/BK (PREMIUM) RADIO CONTROL MUX
4 X10 20RD/DB (PREMIUM) RADIO CONTROL MUX RETURN
6 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
CLOCKSPRING C2 - YELLOW 4 WAY
CLOCKSPRING C3 - BLACK 6 WAY
1 - -
3 X20 20RD/BK (PREMIUM) RADIO CONTROL MUX
4 X10 20RD/DB (PREMIUM) RADIO CONTROL MUX RETURN
5 K4 20BK/LB (EXCEPT BASE) SENSOR GROUND
6 V37 20RD/LG (EXCEPT BASE) SPEED CONTROL SWITCH SIGNAL
CLUTCH INTERLOCK SWITCH (M/T) - BLACK 2 WAY
1 T141 18YL/RD CLUTCH SWITCH OVERRIDE RELAY OUTPUT
2 F45 18YL/BR FUSED IGNITION SWITCH OUTPUT (START)
COIL ON PLUG NO. 1 (3.7L) - BLACK 3 WAY
1 K91 14TN/RD COIL ON PLUG DRIVER NO.1
3 - -
1 K92 14TN/PK COIL ON PLUG DRIVER NO. 2
3 - -
1 K93 14TN/OR COIL ON PLUG DRIVER NO. 3
3 - -
1 K94 14TN/LG COIL ON PLUG DRIVER NO. 4
3 - -
1 K95 14TN/DG COIL ON PLUG DRIVER NO. 5
3 - -
1 K96 14TN/LB COIL ON PLUG DRIVER NO. 6
3 - -
COIL RAIL (2.4L) - BLACK 3 WAY
1 K17 18DB/TN IGNITION COIL DRIVER NO. 2
3 K19 18BK/GY IGNITION COIL DRIVER NO. 1
COMPASS MINI-TRIP COMPUTER (PREMIUM) - BLACK 6 WAY
1 - -
4 Z2 20BK/LG CLEAN GROUND
5 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 - -
CONTROLLER ANTILOCK BRAKE - LT.GRAY 24 WAY
2 - -
3 - -
4 - -
6 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
7 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
8 D24 18WT/DG FLASH ABS
9 A20 12RD/DB FUSED B(+)
11 - -
12 - -
13 B12 18DG/OR VEHICLE SPEED SIGNAL
14 - -
15 - -
17 S43 18LB/YL FLUID PRESSURE SWITCH SIGNAL
19 B1 18YL/DB REAR WHEEL SPEED SENSOR SIGNAL
20 B2 18YL REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
21 - -
22 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL
23 B9 18RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
24 A10 12RD/DG FUSED B(+)
CRANKSHAFT POSITION SENSOR (2.4L) - BLACK 3 WAY
1 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
CRANKSHAFT POSITION SENSOR (3.7L) - BLACK 3 WAY
CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY
1 K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL 1
2 K3 20LB/BK CRANKSHAFT POSITION SENSOR SIGNAL 2
3 Y101 20BK/OR CRANKSHAFT POSITION SENSOR SHIELD
DATA LINK CONNECTOR - BLACK 16 WAY
1 - -
3 - -
6 D32 20LG/DG (GAS) SCI RECEIVE
6 D32 20LG/DG (DIESEL) NOT USED
7 D21 20PK/RD SCI TRANSMIT
8 D24 18WT/DG FLASH ABS
9 D19 20VT/OR BODY CONTROL MODULE FLASH ENABLE
10 - -
11 - -
12 - -
13 - -
14 D20 20LG (DIESEL) NOT USED
14 D20 20LG (GAS) SCI RECEIVE
15 - -
16 F33 20PK/RD FUSED B(+)
DIAGNOSTIC J UNCTION PORT - BLACK 16 WAY
1 D25 18YL/VT/BR PCI BUS (PCM TCM CAB SKIM)
2 D25 18YL/VT/GY PCI BUS (PCM TCM CAB SKIM)
3 D25 18YL/VT/DB PCI BUS (O/C RADIO LSIACM RSIACM)
4 D25 18YL/VT/OR PCI BUS (ACM)
5 D25 20YL/VT/RD PCI BUS (EMIC)
6 D25 18YL/VT/WT PCI BUS (BCM)
7 D25 18YL/VT PCI BUS (DLC)
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 - -
15 - -
16 - -
DOME LAMP (BASE) - BLACK 3 WAY
1 - -
DRIVER AIRBAG SQUIB 1 - GRAY 2 WAY
DRIVER AIRBAG SQUIB 2 - BLACK 2 WAY
DRIVER SEAT BELT SWITCH - LT. GRAY 2 WAY
1 R57 18DG DRIVER SEAT BELT SWITCH SENSE
2 R59 18LB DRIVER SEAT BELT SWITCH GROUND
DRIVER SEAT BELT TENSIONER - YELLOW 2 WAY
1 R55 18OR/BK DRIVER SEAT BELT TENSIONER LINE 1
2 R53 18OR/YL DRIVER SEAT BELT TENSIONER LINE 2
EGR SOLENOID (DIESEL) - 2 WAY
1 A71 18DG/RD FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K35 18GY/YL EGR SOLENOID CONTROL
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
1 Z108 14BK/DG GROUND
2 Z108 14BK/DG GROUND
3 K20 18DG GENERATOR FIELD CONTROL
6 - -
7 D25 20VT/YL PCI BUS
8 K944 20BK/LB CAMSHAFT POSITION SENSOR GROUND
10 - -
11 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
12 - -
13 K78 20GY FUEL PRESSURE SENSOR SIGNAL
14 - -
15 K81 20VT/TN ACCELERATOR PEDAL POSITION SENSOR SIGNAL
16 K80 20BK/VT FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
19 F92 20YL/BR BATTERY SENSE (+)
20 Z109 20BK/DB BATTERY SENSE (-)
22 F1 20DB FUSED IGNITION SWITCH OUTPUT (RUN-START)
24 K3 20LB/BK CRANKSHAFT POSITION SENSOR SIGNAL 2
25 - -
26 - -
27 - -
28 - -
29 K77 20BR/WT TRANSFER CASE POSITION SENSOR INPUT
30 G60 20GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
31 G123 20DG/WT WATER IN FUEL SENSOR SIGNAL
33 - -
34 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR GROUND
35 K852 20VT/WT ACCELERATOR PEDAL POSITION SENSOR 5 VOLT
SUPPLY
36 - -
37 - -
39 K226 20DB/WT FUEL LEVEL SENSOR SIGNAL
40 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
42 Y101 20BK/OR CRANKSHAFT POSITION SENSOR SHIELD
43 K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL 1
44 - -
45 - -
46 - -
48 K29 20WT/PK BRAKE SWITCH SENSE
49 - -
50 - -
51 - -
52 - -
53 - -
54 - -
55 B22 20DG/YL VEHICLE SPEED SIGNAL
56 - -
57 - -
58 - -
59 - -
60 K7 20OR FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20DB/YL AUTO SHUT DOWN RELAY CONTROL
62 - -
63 - -
64 K151 20WT LOW IDLE POSITION SWITCH SENSE
65 - -
66 - -
67 - -
68 - -
69 C13 20DG A/C COMPRESSOR CLUTCH RELAY CONTROL
70 - -
71 - -
72 K236 20GY/PK GLOW PLUG RELAY RELAY NO. 2 CONTROL
73 - -
74 K90 20TN CLUTCH SWITCH OVERRIDE RELAY CONTROL
75 K132 20DG/LB CABIN HEATER RELAY CONTROL
76 - -
77 K152 20WT GLOW PLUG RELAY NO. 1 CONTROL
78 - -
79 - -
80 K46 20OR/BK FUEL PRESSURE SOLENOID CONTROL
82 D21 20PK SCI TRANSMIT
83 - -
84 - -
85 - -
86 - -
87 - -
88 - -
89 K35 20GY/YL EGR SOLENOID CONTROL
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
97 - -
98 - -
99 - -
100 - -
102 - -
103 - -
104 - -
105 - -
106 - -
107 - -
108 - -
109 - -
110 - -
111 - -
112 - -
113 - -
114 - -
115 K14 2.5mmLB/BR FUEL INJ ECTOR NO. 4 CONTROL
116 K63 2.5mmDB/BK COMMON INJ ECTOR DRIVER
117 - -
118 K11 2.5mmWT/DB FUEL INJ ECTOR NO. 1 CONTROL
119 K12 2.5mmTN FUEL INJ ECTOR NO. 2 CONTROL
120 K13 2.5mmYL/WT FUEL INJ ECTOR NO. 3 CONTROL
121 - -
ENGINE COOLANT LEVEL SENSOR (DIESEL) - LT. GRAY 2 WAY
1 G18 18PK/BK COOLANT LEVEL SENSOR SIGNAL
2 Z246 18BK/GY SENSOR GROUND
ENGINE COOLANT TEMP SENSOR (DIESEL) - BLACK 2 WAY
ENGINE COOLANT TEMPERATURE SENSOR (GAS) - BLACK 2 WAY
ENGINE OIL PRESSURE SENSOR - BLACK 3 WAY
2 G60 20GY/YL (DIESEL) ENGINE OIL PRESSURE SENSOR SIGNAL
2 G60 18GY/YL (GAS) ENGINE OIL PRESSURE SENSOR SIGNAL
EVAP/PURGE SOLENOID - BLACK 2 WAY
1 K52 18PK/BK EVAP/PURGE SOLENOID CONTROL
FLIP-UP GLASS RELEASE MOTOR - BLACK 2 WAY
1 Z235 18BK GROUND
2 P100 18OR/BR FLIP-UP GLASS RELEASE MOTOR DRIVER
FLIP-UP GLASS RELEASE SWITCH - WHITE 2 WAY
2 P101 20OR/PK FLIP-UP GLASS RELEASE SWITCH SENSE
FRONT WIPER MOTOR - BLACK 6 WAY
1 V6 16DB/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 V55 16TN/RD FRONT WIPER PARK SWITCH SENSE
3 - -
4 Z141 14BK GROUND
5 V3 14BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUT-
PUT
6 V4 14RD/YL FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUT-
PUT
FUEL HEATER (DIESEL) - BLACK 2 WAY
1 A93 16RD/BK FUEL HEATER RELAY OUTPUT
FUEL INJ ECTOR NO. 1 (DIESEL) - BLACK 2 WAY
2 K11 2.5mmWT/DB FUEL INJ ECTOR NO. 1 CONTROL
FUEL INJ ECTOR NO. 1 (GAS) - BLACK 2 WAY
1 F142 18OR/DG FUSED AUTO SHUT DOWN RELAY OUTPUT
2 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
2 K12 2.5mmTN FUEL INJ ECTOR NO. 2 CONTROL
2 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
2 K13 2.5mmYL/WT FUEL INJ ECTOR NO. 3 CONTROL
2 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
2 K14 2.5mmLB/BR FUEL INJ ECTOR NO. 4 CONTROL
2 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
FUEL INJ ECTOR NO. 5 (3.7L) - BLACK 2 WAY
2 K38 18GY FUEL INJ ECTOR NO. 5 DRIVER
FUEL INJ ECTOR NO. 6 (3.7L) - BLACK 2 WAY
2 K58 18BR/DB FUEL INJ ECTOR NO. 6 DRIVER
FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY
1 K80 20BK/VT FUEL PRESSURE SENSOR GROUND
2 K78 20GY FUEL PRESSURE SENSOR SIGNAL
3 K7 20OR FUEL PRESSURE SENSOR 5 VOLT SUPPLY
FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY
FUEL PUMP MODULE - LT. GRAY 4 WAY
1 Z211 16BK (GAS) GROUND
4 A141 16DG/WT (GAS) FUEL PUMP RELAY OUTPUT
G 202 - BLACK 14 WAY
2 Z3 18BK/OR (BASE) GROUND
2 Z3 14BK/OR (EXCEPT BASE) GROUND
3 Z11 20BK/WT (EXCEPT BASE) GROUND
G 202 - BLACK 14 WAY
4 - -
5 - -
6 Z105 20BK/LG GROUND
10 Z300 16BK GROUND
11 Z232 16BK/LB GROUND
12 - -
14 Z110 20BK/TN (EXCEPT BASE) GROUND
GENERATOR - BLACK 2 WAY
1 A71 18DG/RD (DIESEL) FUSED AUTO SHUT DOWN RELAY OUTPUT
1 K20 18DG (GAS) GENERATOR FIELD DRIVER
2 K20 18DG (DIESEL) GENERATOR FIELD CONTROL
2 K125 18WT/DB (GAS) GENERATOR SOURCE
GLOW PLUG ASSEMBLY (DIESEL) - BLACK 2 WAY
1 K154 10GY GLOW PLUG RELAY NO. 1 OUTPUT
2 K104 10RD/WT GLOW PLUG RELAY NO. 2 OUTPUT
HAZARD SWITCH/COMBINATION FLASHER - WHITE 10 WAY
1 A15 18PK/OR FUSED B(+)
2 Z3 18BK/OR GROUND
3 L62 18BR/RD RIGHT TURN SIGNAL
4 L91 20DB/PK HAZARD LAMP CONTROL
5 L305 20LB/WT LEFT TURN SWITCH SENSE
6 - -
7 L63 18DG/RD LEFT TURN SIGNAL
9 L302 20LB/YL RIGHT TURN SWITCH SENSE
HEADLAMP LEVELING SWITCH (BUILT-UP-EXPORT) - 4 WAY
1 L13 18BR/YL HEADLAMP ADJ UST SIGNAL
2 L78 18DG/YL FUSED PARK LAMP RELAY OUTPUT
4 - -
HEATED SEAT MODULE (HIGHLINE) - GREEN 14 WAY
1 P133 20TN/DG LEFT SEAT HEATER SWITCH MUX
2 P86 20PK/BK HEATED SEAT TEMPERATURE SENSOR SIGNAL
3 F98 16RD/WT PASSENGER HEATED SEAT FEED
4 A3 16RD/WT FUSED B(+)
5 F99 16RD/YL DRIVER HEATED SEAT FEED
7 P142 20TN/DB PASSENGER HEATED SEAT TEMPERATURE SENSOR
GROUND
8 P141 20TN/LB DRIVER HEATED SEAT TEMPERATURE SENSOR
GROUND
9 P134 20TN/LG RIGHT SEAT HEATER SWITCH MUX
10 P138 20VT/LG RIGHT SEAT LOW HEAT LED DRIVER
11 P140 20VT/BK RIGHT SEAT HIGH HEAT LED DRIVER
12 P137 20VT/DG LEFT SEAT LOW HEAT LED DRIVER
14 P139 20VT/WT LEFT SEAT HIGH HEAT LED DRIVER
HIGH NOTE HORN - BLACK 2 WAY
1 X2 18DG/RD HORN RELAY OUTPUT
2 Z141 18BK GROUND
HOOD AJ AR SWITCH (EXCEPT BASE) - 2 WAY
1 G70 18BR/TN HOOD AJ AR SWITCH SENSE
IDLE AIR CONTROL MOTOR - BLACK 4 WAY
1 K59 18VT/BK IDLE AIR CONTROL MOTOR NO. 4 DRIVER
2 K40 18BR/WT IDLE AIR CONTROL MOTOR NO. 1 DRIVER
3 K60 18YL/BK IDLE AIR CONTROL MOTOR NO. 2 DRIVER
4 K39 18GY/RD IDLE AIR CONTROL MOTOR NO. 3 DRIVER
IGNITION SWITCH - BLACK 10 WAY
1 A1 12RD FUSED (+)
2 A21 12RD/DB IGNITION SWITCH OUTPUT (RUN-START)
3 F81 12TN IGNITION SWITCH OUTPUT (RUN-ACC)
4 A25 12DB FUSED B(+)
5 G26 20LB KEY-IN IGNITION SWITCH SENSE
6 A41 12YL IGNITION SWITCH OUTPUT (START)
7 A31 12BK/WT IGNITION SWITCH OUTPUT (RUN-ACC)
8 A22 12BK/OR IGNITION SWITCH OUTPUT (RUN)
9 A2 12PK/BK FUSED B (+)
INPUT SPEED SENSOR (3.7L) - BLACK 2 WAY
1 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
2 T13 18DB/BK SPEED SENSOR GROUND
INSTRUMENT CLUSTER - BLACK 20 WAY
2 - -
3 Y98 20GY/DB INSTRUMENT CLUSTER WAKE UP SIGNAL
4 - -
5 G18 20PK/BK LOW COOLANT FLUID LEVEL SENSE
7 G9 20GY/BK PARK BRAKE SWITCH SENSE
8 G69 20BK/OR VTSS INDICATOR DRIVER
9 - -
13 - -
14 D25 20YL/VT/RD PCI BUS
15 - -
INSTRUMENT CLUSTER - BLACK 20 WAY
17 G11 20WT/BK RED BRAKE WARNING INDICATOR DRIVER
18 G29 20BK/TN LOW WASHER FLUID SENSE
19 F87 20TN/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
20 - -
INTAKE AIR TEMPERATURE SENSOR (GAS) - GRAY 2 WAY
INTRUSION SENSOR (BUILT-UP-EXPORT) - BLACK 6 WAY
1 Z2 20BK/LG GROUND
2 - -
3 X75 20DG SIREN SIGNAL CONTROL
4 - -
J UNCTION BLOCK BODY CONTROL MODULE-J B - 26 WAY
1 X3 (PREMIUM) HORN RELAY CONTROL
2 P334 DOOR UNLOCK RELAY CONTROL
3 L308 PARK LAMP RELAY CONTROL
4 L96 (PREMIUM) REAR FOG LAMP RELAY CONTROL
5 P109 (EXCEPT BASE) DRIVER DOOR UNLOCK RELAY CONTROL
6 C80 REAR WINDOW DEFOGGER RELAY CONTROL
7 - -
8 Z300 GROUND
9 F35 FUSED B(+)
10 L309 HIGH BEAM RELAY CONTROL
11 P31 TAILGATE UNLOCK DRIVER
12 P37 DOOR LOCK SWITCH GROUND
13 L94 LOW BEAM RELAY CONTROL
14 F89 FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
15 M1 FUSED B(+)
16 F87 FUSED IGNITION SWITCH OUTPUT (RUN-START)
17 L26 (EXCEPT BASE) FRONT FOG LAMP RELAY CONTROL
18 P333 DOOR LOCK RELAY CONTROL
19 V16 FRONT WIPER HIGH/LOW RELAY CONTROL
20 V55 FRONT WIPER PARK SWITCH SENSE
J UNCTION BLOCK BODY CONTROL MODULE-J B - 26 WAY
21 V14 FRONT WIPER ON/OFF RELAY CONTROL
22 P30 TAILGATE LOCK DRIVER
23 P36 DOOR LOCK SWITCH MUX
24 M2 COURTESY LAMP DRIVER
25 Z131 GROUND
26 M20 COURTESY LAMP LOAD SHED
J UNCTION BLOCK C1 - GRAY 42 WAY
1 - -
2 - -
3 A21 12RD/DB IGNITION SWITCH OUTPUT (RUN-START)
6 - -
8 L78 20DG/YL (EXCEPT BUILT-UP-EX-
PORT)
FUSED PARK LAMP RELAY OUTPUT
8 L78 18DG/YL (BUILT-UP-EXPORT) FUSED PARK LAMP RELAY OUTPUT
9 F1 20DB (PREMIUM) FUSED IGNITION SWITCH OUTPUT (RUN-START)
14 - -
17 Z300 16BK GROUND
18 - -
19 - -
21 L309 20LG/WT HIGH BEAM RELAY CONTROL
25 F33 20PK/RD (PREMIUM) FUSED B(+)
26 F88 20BR/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
30 - -
31 F87 20TN/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
32 - -
33 F38 16RD/WT FUSED B(+)
34 C16 20LB/YL FUSED DEFOGGER RELAY OUTPUT
35 F30 16RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
36 - -
37 F32 18PK/DB FUSED B(+)
39 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (RUN)
40 A31 12BK/WT IGNITION SWITCH OUTPUT (RUN-ACC)
41 A15 18PK/OR FUSED B(+)
42 A22 12BK/OR IGNITION SWITCH OUTPUT (RUN)
J UNCTION BLOCK C2 - GREEN 42 WAY
1 F37 14RD/LB (MIDLINE/HIGHLINE) FUSED B(+)
2 - -
3 C15 12BK/WT DEFOGGER RELAY OUTPUT
4 F89 18OR/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
5 P37 20LG (EXCEPT BASE) DOOR LOCK SWITCH GROUND
6 P33 18OR/BK (EXCEPT BASE) DOOR LOCK RELAY OUTPUT
8 P34 18PK/BK (EXCEPT BASE) DRIVER DOOR UNLOCK RELAY OUTPUT
9 P35 18OR/VT (EXCEPT BASE) PASSENGER DOOR UNLOCK RELAY OUTPUT
10 P36 20PK/VT (EXCEPT BASE) DOOR LOCK SWITCH MUX
11 P37 20LG (EXCEPT BASE) DOOR LOCK SWITCH GROUND
12 M20 20BR COURTESY LAMP LOAD SHED
14 P36 20PK/VT (EXCEPT BASE) DOOR LOCK SWITCH MUX
15 P30 16OR/WT TAILGATE LOCK DRIVER
16 F70 18PK/BK FUSED B(+)
17 L77 18BK/YL FUSED LEFT INBOARD TAIL LAMP
22 - -
23 V23 20BR/PK (HIGHLINE) FUSED IGNITION SWITCH OUTPUT (RUN)
24 V23 20BR/PK (EXCEPT BASE) FUSED IGNITION SWITCH OUTPUT (RUN)
25 V23 20BR/PK (MIDLINE/HIGHLINE) FUSED IGNITION SWITCH OUTPUT (RUN)
27 - -
28 A6 16RD/BK (PREMIUM GAS) FUSED B(+)
29 - -
31 C16 18LB/YL (EXCEPT BASE) FUSED DEFOGGER RELAY OUTPUT
34 L38 18BR/WT (HIGHLINE) REAR FOG LAMP RELAY OUTPUT
35 P31 16PK/WT TAILGATE UNLOCK DRIVER
36 - -
37 F60 16DG/RD (PREMIUM) FUSED B(+)
38 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
39 C16 18LB/YL (EXCEPT BASE) FUSED DEFOGGER RELAY OUTPUT
40 F85 16VT/WT (MIDLINE/HIGHLINE) FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
41 F41 16PK/VT FUSED B(+)
42 A3 16RD/WT (HIGHLINE) FUSED B(+)
J UNCTION BLOCK C3 - LT. BLUE 42 WAY
1 A12 10RD/TN FUSED B(+)
2 A13 10PK/WT FUSED B(+)
3 A4 12BK/PK FUSED B(+)
4 L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
5 L43 18VT FUSED LEFT LOW BEAM OUTPUT
6 - -
7 V55 16TN/RD FRONT WIPER PARK SWITCH SENSE
8 F1 18DB (LHD) FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 F1 20DB (RHD) FUSED IGNITION SWITCH OUTPUT (RUN-START)
9 V6 14DB/YL (RHD) FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
9 VG 16DB/YL (LHD) FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
10 - -
11 A12 10RD/TN FUSED B(+)
12 - -
13 - -
14 - -
15 V14 18RD/VT FRONT WIPER ON/OFF RELAY CONTROL
16 L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT
17 - -
18 V16 18VT/YL WIPER HIGH/LOW RELAY CONTROL
19 F20 18WT FUSED IGNITION SWITCH OUTPUT (RUN)
20 - -
21 - -
22 - -
23 - -
24 L50 18WT/TN (ABS) BRAKE LAMP SWITCH OUTPUT
25 - -
26 - -
27 - -
31 - -
33 L39 18LB FRONT FOG LAMP RELAY OUTPUT
34 A18 10PK FUSED B(+)
35 - -
36 - -
37 L33 18LG/BR FUSED LEFT HIGH BEAM OUTPUT
38 F22 18DB/PK (ABS) FUSED IGNITION SWITCH OUTPUT (RUN)
40 A18 10PK FUSED B(+)
41 - -
42 A7 10RD/BK FUSED B(+)
KNOCK SENSOR (3.7L) - BLACK 4 WAY
2 K42 18DB/LB KNOCK SENSOR NO. 1 SIGNAL
4 K142 18GY/BK KNOCK SENSOR NO. 2 SIGNAL
LEAK DETECTION PUMP - BLACK 4 WAY
1 - -
2 K125 18WT/DB GENERATOR SOURCE
3 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
4 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
LEFT COURTESY LAMP - BLACK 2 WAY
LEFT CURTAIN AIRBAG - YELLOW 2 WAY
1 R77 18YL/RD LEFT CURTAIN SQUIB LINE 2
2 R75 18YL/BK LEFT CURTAIN SQUIB LINE 1
LEFT CYLINDER LOCK SWITCH (EXCEPT BASE) - LT. GRAY 2 WAY
1 P37 18LG DOOR LOCK SWITCH GROUND
2 G73 18LG/OR (LHD) LEFT CYLINDER LOCK SWITCH MUX
2 G72 18DG/OR (RHD) LEFT CYLINDER LOCK SWITCH MUX
LEFT DOOR LOCK SWITCH (EXCEPT BASE) - BLACK 4 WAY
1 P36 20PK/VT DOOR LOCK SWITCH MUX
LEFT FOG LAMP - BLACK 2 WAY
A Z141 18BK GROUND
B L39 18LB FRONT FOG LAMP RELAY OUTPUT
LEFT FRONT DOOR AJ AR SWITCH (BASE) - BLACK 2 WAY
1 G75 20TN DRIVER DOOR AJ AR SWITCH SENSE
LEFT FRONT DOOR LOCK MOTOR/AJ AR SWITCH (EXCEPT BASE) - BLACK 4 WAY
1 G74 20TN/WT (RHD) PASSENGER DOOR AJ AR SWITCH SENSE
1 G75 20TN (LHD) DRIVER DOOR AJ AR SWITCH SENSE
3 P35 18OR/VT (RHD) PASSENGER DOOR UNLOCK RELAY OUTPUT
3 P34 18PK/BK (LHD) DRIVER DOOR UNLOCK RELAY OUTPUT
4 P33 18OR/BK DOOR LOCK RELAY OUTPUT
LEFT FRONT DOOR SPEAKER (BASE) - 2 WAY
1 X53 18DG LEFT FRONT SPEAKER (+)
2 X55 18BR/RD LEFT FRONT SPEAKER (-)
LEFT FRONT DOOR SPEAKER (PREMIUM) - BLACK 10 WAY
1 X53 18DG LEFT FRONT SPEAKER (+)
2 X55 18BR/RD LEFT FRONT SPEAKER (-)
3 Z9 16BK GROUND
4 X81 18YL/BK AMPLIFIED HIGH LEFT FRONT SPEAKER (-)
5 X91 18WT/BK AMPLIFIED LOW LEFT REAR SPEAKER (-)
6 X57 18BR/LB LEFT REAR SPEAKER (-)
7 X51 18BR/YL LEFT REAR SPEAKER (+)
8 X13 16BK/RD RADIO CHOKE OUTPUT
9 X83 18YL/RD AMPLIFIED HIGH LEFT FRONT SPEAKER (+)
10 X93 18WT/RD AMPLIFIED LOW LEFT REAR SPEAKER (+)
LEFT FRONT IMPACT SENSOR - BLACK 4 WAY
1 - -
2 - -
3 R47 18DB/LB LEFT FRONT IMPACT SENSOR GROUND
4 R49 18LB LEFT FRONT IMPACT SENSOR SIGNAL
LEFT FRONT PARK/TURN SIGNAL LAMP - BLACK 3 WAY
2 L77 18BK/YL (EXCEPT BUILT-UP-EX-
PORT)
PARK LAMP RELAY OUTPUT
3 Z141 18BK GROUND
LEFT FRONT POWER WINDOW MOTOR (MIDLINE/HIGHLINE) - LT. GRAY 2 WAY
1 Q21 16WT LEFT FRONT WINDOW DRIVER DOWN
2 Q11 16LB LEFT FRONT WINDOW DRIVER UP
LEFT FRONT WHEEL SPEED SENSOR (ABS) - BLACK 2 WAY
1 B9 18RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
2 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL
LEFT HEADLAMP (BUILT-UP-EXPORT) - 3 WAY
1 L33 18LG/BR FUSED LEFT HIGH BEAM OUTPUT
2 L43 18VT FUSED LEFT LOW BEAM OUTPUT
3 Z141 18BK GROUND
LEFT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLUE 3 WAY
A L43 18VT FUSED LEFT LOW BEAM OUTPUT
B Z141 18BK GROUND
C L33 18LG/BR FUSED LEFT HIGH BEAM OUTPUT
LEFT HEATED SEAT ASSEMBLY (HIGHLINE) - LT. GRAY 4 WAY
1 F99 16RD/YL DRIVER HEATED SEAT FEED
4 P141 20TN/LB DRIVER HEATED SEAT TEMPERATURE SENSOR
GROUND
LEFT HEATED SEAT SWITCH (HIGHLINE) - BLACK 8 WAY
2 P139 20VT/WT LEFT SEAT HIGH HEAT LED DRIVER
3 P133 20TN/DG LEFT SEAT HEATER SWITCH MUX
4 P137 20VT/DG LEFT SEAT LOW HEAT LED DRIVER
6 - -
7 - -
8 - -
LEFT INSTRUMENT PANEL SPEAKER - WHITE 2 WAY
1 X53 18DG (BASE) LEFT FRONT SPEAKER (+)
1 X83 18YL/RD (PREMIUM) AMPLIFIED HIGH LEFT FRONT SPEAKER (+)
2 X55 18BR/RD (BASE) LEFT FRONT SPEAKER (-)
2 X81 18YL/BK (PREMIUM) AMPLIFIED HIGH LEFT FRONT SPEAKER (-)
LEFT LEVELING MOTOR (BUILT-UP-EXPORT) - BLACK 3 WAY
1 Z141 18BK GROUND
3 L77 18BK/YL FUSED PARK LAMP RELAY OUTPUT
LEFT POSITION LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY
2 Z141 18BK GROUND
LEFT POWER MIRROR (EXCEPT BASE) - WHITE 8 WAY
1 P71 20YL/DG LEFT MIRROR UP DRIVER
2 P76 20OR/YL MIRROR COMMON DRIVER
3 P75 20LB/WT LEFT MIRROR LEFT DRIVER
4 - -
7 P99 20GY (WITH FOLD) FOLDING MIRROR FEED
8 P110 20YL (WITH FOLD) FOLDING MIRROR RETURN
LEFT POWER SEAT MOTORS (MIDLINE/HIGHLINE) - BLACK 6 WAY
1 P11 14YL/WT DRIVER SEAT REAR UP DRIVER
2 P13 14RD/WT DRIVER SEAT REAR DOWN DRIVER
3 P19 14YL/LG DRIVER SEAT FRONT UP DRIVER
4 P21 14RD/LG DRIVER SEAT FRONT DOWN DRIVER
5 P17 14RD/YL DRIVER SEAT HORIZONTAL REARWARD DRIVER
6 P15 14YL/LB DRIVER SEAT HORIZONTAL FORWARD DRIVER
LEFT POWER SEAT SWITCH (MIDLINE/HIGHLINE) - GREEN 10 WAY
2 - -
3 P15 14YL/LB DRIVER SEAT HORIZONTAL FORWARD DRIVER
4 - -
5 F37 14RD/LB FUSED B(+)
6 P17 14RD/YL DRIVER SEAT HORIZONTAL REARWARD DRIVER
7 P13 14RD/WT DRIVER SEAT REAR DOWN DRIVER
8 P21 14RD/LG DRIVER SEAT FRONT DOWN DRIVER
9 P19 14YL/LG DRIVER SEAT FRONT UP DRIVER
10 P11 14YL/WT DRIVER SEAT REAR UP DRIVER
LEFT REAR DOOR AJ AR SWITCH (BASE) - BLACK 2 WAY
LEFT REAR DOOR LOCK MOTOR/AJ AR SWITCH (EXCEPT BASE) - BLACK 4 WAY
3 P35 18OR/VT PASSENGER DOOR UNLOCK RELAY OUTPUT
LEFT REAR DOOR SPEAKER - 2 WAY
1 X51 18BR/YL (BASE) LEFT REAR DOOR SPEAKER (+)
1 X93 18WT/RD (PREMIUM) AMPLIFIED LOW LEFT REAR SPEAKER (+)
2 X57 18BR/LB (BASE) LEFT REAR DOOR SPEAKER (-)
2 X91 18WT (PREMIUM) AMPLIFIED LOW LEFT REAR SPEAKER (-)
LEFT REAR POWER WINDOW MOTOR (MIDLINE/HIGHLINE) - LT. GRAY 2 WAY
1 Q23 16DG LEFT REAR WINDOW DRIVER DOWN
2 Q13 16GY LEFT REAR WINDOW DRIVER UP
LEFT REMOTE RADIO SWITCH (PREMIUM) - BLACK 2 WAY
1 X10 20RD/DB RADIO CONTROL MUX RETURN
2 X20 20RD/BK RADIO CONTROL MUX
LEFT SIDE IMPACT AIRBAG CONTROL MODULE (LSIACM) - YELLOW 8 WAY
2 - -
3 R77 18YL/RD LEFT CURTAIN SQUIB LINE 2
4 R75 18YL/BK LEFT CURTAIN SQUIB LINE 1
5 Z104 18BK/YL GROUND
6 - -
7 - -
LEFT SIDE MARKER LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 2 WAY
LEFT SIDE REPEATER LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY
2 Z141 18BK GROUND
LEFT SPEED CONTROL SWITCH (EXCEPT BASE) - BLACK 4 WAY
1 - -
4 - -
LEFT TAIL/STOP LAMP - BLACK 6 WAY
1 L38 18BR/WT (BUILT-UP-EXPORT) REAR FOG LAMP RELAY OUTPUT
LEFT VISOR/VANITY LAMP (EXCEPT BASE) - WHITE 2 WAY
LICENSE LAMP (BUILT-UP-EXPORT) - 2 WAY
2 Z235 18BK GROUND
LICENSE LAMP (EXCEPT BUILT-UP-EXPORT) - LT. GRAY 2 WAY
1 L77 18BR/YL FUSED PARK LAMP RELAY OUTPUT
LINE PRESSURE SENSOR (3.7L) - BLACK 4 WAY
1 Z112 18BK GROUND
2 T39 18GY/LB 5 VOLT SUPPLY
3 T38 18VT/TN LINE PRESSURE SENSOR SIGNAL
4 - -
LOW NOTE HORN - BLACK 2 WAY
2 Z141 18BK GROUND
MANIFOLD ABSOLUTE PRESSURE SENSOR - BLACK 3 WAY
1 K1 18DG/RD MANIFOLD ABOLUTE PRESSURE SENSOR SIGNAL
MULTI-FUNCTION SWITCH C1 - GRAY 10 WAY
1 E21 20OR/RD PANEL LAMPS DIMMER SWITCH MUX
2 L27 20WT/TN (EXCEPT BASE) FRONT FOG LAMP SWITCH SENSE
3 - -
4 L80 20WT/DG HEADLAMP SWITCH RETURN
5 L307 20LG/OR HEADLAMP SWITCH MUX
6 L305 20LB/WT LEFT TURN SWITCH SENSE
7 L309 20LG/WT HIGH BEAM RELAY CONTROL
9 L324 20WT/LG HIGH BEAM SWITCH SENSE
10 L302 20LB/YL RIGHT TURN SWITCH SENSE
MULTI-FUNCTION SWITCH C2 - GRAY 8 WAY
3 V20 18BK/WT WASHER MOTOR SENSE
4 V52 20DG/RD FRONT WIPER SWITCH MUX
5 F88 20BR/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
6 - -
8 - -
OUTPUT SPEED SENSOR (3.7L) - BLACK 2 WAY
1 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
OVERHEAD MAP/READING LAMP (EXCEPT BASE) - BLACK 3 WAY
2 M2 20YL REAR COURTESY LAMP CONTROL
3 M20 20BR COURTESY LAMPS LOAD SHEED
OXYGEN SENSOR 1/1 UPSTREAM - BLACK 4 WAY
2 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
4 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
OXYGEN SENSOR 1/2 DOWNSTREAM - NATURAL 4 WAY
1 A71 18DG/RD (2.4L) FUSED AUTO SHUT DOWN RELAY OUTPUT
1 F18 18LG/BK (3.7L) OXYGEN SENSOR DOWNSTREAM RELAY
2 K299 18BR/WT (2.4L) OXYGEN SENSOR 1/2 HEATER CONTROL
2 Z186 18BK/OR (3.7L) GROUND
4 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
OXYGEN SENSOR 2/1 UPSTREAM (3.7L) - BLACK 4 WAY
2 K299 18BR/WT OXYGEN SENSOR 2/1 HEATER CONTROL
4 K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
OXYGEN SENSOR 2/2 DOWNSTREAM (3.7L) - NATURAL 4 WAY
1 F18 18LG/BK OXYGEN SENSOR DOWNSTREAM RELAY OUTPUT
PASSENGER AIRBAG - YELLOW 4 WAY
1 R62 18OR/YL PASSENGER SQUIB 2 LINE 2
2 R64 18TN/YL PASSENGER SQUIB 2 LINE 1
3 R42 18BK/YL PASSENGER SQUIB 1 LINE 1
4 R44 18DG/YL PASSENGER SQUIB 1 LINE 2
PASSENGER SEAT BELT SWITCH - LT. GRAY 2 WAY
1 R58 18GY (EXCEPT BASE) PASSENGER SEAT BELT SWITCH SENSE
1 R58 18DG (BASE) PASSENGER SEAT BELT SWITCH SENSE
2 R60 18LB (BASE) PASSENGER SEAT BELT SWITCH GROUND
2 R60 18VT (EXCEPT BASE) PASSENGER SEAT BELT SWITCH GROUND
POWER MIRROR SWITCH (EXCEPT BASE) - WHITE 10 WAY
1 P75 20LB/WT LEFT MIRROR LEFT DRIVER
2 P71 20YL/DG LEFT MIRROR UP DRIVER
3 Z351 18BK/LG (RHD) GROUND
3 Z350 18BK/LG (LHD) GROUND
4 P110 18YL (FOLD) FOLDING MIRROR RETURN
7 P99 18GY (FOLD) FOLDING MIRROR FEED
8 - -
9 P72 20YL/BK (FOLD) RIGHT MIRROR UP DRIVER
9 P72 18YL/BK (WITHOUT FOLD) RIGHT MIRROR UP DRIVER
10 P74 20DB (FOLD) RIGHT MIRROR LEFT DRIVER
10 P74 18DB (WITHOUT FOLD) RIGHT MIRROR LEFT DRIVER
POWER OUTLET - RED 3 WAY
1 F38 16RD/WT FUSED B(+)
2 - -
2 - -
3 Z3 16BK/OR GROUND
POWER STEERING PRESSURE SWITCH - BLACK 2 WAY
1 K10 18DB/OR POWER STEERING PRESSURE SWITCH SENSE
POWER WINDOW MASTER SWITCH (MIDLINE/HIGHLINE) - LT. GRAY 14 WAY
1 - -
2 Q1 16YL POWER WINDOW SWITCH FEED
3 - -
4 Q27 14RD/BK LEFT REAR WINDOW DRIVER DOWN
5 Q17 14DB/WT LEFT REAR WINDOW DRIVER UP
6 Q28 14DG/WT RIGHT REAR WINDOW DRIVER DOWN
7 Q18 14GY/BK RIGHT REAR WINDOW DRIVER UP
8 - -
9 Q21 14WT LEFT FRONT WINDOW DRIVER DOWN
10 F81 12TN FUSED B(+)
11 Q11 14LB LEFT FRONT WINDOW DRIVER UP
12 Q12 14BR RIGHT FRONT WINDOW DRIVER UP
13 Q22 14VT/WT RIGHT FRONT WINDOW DRIVER DOWN
POWERTRAIN CONTROL MODULE-C1 (2.4L) - BLACK 32 WAY
1 - -
3 - -
5 - -
6 - -
7 K19 18BK/GY IGNITION COIL NO. 1 DRIVER
9 - -
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 1 DRIVER
13 - -
19 K39 18GY/RD IDLE AIR CONTROL NO. 3 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 - -
23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
26 - -
28 - -
29 - -
30 - -
POWERTRAIN CONTROL MODULE-C1 (3.7L) - BLACK 32 WAY
1 K93 14TN/OR COIL ON PLUG DRIVER NO. 3
3 K94 14TN/LG COIL ON PLUG DRIVER NO. 4
5 K96 14TN/LB COIL ON PLUG DRIVER NO. 6
6 T41 18BK/WT (A/T) PARK/NEUTRAL POSITION SWITCH SENSE
7 K91 14TN/RD COIL ON PLUG DRIVER NO.1
9 - -
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
11 K40 18BR/WT IDLE AIR CONTROL NO. 1 DRIVER
13 T141 18 YL/RD (M/T) FUSED IGNITION SWITCH OUTPUT (START)
13 F45 18YL/BR (A/T) FUSED IGNITION SWITCH OUTPUT (START)
19 K39 18GY/RD IDLE AIR CONTROL NO. 3 DRIVER
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
21 K95 14TN/DG COIL ON PLUG DRIVER NO. 5
26 K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
28 - -
30 - -
POWERTRAIN CONTROL MODULE-C2 (GAS) - WHITE 32 WAY
1 - -
2 - -
3 - -
4 K11 18WT/DB FUEL INJ ECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJ ECTOR NO. 3 DRIVER
6 K38 18GY (3.7L) FUEL INJ ECTOR NO. 5 DRIVER
7 - -
8 - -
9 K92 14TN/PK (3.7L) COIL ON PLUG DRIVER NO. 2
9 K17 18DB/TN (2.4L) IGNITION COIL NO. 2 DRIVER
10 K20 18DG GENERATOR FIELD
11 - -
12 K58 18BR/DB (3.7L) FUEL INJ ECTOR NO. 6 DRIVER
POWERTRAIN CONTROL MODULE-C2 (GAS) - WHITE 32 WAY
13 - -
14 - -
15 K12 18TN FUEL INJ ECTOR NO. 2 DRIVER
16 K14 18LB/BR FUEL INJ ECTOR NO. 4 DRIVER
17 K173 18LG RADIATOR FAN RELAY CONTROL
18 - -
20 - -
21 - -
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 K6 18VT/WT 5 VOLT SUPPLY
32 - -
POWERTRAIN CONTROL MODULE-C3 (GAS) - LT. GRAY 32 WAY
1 C13 18DG A/C COMPRESSOR CLUTCH RELAY CONTROL
2 - -
3 K51 18DB/YL AUTO SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6 K90 18TN (M/T) CLUTCH INTERLOCK RELAY CONTROL
7 K42 18DB/LB (3.7L) KNOCK SENSOR NO. 1 SIGNAL
7 K42 18DB/LB (2.4L) NOT USED
8 K99 18BR/OR OXYGEN SENSOR 1/1 HEATER CONTROL
9 K512 18RD/YL OXYGEN SENSOR DOWNSTEAM RELAY CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 F142 18OR/DG FUSED AUTO SHUT DOWN RELAY SENSE INPUT
13 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
14 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
17 B22 18DG/YL VEHICLE SPEED OUTPUT
18 K142 18GY/BK (2.4L) NOT USED
18 K142 18GY/BK (3.7L) KNOCK SENSOR NO. 2 SIGNAL
19 K31 18BR FUEL PUMP RELAY CONTROL
20 K52 18PK/BK EVAP PURGE/SOLENOID CONTROL
21 - -
23 - -
24 K29 18WT/PK BRAKE LAMP SWITCH SENSE
25 K125 18WT/DB GENERATOR SOURCE
POWERTRAIN CONTROL MODULE-C3 (GAS) - LT. GRAY 32 WAY
28 - -
29 D32 18LG SCI RECEIVE (PCM)
31 - -
RADIATOR FAN MOTOR - BLACK 2 WAY
1 C25 12YL RADIATOR FAN RELAY OUTPUT
RADIATOR FAN RELAY - BLACK 4 WAY
1 C24 12DB/PK FUSED B(+)
2 C25 12YL RADIATOR FAN RELAY OUTPUT
4 K173 18LG RADIATOR FAN RELAY CONTROL
RADIO C1 - GRAY 22 WAY
4 - -
5 - -
6 - -
7 X54 18VT RIGHT FRONT DOOR SPEAKER (+)
8 X56 18DB/RD RIGHT FRONT DOOR SPEAKER (-)
9 X55 18BR/RD LEFT FRONT DOOR SPEAKER (-)
10 X53 18DG LEFT FRONT DOOR SPEAKER (+)
11 Z9 16BK GROUND
13 X16 18LG (PREMIUM) ANTENNA RELAY OUTPUT
15 - -
16 - -
17 - -
18 X51 18BR/YL LEFT REAR SPEAKER (+)
19 X57 18BR/LB LEFT REAR SPEAKER (-)
20 X58 18DB/OR RIGHT REAR SPEAKER (-)
21 X52 18DB/WT RIGHT REAR SPEAKER (+)
22 Z9 16BK GROUND
RADIO C2 - 10 WAY
1 X40 20WT/RD AUDIO OUT RIGHT
2 Z30 20WT/BK GROUND
3 Z9 20BK/DB GROUND
5 X112 20RD IGNITION SWITCH OUTPUT
6 X41 20WT/DG AUDIO OUT LEFT
7 Z17 20BK GROUND
8 - -
9 - -
10 X160 20YL B(+)
RADIO C3 - 2 WAY
RADIO CHOKE (PREMIUM) - GRAY 4 WAY
1 F60 16DG/RD FUSED B(+)
3 X16 18LG ANTENNA RELAY OUTPUT
REAR POWER OUTLET - RED 3 WAY
2 - -
REAR POWER WINDOW SWITCH (MIDLINE/HIGHLINE) - WHITE 10 WAY
1 Q28 14DG/WT RIGHT REAR WINDOW DRIVER DOWN
2 Q14 14GY RIGHT REAR WINDOW DRIVER UP
3 Q24 14DG RIGHT REAR WINDOW DRIVER DOWN
4 Q18 14GY/BK RIGHT REAR WINDOW DRIVER UP
7 Q17 14DB/WT LEFT REAR WINDOW DRIVER UP
8 Q23 14RD/WT LEFT REAR WINDOW DRIVER DOWN
9 Q27 14RD/BK LEFT REAR WINDOW DRIVER DOWN
10 Q13 14DB LEFT REAR WINDOW DRIVER UP
REAR WHEEL SPEED SENSOR - BLACK 2 WAY
1 B2 18YL REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY
2 B1 18YL/DB REAR WHEEL SPEED SENSOR SIGNAL
REAR WIPER MOTOR - BLACK 6 WAY
1 Z235 18BK GROUND
5 F70 18PK/BK FUSED B(+)
6 - -
RED BRAKE WARNING INDICATOR SWITCH - GRAY 2 WAY
1 G11 18WT/BK RED BRAKE WARNING INDICATOR DRIVER
REMOTE KEYLESS ENTRY MODULE (EXCEPT BASE) - 6 WAY
1 Y60 RKE DATA
2 Y62 RKE SUPPLY
3 Y61 RKE PROGRAM
4 Y63 RKE GROUND
5 Y64 RKE ANTENNA (+)
6 Y65 RKE ANTENNA (-)
RIGHT COURTESY LAMP - BLACK 2 WAY
RIGHT CURTAIN AIRBAG - YELLOW 2 WAY
1 R76 18YL/DB RIGHT CURTAIN SQUIB LINE 2
2 R74 18YL/BR RIGHT CURTAIN SQUIB LINE 1
RIGHT CYLINDER LOCK SWITCH (EXCEPT BASE) - LT. GRAY 2 WAY
2 G72 18DG/OR (LHD) RIGHT CYLINDER LOCK SWITCH MUX
2 G73 18LG/OR (RHD) RIGHT CYLINDER LOCK SWITCH MUX
RIGHT DOOR LOCK SWITCH (EXCEPT BASE) - BLACK 4 WAY
1 P36 20PK/VT DOOR LOCK SWITCH MUX
RIGHT FOG LAMP - BLACK 2 WAY
A Z142 18BK/WT GROUND
B L39 18LB FOG LAMP RELAY OUTPUT
RIGHT FRONT DOOR AJ AR SWITCH (BASE) - BLACK 2 WAY
RIGHT FRONT DOOR LOCK MOTOR/AJ AR SWITCH (EXCEPT BASE) - BLACK 4 WAY
1 G75 20TN (RHD) DRIVER DOOR AJ AR SWITCH SENSE
1 G74 20TN/WT (LHD) PASSENGER DOOR AJ AR SWITCH SENSE
3 P34 18PK/BK (RHD) DRIVER DOOR UNLOCK RELAY OUTPUT
3 P35 18OR/VT (LHD) PASSENGER DOOR UNLOCK RELAY OUTPUT
RIGHT FRONT DOOR SPEAKER (BASE) - 2 WAY
1 X54 18VT RIGHT FRONT SPEAKER (+)
2 X56 18DB/RD RIGHT FRONT SPEAKER (-)
RIGHT FRONT DOOR SPEAKER (PREMIUM) - BLACK 10 WAY
1 X54 18VT RIGHT FRONT SPEAKER (+)
2 X56 18DB/RD RIGHT FRONT SPEAKER (-)
3 Z9 16BK GROUND
4 X86 18OR/RD AMPLIFIED HIGH RIGHT FRONT SPEAKER (-)
5 X92 18TN/BK AMPLIFIED LOW RIGHT REAR SPEAKER (-)
6 X58 18DB/OR RIGHT REAR DOOR SPEAKER (-)
7 X52 18DB/WT RIGHT REAR DOOR SPEAKER (+)
9 X84 18TN/BK AMPLIFIED HIGH RIGHT FRONT SPEAKER (+)
10 X94 18TN/VT AMPLIFIED LOW RIGHT REAR SPEAKER (+)
RIGHT FRONT IMPACT SENSOR - BLACK 4 WAY
1 - -
2 - -
3 R46 18BR/LB RIGHT FRONT IMPACT SENSOR GROUND
4 R48 18TN RIGHT FRONT IMPACT SENSOR SIGNAL
RIGHT FRONT PARK/ TURN SIGNAL LAMP - BLACK 3 WAY
2 L78 18DG/YL (EXCEPT BUILT-UP-EX-
PORT)
FUSED PARK LAMP RELAY OUTPUT
RIGHT FRONT POWER WINDOW MOTOR (MIDLINE/HIGHLINE) - LT. GRAY 2 WAY
1 Q22 16VT/WT RIGHT FRONT WINDOW DRIVER DOWN
2 Q12 16BR RIGHT FRONT WINDOW DRIVER UP
RIGHT FRONT WHEEL SPEED SENSOR (ABS) - BLACK 2 WAY
1 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
RIGHT HEADLAMP (BUILT-UP-EXPORT) - 3 WAY
1 L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT
2 L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
RIGHT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLUE 3 WAY
A L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
B Z142 18BK/WT GROUND
C L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT
RIGHT HEATED SEAT ASSEMBLY (HIGHLINE) - LT. GRAY 4 WAY
1 F98 16RD/WT PASSENGER HEATED SEAT FEED
4 P142 20TN/DB PASSENGER HEATED SEAT TEMPERATURE SENSOR
GROUND
RIGHT HEATED SEAT SWITCH (HIGHLINE) - BLACK 8 WAY
2 P140 20VT/BK RIGHT SEAT HIGH HEAT LED DRIVER
3 P134 20TN/LG RIGHT SEAT HEATER SWITCH MUX
4 P138 20VT/LG RIGHT SEAT LOW HEAT LED DRIVER
6 - -
7 - -
8 - -
RIGHT INSTRUMENT PANEL SPEAKER - WHITE 2 WAY
1 X84 18TN/BK (PREMIUM) AMPLIFIED HIGH RIGHT FRONT SPEAKER (+)
1 X54 18VT (BASE) RIGHT FRONT SPEAKER (+)
2 X86 18OR/RD (PREMIUM) AMPLIFIED HIGH RIGHT FRONT SPEAKER (-)
2 X56 18DB/RD (BASE) RIGHT FRONT SPEAKER (-)
RIGHT LEVELING MOTOR (BUILT-UP-EXPORT) - BLACK 3 WAY
RIGHT POSITION LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY
RIGHT POWER MIRROR (EXCEPT BASE) - WHITE 8 WAY
1 P72 20YL/BK RIGHT MIRROR UP DRIVER
3 P74 20DB RIGHT MIRROR LEFT DRIVER
4 - -
7 P99 20GY (WITH FOLD) FOLDING MIRROR FEED
8 P110 20YL (WITH FOLD) FOLDING MIRROR RETURN
RIGHT POWER SEAT MOTORS (MIDLINE/HIGHLINE) - BLACK 6 WAY
1 P10 14YL/WT PASSENGER SEAT REAR UP DRIVER
2 P12 14RD/WT PASSENGER SEAT REAR DOWN DRIVER
3 P18 14YL/LG PASSENGER SEAT FRONT UP DRIVER
4 P20 14RD/LG PASSENGER SEAT FRONT DOWN DRIVER
5 P16 14RD/YL PASSENGER SEAT HORIZONTAL REARWARD DRIVER
6 P14 14YL/LB PASSENGER SEAT HORIZONTAL FORWARD DRIVER
RIGHT POWER SEAT SWITCH (MIDLINE/HIGHLINE) - GREEN 10 WAY
2 - -
3 P14 14YL/LB PASSENGER SEAT HORIZONTAL FORWARD DRIVER
4 - -
5 F37 14RD/LB FUSED B(+)
6 P16 14RD/YL PASSENGER SEAT HORIZONTAL REARWARD DRIVER
7 P10 14YL/WT PASSENGER SEAT REAR UP DRIVER
8 P18 14YL/LG PASSENGER SEAT FRONT UP DRIVER
9 P20 14RD/LG PASSENGER SEAT FRONT DOWN DRIVER
10 P12 14RD/WT PASSENGER SEAT REAR DOWN DRIVER
RIGHT REAR DOOR AJ AR SWITCH (BASE) - BLACK 2 WAY
RIGHT REAR DOOR LOCK MOTOR/AJ AR SWITCH (EXCEPT BASE) - BLACK 4 WAY
3 P35 18OR/VT PASSENGER DOOR UNLOCK RELAY OUTPUT
RIGHT REAR DOOR SPEAKER - 2 WAY
1 X52 18DB/WT (BASE) RIGHT REAR DOOR SPEAKER (+)
1 X94 18TN/VT (PREMIUM) AMPLIFIED LOW RIGHT REAR SPEAKER (+)
2 X58 18DB/OR (BASE) RIGHT REAR DOOR SPEAKER (-)
2 X92 18TN/BK (PREMIUM) AMPLIFIED LOW RIGHT REAR SPEAKER (-)
RIGHT REAR POWER WINDOW MOTOR (MIDLINE/HIGHLINE) - LT. GRAY 2 WAY
1 Q24 16DG RIGHT REAR WINDOW DRIVER DOWN
2 Q14 16GY RIGHT REAR WINDOW DRIVER UP
RIGHT REMOTE RADIO SWITCH (PREMIUM) - BLACK 2 WAY
1 X10 20RD/DB RADIO CONTROL MUX RETURN
2 X20 20RD/BK RADIO CONTROL MUX
RIGHT SIDE IMPACT AIRBAG CONTROL MODULE (RSIACM) - YELLOW 8 WAY
2 - -
3 R76 18YL/DB RIGHT CURTAIN SQUIB LINE 2
4 R74 18YL/BR RIGHT CURTAIN SQUIB LINE 1
6 - -
7 - -
RIGHT SIDE MARKER LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 2 WAY
RIGHT SIDE REPEATER LAMP (BUILT-UP-EXPORT) - BLACK 2 WAY
RIGHT SPEED CONTROL SWITCH (EXCEPT BASE) - BLACK 4 WAY
1 - -
4 - -
RIGHT TAIL/STOP LAMP - BLACK 6 WAY
1 L38 18BR/WT (BUILT-UP-EXPORT) REAR FOG LAMP RELAY OUTPUT
RIGHT VISOR/VANITY LAMP (EXCEPT BASE) - WHITE 2 WAY
SENTRY KEY IMMOBILIZER MODULE (EXCEPT BASE) - BLACK 6 WAY
5 D25 20YL/VT/BK PCI BUS
6 - -
SHIFTER ASSEMBLY - WHITE 6 WAY
3 T6 20VT/WT OVERDRIVE OFF SWITCH SENSE
6 K29 20WT/PK BRAKE SWITCH SENSE
SIREN (BUILT-UP-EXPORT) - 3 WAY
2 X75 18DG SIREN SIGNAL CONTROL
SPEED CONTROL SERVO - BLACK 4 WAY
1 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
3 V30 18DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
SUNROOF MOTOR - LT. GRAY 6 WAY
1 F85 16VT/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 Z111 16BK GROUND
3 Q44 20BR SUNROOF SWITCH GROUND
4 Q43 20VT SUNROOF VENT
5 Q42 20LB SUNROOF CLOSE
6 Q41 20WT SUNROOF OPEN
SUNROOF SWITCH - BLACK 4 WAY
1 Q41 20WT SUNROOF OPEN
2 Q42 20LB SUNROOF CLOSE
3 Q43 20VT SUNROOF VENT
4 Q44 20BR SUNROOF SWITCH GROUND
TAILGATE CYLINDER LOCK SWITCH - LT. GRAY 2 WAY
2 G71 18VT/YL TAILGATE CYLINDER LOCK SWITCH MUX
TAILGATE FLIP-UP AJ AR SWITCH - GRAY 2 WAY
2 Z235 18BK GROUND
TAILGATE LOCK MOTOR/AJ AR SWITCH - BLACK 4 WAY
1 P31 16PK/WT TAILGATE UNLOCK DRIVER
2 P30 16OR/WT TAILGATE LOCK DRIVER
3 G78 20TN/BK TAILGATE AJ AR SWITCH SENSE
THROTTLE POSITION SENSOR - WHITE/BLUE 3 WAY
TRAILER TOW BRAKE LAMP RELAY - 5 WAY
30 A6 16RD/BK FUSED B(+)
87 L95 16DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT
87A L76 16BK/OR TRAILER TOW BRAKE LAMP RELAY OUTPUT
87 L95 16DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT
TRAILER TOW CIRCUIT BREAKER - 2 WAY
1 A99 14RD/VT FUSED B(+)
2 F71 14RD FUSED B(+)
TRAILER TOW CONNECTOR - BLACK 10 WAY
1 - -
2 L74 16PK/BK RIGHT TURN SIGNAL
4 F73 14YL TRAILER TOW RELAY OUTPUT
6 - -
7 B40 14LB TRAILER TOW BRAKE B(+)
10 L73 16PK/WT LEFT TURN SIGNAL
TRAILER TOW LEFT TURN RELAY - 5 WAY
30 L73 16PK/WT LEFT TURN SIGNAL
87 L76 16BK/OR TRAILER TOW BRAKE LAMP RELAY OUTPUT
87A L95 16DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT
TRAILER TOW RELAY - 5 WAY
30 F71 14RD FUSED B(+)
87A - -
87 F73 14YL TRAILER TOW RELAY OUTPUT
TRAILER TOW RIGHT TURN RELAY - 5 WAY
30 L74 16PK/BK RIGHT TURN SIGNAL
87A L95 16DG/YL TRAILER TOW BRAKE LAMP RELAY OUTPUT
TRANSFER CASE POSITION SENSOR - BLACK 2 WAY
1 K77 20BR/WT (DIESEL) TRANSFER CASE POSITION SENSOR INPUT
1 K77 18BR/WT (GAS) TRANSFER CASE POSITION SENSOR INPUT
TRANSMISSION CONTROL MODULE (3.7L) - BLACK 60 WAY
1 T1 18LG/BK TRS T1 SENSE
2 T4 18PK/OR TRS T2 SENSE
3 T3 18VT TRS T3 SENSE
4 - -
5 - -
8 F45 18YL/BR FUSED IGNITION SWITCH OUTPUT (START)
9 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18YL/DG TORQUE MANAGEMENT REQUEST SENSE
14 T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL
15 K30 18PK TRANSMISSION CONTROL RELAY CONTROL
16 T16 14RD TRANSMISSION CONTROL RELAY OUTPUT
18 T591 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
19 T119 18WT/DB 2C SOLENOID CONTROL
20 T20 18LB LOW/REVERSE SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
30 T38 18VT/TN LINE PRESSURE SENSOR SIGNAL
31 - -
32 - -
33 - -
34 - -
35 - -
38 T39 18GY/LB 5 VOLT SUPPLY
40 T140 18VT/LG MS SOLENOID CONTROL
41 T411 18WT/PK TRS T41 SENSE
42 T42 18VT/WT TRS T42 SENSE
43 D25 18VT/YL PCI BUS
44 - -
45 - -
46 D20 18LG SCI RECEIVE
47 T147 18LB 2C PRESSURE SWITCH SENSE
48 T48 18DB 4C PRESSURE SWITCH SENSE
49 T6 18OR/WT OVERDRIVE OFF SWITCH SENSE
50 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
52 T52 18RD/BK INPUT SPEED SENSOR SIGNAL
53 Z112 14BK GROUND
TRANSMISSION CONTROL MODULE (3.7L) - BLACK 60 WAY
54 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 T59 18PK UNDERDRIVE SOLENOID CONTROL
58 - -
59 T159 18DG/WT 4C SOLENOID CONTROL
60 T60 18BR OVERDRIVE SOLENOID CONTROL
TRANSMISSION SOLENOID/TRS ASSEMBLY (3.7L) - GRAY 23 WAY
2 T20 18LB LOW/REVERSE SOLENOID CONTROL
3 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
4 T411 18WT/PK TRS T41 SENSE
5 T42 18VT/WT TRS T42 SENSE
7 T60 18BR OVERDRIVE SOLENOID CONTROL
8 T3 18VT TRS T3 SENSE
9 T1 18LG/BK TRS T1 SENSE
11 T48 18DB 4C PRESSURE SWITCH SENSE
12 T591 18YL/DB PRESSURE CONTROL SOLENOID CONTROL
13 T4 18PK/OR TRS T2 SENSE
14 T50 18DG LOW/REVERSE PRESSURE SWITCH SENSE
15 T147 18LB 2C PRESSURE SWITCH SENSE
16 T9 18OR/BK OVERDRIVE PRESSURE SWITCH SENSE
17 T59 18PK UNDERDRIVE SOLENOID CONTROL
18 T29 18GY UNDERDRIVE PRESSURE SWITCH SENSE
19 T159 18DG/WT 4C SOLENOID CONTROL
20 T119 18WT/DB 2C SOLENOID CONTROL
21 T140 18VT/LG MS SOLENOID CONTROL
23 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
WASHER FLUID LEVEL SWITCH - LT. GRAY 2 WAY
1 G29 18BK/TN LOW WASHER FLUID SENSE
2 Z141 18BK GROUND
WASHER PUMP - BLACK 2 WAY
1 V20 18BK/WT WASHER MOTOR SENSE
WATER IN FUEL SENSOR (DIESEL) - GRAY 2 WAY
1 G123 20DG/WT WATER IN FUEL SENSOR SIGNAL
8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng con-
nector, ground, and spl i ce l ocati ons i n the vehi cl e.
Connector, ground, and spl i ce i ndexes are provi ded.
Use the wi ri ng di agrams i n each secti on for connec-
tor, ground, and spl i ce i denti fi cati on. Refer to the
appropri ate i ndex for the proper fi gure number. For
i tems that are not shown i n thi s secti on N/S i s pl aced
i n the Fi g. col umn.
CONNECTORS
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
A/C Compressor Clutch BK At A/C Compressor 2, 20
A/C Heater Control C1 BK Center of Dash, Behind
A/C-Heater Controls
N/S
A/C Heater Control C2 WT Center of Dash, Behind
A/C-Heater Controls
N/S
A/C High Pressure Switch (Diesel) GY Left Front Side of Engine
Compartment
20
A/C Low Pressure Switch (LHD) GY Left Rear Side of Engine
Compartment
31
A/C Low Pressure Switch (RHD) GY Right Rear Side of Engine
Compartment
24
A/C Pressure Transducer (2.4L) BK Front Side of Engine 12, 15
A/C Pressure Transducer (3.7L) BK Front Side of Engine 2
Accelerator Pedal Position Sensor
(Diesel)
BK Left Rear Side of Engine
Compartment
19
Airbag Control Module C1 (ORC C1) YL Under Center Console 33, 37
Airbag Control Module C2 (ORC C2) BK Under Center Console 33, 37
Ambient Temperature Sensor BK Front of Engine
Compartment
N/S
Antenna Module C1 (BUX) Above Right Quarter Window 44, 45
Antenna Module C2 (BUX) Above Right Quarter Window N/S
Ash Receiver Lamp Center of Dash N/S
Back-Up Lamp Switch (2.4L) BK Right Side of Transmission 12
Back-Up Lamp Switch (M/T) (3.7L)
(Diesel)
BK Left Side of Transmission 7, 22
Battery Temperature Sensor BK Left Side of Engine
Compartment
30
KJ 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8Wa - 91 - 1
Blend Door Actuator BK Behind Right Side of
Instrument Panel
N/S
Blower Motor BK Behind Right Side of
Instrument Panel
N/S
Blower Motor Resistor Block BK Behind Right Side of
Instrument Panel
N/S
Body Control Module C1 GY Under Left Side of
Instrument Panel
N/S
Body Control Module C2 GY Under Left Side of
Instrument Panel
N/S
Body Control Module C3 (Premium) Under Left Side of
Instrument Panel
N/S
Boost Pressure Sensor (Diesel) Left Side of Engine 22
Brake Lamp Switch BK At Brake Pedal N/S
Brake Pressure Switch (ABS) BK On Master Cylinder N/S
C100 GY Left Kick Panel 32, 33, 37
C101 (2.4L) BK Left Side of Engine
Compartment
11, 12
C102 (RHD) Left Kick Panel 32
C103 (Gas) BK Right Rear Side of Engine
Compartment
8, 9, 10, 13, 14, 16
C104 BK Right Rear Side of Engine
Compartment
8, 9, 10, 13, 14, 16, 17,
18
C105 GY Right Rear Side of Engine
Compartment
8, 9, 10, 13, 14, 16, 17,
18
C106 BK Left Front Side of Engine
Compartment
29
C107 BK Left Front Side of Engine
Compartment
N/S
C108 (Gas) GY Left Front Side of Engine 30
C110 (2.4L) BK Left Side of Engine 11, 12
C111 (Diesel) LG Right Rear Side of Engine
Compartment
17, 18
C112 (Gas) BK Right Side of Engine
Compartment
8, 9, 10, 13, 14, 31
C113 (Diesel) LG Left Rear Side of Engine
Compartment
N/S
C114 (Diesel) LG Top of Engine N/S
C201 BK Behind Center of Instrument
Panel
N/S
C202 YL Behind Center of Instrument
Panel
N/S
C300 (LHD) OR Left A-Pillar 35, 41
C300 (RHD) OR Right A-Pillar 39, 41
C301 (LHD) OR Left A-Pillar 35, 41
C301 (RHD) OR Right A-Pillar 39, 41
8Wa - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION KJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
C302 (LHD) OR Right A-Pillar 34, 41, 42
C302 (RHD) OR Left A-Pillar 38, 41
C303 (LHD) OR Right A-Pillar 34, 41, 42
C303 (RHD) OR Left A-Pillar 38, 41
C304 DB Right Mid B-Pillar 34, 39
C305 DB Left Mid B-Pillar 35, 38
C306 (LHD) WT Left Lower B-Pillar 35, 43
C306 (RHD) WT Right Lower B-Pillar 39, 45
C307 (LHD) LG Left Lower B-Pillar 35, 38, 44
C308 LG Left Rear Quarter Panel 43
C309 DB Left Rear Quarter Panel 43, 46
C310 LG Right Rear Quarter Panel 44, 45, 47
C311 LG Left Front Seat 35, 38
C312 (Highline) LG Left Front Seat 35, 38
C313 LG Right Front Seat 36, 39, 40
C314 LG Right Front Seat 36, 39, 40
C315 (Midline/Highline) (LHD) LG Right Front Seat 34
C315 (Midline/Highline) (RHD) LG Left Front Seat 38
C317 (Except BUX) LG On Rear Bumper 45
Cabin Heater (Diesel) BK Right Front Side of Engine 21
Camshaft Position Sensor (2.4L) BK Top of Engine N/S
Camshaft Position Sensor (3.7L) LG Right Side of Engine 4
Camshaft Position Sensor (Diesel) Top of Engine 22
Capacitor (3.7L) BK Rear Side of Engine
Compartment
9, 10
Capacitor (2.4L) BK Left Rear Side of Engine 11, 12
CD Changer GN At CD Changer N/S
Center High Mounted Stop Lamp WT At Lamp 46
Cigar Lighter RD Behind Cigar Lighter N/S
Clockspring C1 WT Behind Steering Wheel N/S
Clockspring C2 YL Behind Steering Wheel N/S
Clockspring C3 BK At Steering Wheel N/S
Clutch Interlock Switch (LHD) BK Left Rear Side of Engine
Compartment
31
Clutch Interlock Switch (RHD) BK Right Rear Side of Engine
Compartment
26
Coil On Plug No.1 (3.7L) BK Left Side of Engine Near
Fuel Injector No.1
1
Coil On Plug No.2 (3.7L) BK Right Side of Engine Near
Fuel Injector No.2
2
Fuel Injector No.3
1
Fuel Injector No.4
2
Fuel Injector No.5
1
Fuel Injector No.6
2
Coil Rail (2.4L) BK Right Side of Engine 11, 12
Combination Flasher WT Under Left Side of
Instrument Panel
N/S
Compass Mini-Trip Computer BK At Overhead Console N/S
Controller Antilock Brake BK Left Side of Engine
Compartment
30
Crankshaft Position Sensor (2.4L) BK Top of Engine N/S
Crankshaft Position Sensor (3.7L) BK Right Lower Side of Engine 4
Crankshaft Position Sensor (Diesel) BK Right Rear Side of Engine 17
Data Link Connector BK Under Center of Instrument
Panel
N/S
Diagnostic Junction Port BK Under Center of Instrument
Panel
49
Dome Lamp (Base) BK On Headliner N/S
Driver Airbag Squib 1 GY In Steering Wheel N/S
Driver Airbag Squib 2 BK In Steering Wheel N/S
Driver Seat Belt Switch LG At Drive Seat N/S
Driver Seat Belt Tensioner (LHD) YL Lower Left B-Pillar 35
Driver Seat Belt Tensioner (RHD) YL Lower Right B-Pillar 39
EGR Solenoid Right Rear Side of Engine
Compartment
27
Engine Control Module C1 BK Left Rear Side of Engine
Compartment
19
Engine Control Module C2 BK Left Rear Side of Engine
Compartment
19
Engine Coolant Level Sensor (Diesel) LG Rear Side of Engine
Compartment
18
Engine Coolant Temperature Sensor
(Diesel)
BK Left Side of Engine 20
Engine Coolant Temperature Sensor
(Gas)
BK Front Side of Engine 2
Engine Oil Pressure Sensor (2.4L) BK Top of Engine N/S
Engine Oil Pressure Sensor (3.7L) BK Left Front Side of Engine 3
Engine Oil Pressure Sensor (Diesel) BK Right Rear Side of Engine 17
Engine Starter Motor Right Front Side of Engine 20
Evap/Purge Solenoid BK At Solenoid N/S
Flip-Up Glass Release Motor BK In Tailgate 46
Flip-Up Glass Release Switch WT In Tailgate 46
Front Washer Pump BK Right Front Side of Engine
Compartment
28
Front Wiper Motor (LHD) BK Left Side of Cowl 24
Front Wiper Motor (RHD) BK Right Side of Cowl 24
Fuel Heater (Diesel) BK Left Rear Side of Engine
Compartment
19
Fuel Injector No.1 (Diesel) BK At Fuel Injector 23
Fuel Injector No.1 (Gas) BK At Fuel Injector 1
Fuel Injector No.5 (3.7L) BK At Fuel Injector 1
Fuel Injector No.6 (3.7L) BK At Fuel Injector 2
Fuel Pressure Sensor (Diesel) Left Side of Engine 22
Fuel Pressure Solenoid (Diesel) BK Left Side of Engine 20
Fuel Pump Module LG At Fuel Tank N/S
Generator BK Left Front Side of Engine 20
Glow Plug Assembly (Diesel) Top of Engine N/S
Headlamp Leveling Switch (BUX) BK Center of Instrument Panel N/S
Heated Seat Module (Highline) GN At Left Seat N/S
High Note Horn BK Left Front Side of Engine
Compartment
29
Hood Ajar Switch Right Side of Engine
Compartment
25
Idle Air Control Motor BK On Throttle Body 1
Ignition Switch At Steering Column N/S
Input Speed Sensor (3.7L) BK Left Side of Transmission 5
Instrument Cluster BK Rear of Cluster N/S
Intake Air Temperature Sensor GY Left Side of Intake Manifold 1
Intrusion Sensor (BUX) BK Overhead Console N/S
Junction Block Body Control Module -
JB
Under Left Side of
Instrument Panel
N/S
Junction Block C1 GY Under Left Side of
Instrument Panel
N/S
Junction Block C2 GN Under Left Side of
Instrument Panel
N/S
Junction Block C3 LB Under Left Side of
Instrument Panel
N/S
Knock Sensor (3.7L) BK Near Fuel Injector No.5 1
Leak Detection Pump BK Near Fuel Tank N/S
Left Curtain Airbag YL Left Mid B-Pillar 35, 38
Left Cylinder Lock Switch LG In Left Front Door 41
Left Door Lock Switch BK In Left Front Door 41
Left Fog Lamp BK Left Side of Front Bumper N/S
Left Front Door Ajar Switch (Base) BK In Left Front Door N/S
Switch (Except Base)
BK In Left Front Door 41
Left Front Door Speaker BK Behind Left Front Door Panel 41
Left Front Impact Sensor BK Front Side of Engine
Compartment
28
Left Front Park/Turn Signal Lamp BK Behind Left Turn Signal
Lamp
N/S
Left Front Power Window Motor LG In Left Front Door 41
Left Front Wheel Speed Sensor BK Left Side of Engine
Compartment
30
Left Headlamp (BUX) Behind Left Headlamp N/S
Left Headlamp (Except BUX) DB Behind Left Headlamp N/S
Left Heated Seat Assembly LG At Left Seat N/S
Left Heated Seat Switch BK At Left Seat N/S
Left Instrument Panel Lamp BK Left Side of Instrument Panel N/S
Left Instrument Panel Speaker BK Left Side of Instrument Panel 33, 37
Left Leveling Motor (BUX) BK At Left Headlamp N/S
Left Position Lamp (BUX) BK Left Front Side of Vehicle N/S
Left Power Mirror WT In Left Front Door 41
Left Power Seat Motors BK At Left Seat N/S
Left Power Seat Switch GN At Left Seat N/S
Left Rear Door Ajar Switch (Base) BK In Left Rear Door N/S
Left Rear Door Lock Motor/Ajar
BK In Left Rear Door N/S
Left Rear Door Speaker In Left Rear Door
Left Rear Power Window Motor LG In Left Rear Door N/S
Left Remote Radio Switch BK On Steering Wheel N/S
Left Side Impact Airbag Control
Module (LSIACM)
YL Left Lower B-Pillar 35, 38
Left Side Marker Lamp BK Left Front Fender N/S
Left Side Repeater Lamp (BUX) BK Left Front Fender N/S
Left Speed Control Switch BK On Steering Wheel N/S
Left Tail/Stop Lamp BK Left Rear Quarter Panel 45
Left Visor/Vanity Lamp WT Left Front of Headliner N/S
License Lamp (BUX) LG In Tailgate 46
License Lamp (Except BUX) LG On Bumper N/S
Line Pressure Sensor (3.7L) BK Right Side of Transmission 6
Low Note Horn BK Left Front Side of Engine
Compartment
29
Manifold Absolute Pressure Sensor BK Front Side of Engine 2
Mass Air Flow Sensor (Diesel) Top of Engine 21
Multi-Function Switch C1 GY At Steering Column N/S
Multi-Function Switch C2 GY At Steering Column N/S
Output Speed Sensor BK Left Side of Transmission 5
Overhead Map/Courtesy Lamp BK Overhead Console N/S
Oxygen Sensor 1/1 Upstream (2.4L) BK Right Side of Engine 12
Oxygen Sensor 1/1 Upstream (3.7L) BK Lower Left Side of Engine 3
Oxygen Sensor 1/2 Downstream
(2.4L)
NAT Right Side of Transmission 11, 12
(3.7L)
NAT Left Side of Transmission 5, 7
Oxygen Sensor 2/1 Upstream (3.7L) BK Lower Right Side of Engine 4
(3.7L)
NAT Right Side of Transmission 6
Park Brake Switch BK Center Console 36, 40
Passenger Airbag YL Right Side Instrument Panel N/S
Passenger Seat Belt Switch LG At Passenger Seat N/S
Power Mirror Switch WT In Left Front Door 41
Power Outlet RD Center of Instrument Panel N/S
Power Steering Pressure Switch BK Left Front Side of Engine 3, 15
Power Window Master Switch LG Center Console 36, 40
Powertrain Control Module C1 (2.4L) BK At Powertrain Control Module 13, 14
Powertrain Control Module C1 (3.7L) BK At Powertrain Control Module 8, 9, 10
Powertrain Control Module C2 WT At Powertrain Control Module 8, 9, 10, 13, 14
Powertrain Control Module C3 GY At Powertrain Control Module 31
Radiator Fan Motor BK Right Front Side of Engine
Compartment
28
Radiator Fan Relay BK Left Front Side of Engine
Compartment
29
Radio C1 GY Rear of Radio N/S
Radio C2 Rear of Radio N/S
Radio C3 Rear of Radio N/S
Radio Choke GY Center of Instrument Panel N/S
Rear Map/Reading Lamp BK Overhead Console N/S
Rear Power Outlet RD Right Rear Quarter Panel 44, 45, 48
Rear Power Window Switch WT Center Console 36, 40
Rear Wheel Speed Sensor BK On Rear Axle N/S
Rear Window Defogger BK At Rear Window 46
Rear Wiper Motor BK In Tailgate 46
Red Brake Warning Indicator Switch
(LHD)
GY Left Rear Side of Engine
Compartment
31
Red Brake Warning Indicator Switch
(RHD)
GY Right Rear Side of Engine
Compartment
26
Right Curtain Airbag YL Right Mid B-Pillar 34, 39
Right Cylinder Lock Switch (Except
Base)
LG In Right Front Door 41
Right Door Lock Switch (Except
Base)
BK In Right Front Door 41
Right Fog Lamp BK Right Side of Bumper N/S
Right Front Door Ajar Switch (Base) BK In Right Front Door N/S
Right Front Door Lock Motor/Ajar
BK In Right Front Door 41
Right Front Door Speaker BK In Right Front Door 41
Right Front Impact Sensor BK Right Front Side of Engine
Compartment
28
Right Front Park/Turn Signal Lamp BK At Lamp N/S
Right Front Power Window Motor LG In Right Front Door 41
Right Front Wheel Speed Sensor BK Right Rear Lower Side of
Engine Compartment
25
Right Headlamp (BUX) Right Front Side of Engine
Compartment
N/S
Right Headlamp (Except BUX) DB Right Front Side of Engine
Compartment
N/S
Right Heated Seat Assembly LG At Right Seat N/S
Right Heated Seat Switch BK At Right Seat N/S
Right Instrument Panel Lamp BK Right Side of Instrument
Panel
N/S
Right Instrument Panel Speaker WT Right Side of Instrument
Panel
33, 37
Right Leveling Motor (BUX) BK At Right Headlamp N/S
Right Position Lamp (BUX) BK Right Front Corner of Vehicle N/S
Right Power Mirror WT In Right Front Door 41
Right Power Seat Motors BK At Right Seat N/S
Right Power Seat Switch GN At Right Seat N/S
Right Rear Door Ajar Switch (Base) BK In Right Rear Door N/S
Right Rear Door Lock Motor/Ajar
BK In Right Rear Door 42
Right Rear Door Speaker At Speaker 42
Right Rear Power Window Motor LG In Right Rear Door 42
Right Remote Radio Switch BK On Steering Wheel N/S
Right Side Impact Airbag Control
Module (RSIACM)
YL Lower Right B-Pillar 34, 39
Right Side Marker Lamp BK Right Front Fender N/S
Right Side Repeater Lamp (BUX) BK Right Front Fender N/S
Right Speed Control Switch WT On Steering Wheel N/S
Right Tail/Stop Lamp BK Right Rear Quarter Panel 45
Right Visor/Vanity Lamp WT On Visor N/S
Sentry Key Immobilizer Module BK Under Left Side of
Instrument Panel
N/S
Shifter Assembly WT Center Console 36, 40
Siren (BUX) Right Front Side of Engine
Compartment
28
Speed Control Servo BK Right Rear Side of Engine
Compartment
27
Sunroof Motor LG Overhead Console N/S
Sunroof Switch BK Overhead Console N/S
Tailgate Cylinder Lock Switch LG In Tailgate 46
Tailgate Flip-Up Ajar Switch GY In Tailgate 46
Tailgate Lock Motor/Ajar Switch BK In Tailgate 46
Throttle Position Sensor WT On Throttle Body 1
Trailer Tow Brake Lamp Relay Right Quarter Panel 47
Trailer Tow Circuit Breaker Right Quarter Panel N/S
Trailer Tow Connector BK At Trailer Hitch 47, 48
Trailer Tow Right Turn Relay Right Quarter Panel 47
Trailer Tow Relay Right Quarter Panel 47
Trailer Tow Left Turn Relay Right Quarter Panel 47
Transfer Case Position Sensor BK Rear Side of Transmission 5, 7, 11, 12, 22
Transmission Control Module (3.7L)
(LHD)
BK Right Rear Side of Engine
Compartment
8, 9
Transmission Control Module (3.7L)
(RHD)
BK Left Rear Side of Engine
Compartment
10
Transmission Solenoid/TRS
Assembly (3.7L)
GY Left Side of Transmission 5
Under Hood Lamp BK Underside of Hood 24
Washer Fluid Level Switch LG At Washer Fluid Reservoir 28
Water In Fuel Sensor (Diesel) Left Rear Side of Engine
Compartment
19
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Left Side of Engine Compartment 8, 9, 10, 14, 19
G101 (2.4L) Left Side of Engine Compartment 11
G102 (LHD) Right Rear Side of Engine Compartment 9
G102 (RHD) Left Rear Side of Engine Compartment 10
G103 (3.7L) Right Front Side of Engine 4
G103 (Diesel) Right Front Side of Engine 20
G104 Near Engine Control Module C2 19
G105 Left Side of Engine Compartment N/S
G106 Left Side of Engine Compartment N/S
G110 Left Side of Engine Compartment 30
G111 Left Front Side of Engine Compartment 29
G112 Left Front Side of Engine Compartment 29
G200 Near Body Control Module N/S
GROUND NUMBER LOCATION FIG.
G201 Under Center Console 33, 37
G202 Left Kick Panel (Black Connector) N/S
G203 Under Center of Instrument Panel N/S
G300 Left Front Seat 35
G301 Under Center Console N/S
G302 Right Front Seat 39
G310 Right Quarter Panel 44, 45
G311 Left Quarter Panel 43
G312 Left Quarter Panel N/S
G320 At Fuel Tank N/S
SPLICES
SPLICE NUMBER LOCATION FIG.
S101 Near T/O to Power Distribution Center N/S
S106 Near T/O for G112 N/S
S107 (Diesel) In T/O for C100 32
S108 Near T/O for C106 29
S109 In Trough Near T/O for Radiator Fan Relay N/S
S111 In Trough Near T/O for Radiator Fan Relay N/S
S113 (LHD) In T/O for C100 32
S114 In T/O for C100 N/S
S115 Near T/O for Engine Control Module N/S
S118 In T/O for C100 32
S122 In T/O for Controller Antilock Brake 30
S123 In Trough, Front of Engine Compartment N/S
S124 In T/O for Junction Block C3 N/S
S130 Near T/O for Left Headlamp N/S
S131 In T/O for Right Headlamp N/S
S140 Near T/O for Left Front Park/Turn Signal Lamp N/S
S141 Near T/O for Left Fog Lamp N/S
S142 Near T/O for Left Front Park/Turn Signal Lamp N/S
S143 Near T/O for Right Front Park/Turn Signal Lamp N/S
S144 Near T/O for Left Fog Lamp N/S
S151 (2.4L) Near T/O for C110 11, 12
S151 (3.7L) In Trough Near T/O for Fuel Injector No.3 1
S151 (Diesel) In Trough Near T/O for Accelerator Pedal Position Sensor 19
S152 In Trough Near T/O for Fuel Injector No.4 2
S153 (2.4L) Near T/O for Coil Rail 11, 12
S153 (3.7L) Near T/O for Idle Air Control Motor 1
S153 (Diesel) In Trough Near T/O for Generator 20, 23
S154 Near T/O for Engine Starter Motor 2, 4, 20
S155 Near T/O for Knock Sensor 1
S156 (2.4L) In Trough Near T/O for C112 13, 14
S156 (3.7L) Near T/O for Powertrain Control Module C1 8
S156 (Diesel) Near T/O for A/C Compressor Clutch 20
S157 Near T/O for Oxygen Sensor 2/2 Downstream N/S
S158 In Trough Near T/O for C112 8
S159 Near T/O for Knock Sensor 1, 8
S160 In T/O for C104 10
S161 Near T/O for Oxygen Sensor 1/2 Downstream 5, 7
S163 In T/O for Transmission Control Module 10
S164 In Trough on Right Rear Side of Engine Compartment 10
S165 In Trough on Right Rear Side of Engine Compartment 10
S167 In T/O for Transmission Control Module 10
S168 Near T/O for Fuel Injector No.6 2
S169 (2.4L) Near T/O for C101 11
S169 (3.7L) Near T/O for Oxygen Sensor 1/1 Upstream 1, 3
S169 (Diesel) Near T/O for Generator 20
S170 Near T/O for C103 8, 13, 16
S175 In Trough on Top of Engine 22, 23
S177 In Trough Near T/O for G100 19
S178 Near T/O for Oxygen Sensor 2/2 Downstream 6
S181 In Trough Near T/O for G100 19
S184 Near T/O for Powertrain Control Module C1 8
S200 Near T/O for C201 N/S
S201 Near T/O for Left Instrument Panel Lamp N/S
S204 Near T/O for Data Link Connector N/S
S206 Near T/O for Multifunction Switch C2 N/S
S210 Near T/O for Left Instrument Panel Lamp N/S
S212 Near T/O for Diagnostic Junction Port N/S
S213 Near T/O for Diagnostic Junction Port N/S
S214 Near T/O for Airbag Control Module C1 (ORC C1) N/S
S216 In T/O for Instrument Cluster N/S
S221 Near T/O for Left Speed Control Switch N/S
S222 Near T/O for Right Speed Control Switch N/S
S223 Near T/O for Left Remote Radio Switch N/S
S224 Near T/O for Right Remote Radio Switch N/S
S300 (LHD) Near T/O for C309 43
S300 (RHD) Near T/O for C310 45
S301 In T/O For Radio C1 N/S
S302 Near T/O for Rear Power Outlet 45
S303 Near T/O for Shifter Assembly 36
S304 Near T/O for License Lamp 45
S306 (LHD) Near T/O for G315 44
S306 (RHD) In T/O for C319 45
S308 (RHD) Near T/O for Rear Power Outlet 45
S310 Near T/O for C310 N/S
S313 In T/O for Trailer Tow Relays 47
S318 (RHD) In T/O for C201 39
S319 (RHD) Near T/O for Left Instrument Panel 37
S322 Near T/O for Left Instrument Panel 33, 37
S323 (LHD) Near T/O for Left Instrument Panel 33
S323 (RHD) Near T/O for Right Instrument Panel Speaker 37
S324 (Premium) Near T/O for Right Instrument Panel Speaker 33, 37
S325 Near T/O for C201 33, 37
S326 Near T/O for Heated Seat Module N/S
S327 Near T/O for Left Heated Seat Assembly N/S
S328 In T/O for Heated Seat Module N/S
S329 Near T/O for Right Heated Seat Switch N/S
S330 Near T/O for Heated Seat Module N/S
S331 Near T/O for Shifter Assembly N/S
S333 (RHD) Near T/O for C307 38
S334 Near T/O for G302 34, 39
S336 (LHD) Near T/O for Left Instrument Panel 33
S336 (RHD) Near T/O for Right Instrument Panel Speaker 37
S338 Near T/O for C201 33, 37
S342 (Base) Near T/O for Right Instrument Panel Speaker 33
S344 Near T/O for Right Instrument Panel Speaker 33
S347 Near T/O for Right Tail/Stop Lamp 45
S348 Near T/O for Right Tail/Stop Lamp 45
S351 In T/O for Rear Window Defogger 46
S352 In T/O for Rear Window Defogger N/S
S356 Near T/O for Center High Mounted Stop Lamp N/S
S360 Near T/O for Left Power Mirror 41
S361 Near T/O for Left Power Mirror 41
S362 Near T/O for Power Mirror Switch 41
S363 Near T/O for Left Front Door Speaker N/S
S364 Near T/O for Left Front Door Speaker N/S
S370 Near T/O for Right Power Mirror 41
S371 Near T/O for Right Door Lock Switch 41
S372 Near T/O for Right Front Door Speaker N/S
S373 Near T/O for Right Front Door Speaker N/S
S380 Near T/O for Rear Wiper Motor N/S
S381 Near T/O for Tailgate Cylinder Lock Switch N/S
S382 Near T/O for License Lamp N/S
S390 Near T/O for Intrusion Sensor N/S
S391 Near T/O for Left Visor/Vanity Lamp N/S
S392 Near T/O for Left Visor/Vanity Lamp N/S
S393 Near T/O for Intrusion Sensor N/S
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Fig. 16 RIGHT REAR ENGINE COMPARTMENT, 2.4L
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Fig. 21 FRONT DIESEL ENGINE
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Fig. 23 TOP DIESEL ENGINE
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Fig. 25 RIGHT SIDE ENGINE COMPARTMENT
Fig. 26 RIGHT SIDE ENGINE COMPARTMENT, RHD
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Fig. 34 RIGHT FRONT BODY, LHD
Fig. 35 LEFT FRONT BODY, LHD
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Fig. 38 LEFT FRONT BODY, RHD
Fig. 39 RIGHT FRONT BODY, RHD
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Fig. 47 TRAILER TOW CONNECTORS
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ENGINE - 3.7L
TABLE OF CONTENTS
page page
ENGINE - 3.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . . 4
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . . 4
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 6
DIAGNOSIS - LUBRICATION . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE . . . . . . . . . . . . . . 8
COMBUSTION PRESSURE LEAKAGE. . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION. . . . . . . . . 9
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . . . . . . 9
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS
3.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 15
AIR CLEANER ELEMENT
REMOVAL - 3.7L . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION - 3.7L . . . . . . . . . . . . . . . . . . . . 19
CYLINDER HEAD - LEFT
DESCRIPTION - VALVE GUIDES . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . 19
HEAD GASKET . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
CAMSHAFT(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
CYLINDER HEAD COVER(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
STANDARD PROCEDURE - REFACING . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
ROCKER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
VALVE GUIDE SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
CYLINDER HEAD - RIGHT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD . . . . . . . . 30
DESCRIPTION - VALVE GUIDES . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . 30
HEAD GASKET . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
CAMSHAFT(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
INTAKE/EXHAUST VALVES & SEATS
STANDARD PROCEDURE - REFACING . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
ROCKER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
VALVE GUIDE SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
KJ ENGINE - 3. 7L 9 - 1
ENGINE BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
STANDARD PROCEDURE - CYLINDER BORE
HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING - FITTING . . . . . . . . . . . . . . . 40
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE
MAIN BEARING - FITTING . . . . . . . . . . . . . . . 45
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49
STANDARD PROCEDURE
CONNECTING ROD BEARING - FITTING . . . 49
STANDARD PROCEDURE - PISTON
FITTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
STRUCTURAL COVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 55
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . 61
OIL
STANDARD PROCEDURE - ENGINE OIL . . . . . 61
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63
OIL PAN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 63
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 68
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS . . . . . . . . . . . . . . . . . . . . . 68
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 69
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
VALVE TIMING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR . . . . . . . 71
SERVICE PROCEDURES . . . . . . . . . . . . . . . 72
BALANCE SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76
IDLER SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
TIMING BELT/CHAIN AND SPROCKET(S
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
9 - 2 ENGINE - 3. 7L KJ
ENGINE - 3.7L
DESCRIPTION
The 3.7 l i ter (226 CI D) si x-cyl i nder engi ne i s an
90 si ngl e overhead camshaft engi ne. The cast i ron
cyl i nder bl ock i s made up of two di fferent compo-
nents; the fi rst component i s the cyl i nder bore and
upper bl ock, the second component i s the bedpl ate
that compri ses the l ower porti on of the cyl i nder bl ock
and houses the l ower hal f of the crankshaft mai n
beari ngs. The cyl i nders are numbered from front to
rear wi th the l eft bank bei ng numbered 1,3,and 5
and the ri ght bank bei ng numbered 2,4, and 6. The
fi ri ng order i s 165432. The engi ne seri al num-
ber i s l ocated at the ri ght front si de of the engi ne
bl ock
3.7 L ENGINE
KJ ENGINE - 3. 7L 9 - 3
DIAGNOSIS - INTRODUCTION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
(Refer to 9 - ENGI NE - DI AGNOSI S AND TEST-
I NG)PERFORMANCE and (Refer to 9 - ENGI NE -
DI AGNOSI S AND TESTI NG)MECHANI CAL for
possi bl e causes and correcti ons of mal functi ons.
(Refer to 14 - FUEL SYSTEM/FUEL DELI VERY -
DI AGNOSI S AND TESTI NG) and (Refer to 14 -
FUEL SYSTEM/FUEL I NJECTI ON - DI AGNOSI S
AND TESTI NG) for the fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
Cyl i nder Compressi on Pressure Test (Refer to 9 -
ENGI NE - DI AGNOSI S AND TESTI NG).
Cyl i nder Combusti on Pressure Leakage Test
(Refer to 9 - ENGI NE - DI AGNOSI S AND TEST-
I NG).
Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s
(Refer to 9 - ENGI NE/CYLI NDER HEAD - DI AGNO-
SI S AND TESTI NG).
I ntake Mani fol d Leakage Di agnosi s (Refer to 9 -
ENGI NE/MANI FOLDS/I NTAKE MANI FOLD -
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.
2. Corroded or loose battery
connections.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty starter. 3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).
4. Faulty coil or control unit. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
5. Incorrect spark plug gap. 5. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
6. Incorrect right bank cam timing. 6. Refer to engine timing in this
section.
7. Dirt or water in fuel system. 7. Clean system and replace fuel
filter.
8.Faulty fuel pump, relay or wiring. 8.Repair or replace as necessary.
9. Faulty cam or crank sensor 9. Refer to Ignition system.
ENGINE STALLS OR ROUGH IDLE 1. Vacuum leak. 1. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
2. Faulty crank position sensor 2. Replace crank position sensor.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
COIL - REMOVAL).
9 - 4 ENGINE - 3. 7L KJ
ENGINE - 3.7L (Continued)
5. Incorrect cam timing. 5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD
PROCEDURE).
1. ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark
plugs.
1. (Refer to 8 - ELECTRICAL/
- CLEANING).
filter.
3. Faulty fuel pump. 3. (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL PUMP -
4. Blown cylinder head gasket. 4. Replace cylinder head gasket.
5. Low compression. 5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING), repair
as necessary.
6. Burned, warped or pitted valves. 6. Replace as necessary.
7. Plugged or restricted exhaust
system.
necessary.
COIL - REMOVAL).
9. Incorrect cam timing. 9. Refer to Engine TIming in this
section.
1. ENGINE MISSES ON
ACCELERATION
1. Spark plugs dirty or incorrectly
gapped.
- CLEANING).
2. Dirt in fuel system. 2. Clean fuel system.
3. Burned, warped or pitted valves. 3. Replcae as necessary.
COIL - REMOVAL).
1. ENGINE MISSES AT HIGH
SPEED
1. Spark plugs dirty or incorrectly
gapped.
- CLEANING).
COIL - REMOVAL).
filter.
KJ ENGINE - 3. 7L 9 - 5
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in
crankcase.
1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
SPECIFICATIONS).
2. Thin or diluted oil. 2. Change oil and filter.
3. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
4. Dirt in lash adjusters. 4. Clean or replace as necessary.
5. Worn rocker arms. 5. Replace as necessary.
7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE).
8. Excessive runout of valve seats
on valve faces.
8. Service valves and valve seats.
(Refer to 9 - ENGINE/CYLINDER
& SEATS - STANDARD
PROCEDURE).
ENGINE VIBRATION 1. Counter Balance Shaft not timed
properly
1. Refer to Engine Timing in this
section
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
SPECIFICATIONS).
wear.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Connecting rod journal
out-of-round.
5. Service or replace crankshaft.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
SPECIFICATIONS).
wear.
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque
converter.
7. Tighten to correct torque
9 - 6 ENGINE - 3. 7L KJ
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.
(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary (Refer to 9
- ENGINE/ENGINE BLOCK/
REMOVAL).
3. Crankshaft seal flange.
Scratched, nicked or grooved.
3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
5. Timing chain cover seal
damaged.
5. Re-seal timing cover.
6. Scratched or damaged vibration
damper hub.
6. Polish or replace damper.
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit (Refer to 9
- ENGINE/LUBRICATION/OIL
REMOVAL).
3. Low oil pressure. 3. Check oil pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER
- REMOVAL).
5. Worn oil pump. 5. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
8. Oil pump relief valve stuck. 8. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
9. Oil pump suction tube loose,
damaged or clogged.
9. Replace as necessary.
KJ ENGINE - 3. 7L 9 - 7
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING
1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
3. Incorrect ring size installed. 3. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
4. Worn valve guides. 4. Ream guides and replace valves
(Refer to 9 - ENGINE/CYLINDER
& SEATS - STANDARD
PROCEDURE).
5. Leaking valve guide seals. 5. Replace valve guide seals.
COMPRESSION PRESSURE
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs.
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sabl e the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELI VERY - DESCRI PTI ON).
(5) Remove the ASD rel ay (Refer to 8 - ELECTRI -
CAL/I GNI TI ON CONTROL/AUTO SHUT DOWN
RELAY - REMOVAL).
(6) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(7) Record the compressi on pressure on the 3rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
(8) (Refer to 9 - ENGI NE - SPECI FI CATI ONS) for
the correct engi ne compressi on pressures.
COMBUSTION PRESSURE LEAKAGE
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
Leaks between adjacent cyl i nders or i nto water
jacket.
Any causes for combusti on/compressi on pressure
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(3) Remove the spark pl ugs.
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner.
(6) Cal i brate the tester accordi ng to the manufac-
turers i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturers i nstructi ons.
Set pi ston of cyl i nder to be tested at TDC compres-
si on,Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to CYLI NDER COMBUSTI ON PRESSURE
LEAKAGE DI AGNOSI S CHART .
9 - 8 ENGINE - 3. 7L KJ
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Remove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Remove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engi ne gasket seal i ng, proper surface
preparati on must be performed, especi al l y wi th the
use of al umi num engi ne components and mul ti -l ayer
steel cyl i nder head gaskets.
Never use the fol l owi ng to cl ean gasket surfaces:
Metal scraper
Abrasi ve pad or paper to cl ean cyl i nder bl ock
and head
Hi gh speed power tool wi th an abrasi ve pad or a
wi re brush (Fi g. 1)
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Onl y use the fol l owi ng for cl eani ng gasket surfaces:
Sol vent or a commerci al l y avai l abl e gasket
remover
Pl asti c or wood scraper (Fi g. 1)
Dri l l motor wi th 3M Rol oc Bri stl e Di sc (whi te
or yel l ow) (Fi g. 1)
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.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
Dri l l i ng out worn or damaged threads.
Fig. 1 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOC BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
KJ ENGINE - 3. 7L 9 - 9
Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Usi ng a bl unt tool such as a dri ft and a hammer,
stri ke the bottom edge of the cup pl ug. Wi th the cup
pl ug rotated, grasp fi rml y wi th pl i ers or other sui t-
abl e tool and remove pl ug (Fi g. 2).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughl y cl ean i nsi de of cup pl ug hol e i n cyl i n-
der bl ock or head. Be sure to remove ol d seal er.
Li ghtl y coat i nsi de of cup pl ug hol e wi th Mopar
Stud and Beari ng Mount. Make certai n the new pl ug
i s cl eaned of al l oi l or grease. Usi ng proper dri ve
pl ug, dri ve pl ug i nto hol e so that the sharp edge of
the pl ug i s at l east 0.5 mm (0.020 i n.) i nsi de the
l ead-i n chamfer.
I t i s not necessary to wai t for curi ng of the seal ant.
The cool i ng system can be refi l l ed and the vehi cl e
pl aced i n servi ce i mmedi atel y.
REMOVAL
(2) Remove hood. Mark hood hi nge l ocati on for
rei nstal l ati on.
(3) Remove ai r cl eaner assembl y.
(4) Remove radi ator core support bracket.
(5) Remove fan shroud wi th el ectri c fan assembl y.
(6) Remove mechani cal cool i ng fan.
(7) Remove dri ve bel t.
NOTE: It is NOT necessary to discharge the A/C
system to remove the engine.
(8) Remove A/C compressor and secure away from
engi ne wi th l i nes attached.
(9) Remove generator and secure away from
engi ne.
NOTE: Do NOT remove the phenolic pulley from the
P/S pump. It is not required for P/S pump removal.
(10) Remove power steeri ng pump wi th l i nes
attached and secure away from engi ne.
(11) Drai n cool i ng system.
(12) Remove cool ant bottl e.
(13) Di sconnect the heater hoses from the engi ne.
(14) Di sconnect heater hoses from heater core and
remove hose assembl y.
(15) Di sconnect throttl e and speed control cabl es.
(16) Remove upper radi ator hose from engi ne.
(17) Remove l ower radi ator hose from engi ne.
(18) Di sconnect the engi ne to body ground straps
at the l eft si de of cowl .
(19) Di sconnect the engi ne wi ri ng harness at the
fol l owi ng poi nts:
I ntake ai r temperature (I AT) sensor
Fuel I njectors
Throttl e Posi ti on (TPS) Swi tch
I dl e Ai r Control (I AC) Motor
Engi ne Oi l Pressure Swi tch
Engi ne Cool ant Temperature (ECT) Sensor
Mani fol d Absol ute Pressure MAP) Sensor
Camshaft Posi ti on (CMP) Sensor
Coi l Over Pl ugs
(20) Remove coi l over pl ugs.
(21) Rel ease fuel rai l pressure.
(22) Remove fuel rai l and secure away from
engi ne.
NOTE: It is not necessary to release the quick con-
nect fitting from the fuel supply line for engine
removal.
(23) Remove the PCV hose.
(24) Remove the breather hoses.
(25) Remove the vacuum hose for the power brake
booster.
(26) Di sconnect knock sensors.
(27) Remove engi ne oi l di psti ck tube.
(28) Remove i ntake mani fol d.
(29) I nstal l engi ne l i ft pl ate.
Fig. 2 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 10 ENGINE - 3. 7L KJ
NOTE: Recheck bolt torque for engine lift plate
before removing engine.
(30) Secure the l eft and ri ght engi ne wi ri ng har-
nesses away from engi ne.
(32) Di sconnect oxygen sensor wi ri ng.
(33) Di sconnect crankshaft posti on sensor.
(34) Di sconnect the engi ne bl ock heater power
cabl e, i f equi pped.
(35) Di sconnect the front propshaft at the front
di fferenti al and secure out of way.
NOTE: It is necessary to disconnect the front prop-
shaft for access to the starter and left side exhaust
flange.
(36) Remove the starter.
(37) Remove the ground straps from the l eft and
ri ght si de of the bl ock.
(38) Di sconnect the ri ght and l eft exhaust pi pes at
the mani fol ds and from the crossover, and remove
from the vehi cl e.
NOTE: The exhaust clamps at the manifolds cannot
be reused. New clamps must be used or leaks may
occur.
NOTE: For manual transmission vehicles, the trans-
mission must be removed from the vehicle, before
the engine can be removed. The manual transmis-
sion will contact the floorpan before the engine
clears the motor mounts, so it must be removed.
(39) Remove the structural cover.
(40) Remove torque convertor bol ts, and mark
l ocati on for reassembl y.
(41) Remove transmi ssi on bel l housi ng to engi ne
bol ts.
(42) Loosen l eft and ri ght engi ne mount thru bol ts.
NOTE: It is not necessary to completely remove
engine mount thru bolts, for engine removal.
(44) Support the transmi ssi on wi th a sui tabl e jack.
(45) Connect a sui tabl e engi ne hoi st to the engi ne
l i ft pl ate.
(46) Remove engi ne from vehi cl e.
INSTALLATION
(1) Posi ti on the engi ne i n the vehi cl e.
(2) I nstal l both l eft and ri ght si de engi ne mounts
onto engi ne.
(4) I nstal l the transmi ssi on bel l housi ng to engi ne
mounti ng bol ts. Ti ghten the bol ts to 41 Nm (30ft.
l bs.).
(5) Ti ghten the engi ne mount thru bol ts.
(6) I nstal l the torque convertor bol ts.
(7) Connect the ground straps on the l eft and ri ght
si de of the engi ne.
(8) I nstal l the starter.
(9) Connect the crankshaft posi ti on sensor.
(10) I nstal l the engi ne bl ock heater power cabl e, i f
equi pped.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(11) I nstal l the structural cover.
NOTE: New clamps must be used on exhaust man-
ifold flanges. Failure to use new clamps may result
in exhaust leaks.
(12) I nstal l the l eft and ri ght exhaust pi pes.
(13) Connect the l eft and ri ght oxygen sensors.
(15) Remove the engi ne l i ft pl ate.
(16) Connect the knock sensors.
(17) Connect the engi ne to body ground straps at
the l eft si de of the cowl .
(18) I nstal l the i ntake mani fol d.
(19) I nstal l the engi ne oi l di psti ck tube.
(20) I nstal l the power brake booster vacuum hose.
(21) I nstal l the breather hoses.
(22) I nstal l the PCV hose.
(23) I nstal l the fuel rai l .
(24) I nstal l the coi l over pl ugs.
(25) Connect the engi ne wi ri ng harness at the fol -
l owi ng poi nts:
I ntake ai r temperature (I AT) sensor
Fuel I njectors
Throttl e Posi ti on (TPS) Swi tch
Engi ne Oi l Pressure Swi tch
Engi ne Cool ant Temperature (ECT) Sensor
Mani fol d Absol ute Pressure MAP) Sensor
Camshaft Posi ti on (CMP) Sensor
Coi l Over Pl ugs
(26) Connect l ower radi ator hose.
(27) Connect upper radi ator hose.
(28) Connect throttl e and speed control cabl es.
(29) I nstal l the heater hose assembl y.
(30) I nstal l cool ant recovery bottl e.
(31) I nstal l the power steeri ng pump.
(32) I nstal l the generator.
(33) I nstal l the A/C compressor.
(34) I nstal l the dri ve bel t.
KJ ENGINE - 3. 7L 9 - 11
(35) I nstal l the mechani cal cool i ng fan.
(36) I nstal l the fan shroud wi th the el ectri c fan
assembl y.
(37) I nstal l the radi ator core support bracket.
(38) I nstal l the ai r cl eaner assembl y.
(39) Refi l l the engi ne cool i ng system.
(40) I nstal l the hood.
(41) Check and fi l l engi ne oi l .
(43) Start the engi ne and check for l eaks.
SPECIFICATIONS
TORQUE
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90
Bearing Cap Bolts 11 100
Timing Chain CoverBolts 54 40
Connecting Rod CapBolts 27 20
PLUS 90TURN
Bed PlateBolts Refer to Procedure
Crankshaft DamperBolt 175 130
Cylinder HeadBolts
M11 Bolts Refer ToProcedure
M8 Bolts - - -
Cylinder Head CoverBolts 12 105
Exhaust ManifoldBolts 25 18
Exhaust Manifold Heat
ShieldNuts
8 72
Then loosen 45
FlexplateBolts 60 45
Engine Mount Bracket to
BlockBolts
61 45
Rear Mount to
TransmissionBolts
46 34
Generator MountingBolts
M10 Bolts 54 40
M8 Bolts 28 250
Intake ManifoldBolts 12 105
Refer to Procedure
for
Tightening Sequence
Oil PanBolts 15 130
Lbs. Lbs.
Oil PanDrain Plug 34 25
Oil PumpBolts 28 250
Oil Pump CoverBolts 12 105
Oil Pickup TubeBolt and
Nut
28 250
Oil Dipstick Tube to Engine
BlockBolt 15 130
Oil Fill TubeBolts 12 105
Timing Chain GuideBolts 28 250
Timing Chain Tensioner
ArmSpecial
Pin Bolt 17 150
Hydraulic TensionerBolts 28 250
Timing Chain Primary
TensionerBolts
28 250
Timing Drive Idler Sprocket
Bolt
34 25
Thermostat HousingBolts 12 105
Water PumpBolts 54 40
3. 7L ENGINE
SPECIFICATIONS
Engine Type 90SOHC V-6 12-Valve
Displacement 3.7 Liters / 3700 cc
( Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 90.8 mm (3.40 in.)
Compression Ratio 9.1:1
Horsepower 210 BHP @ 5200 RPM
Torque 225 LB-FT @ 4200 RPM
Lead Cylinder #1 Left Bank
Firing Order 1-6-5-4-3-2
CYLINDER BLOCK
Cylinder Block Cast Iron
Bore Diameter 93.0 .0075 mm
(3.6619 0.0003 in.)
Out of Round (MAX) 0.076 mm (0.003 in.)
Taper (MAX) 0.051 mm (0.002 in.)
9 - 12 ENGINE - 3. 7L KJ
PISTONS
Material Aluminum Alloy
Diameter 92.975 mm (3.6605 in.)
Weight 367.5 grams (12.96 oz)
Ring Groove Diameter
No. 1 83.73 - 83.97 mm
(3.296 - 3.269 in.)
No. 2 82.833 - 83.033 mm
(3.261 - 3.310 in.)
No. 3 83.88 - 84.08 mm
(3.302 - 3.310 in.)
PISTON PINS
Type Floating
Clearance In Piston 0.010 - 0.019 mm
(0.0004 - 0.0008 in.)
Diameter 24.013 - 24.016 mm
(0.9454 - 0.9456 in.)
PISTON RINGS
Ring Gap
Top Compression Ring 0.37 - 0.63 mm
(0.0146 - 0.0249 in.)
Second Compression
Ring
0.37 - 0.63 mm
(0.0146 - 0.0249 in.)
Oil Control (Steel Rails) 0.25 - 0.76 mm
(0.0099 - 0.30 in.)
Side Clearance
Top Compression Ring .051 - .094 mm
(0.0020 - 0.0037 in.)
Second Compression
Ring
0.040 - 0.080 mm
(0.0016 - 0.0031 in.)
Oil Ring (Steel Ring) .019 - .229 mm
(.0007 - .0091 in.)
Ring Width
Top Compression Ring 1.472 - 1.490 mm
(0.057 - 0.058 in.)
Second Compression
Ring
1.472 - 1.490 mm
(0.057 - 0.058 in.)
Oil Ring (Steel Rails) 0.445 - 0.470 mm
(0.017 - 0.018 in.)
CONNECTING RODS
Bearing Clearance 0.010 - 0.048 mm
(0.0004 - 0.0019 in.)
Side Clearance 0.10 - 0.35 mm
(0.004 - 0.0138 in.)
Piston Pin Clearance .015 - .028 mm
(0.0006 - 0.0011 in.)
Bearing Bore Out of
Round
0.004 mm
(MAX) (0.0002 in.)
Total Weight (Less
Bearing)
612 grams (21.588
ounces)
CRANKSHAFT
Main BearingJournal
Diameter 63.488 - 63.512 mm
(2.4996 - 2.5005 in.)
Taper (MAX) 0.006 mm (0.0004 in.)
End Play 0.052 - 0.282 mm
(0.0021 - 0.0112 in.)
End Play (MAX) 0.282 mm (0.0112 in)
Connecting Rod
Journal
Diameter 57.904 - 57.896 mm
Taper (MAX) 0.006 mm (0.0002 in.)
CAMSHAFT
Bore Diameter 26.02 - 26.04 mm
(1.0245 - 1.0252 in.)
Bearing Journal Diameter 25.975 - 25.995 mm
(1.0227 - 1.0235 in.)
(0.001 - 0.0026 in.)
Bearing Clearance (MAX) 0.065 mm (0.0026 in.)
End Play .075 - .200 mm
(0.003 - 0.0079 in.)
End Play (MAX) .200 mm (0.0079 in.)
KJ ENGINE - 3. 7L 9 - 13
VALVE TIMING
Intake
Opens (ATDC) 3.6
Closes (ATDC) 247.1
Duration 243.5
Exhaust
Opens (BTDC) 232.5
Closes (ATDC) 21.2
Duration 253.70
Valve Overlap 17.6
VALVES
Face Angle 45- 45.5
Head Diameter
Intake 48.52 - 48.78 mm
(1.9103 - 1.9205 in.)
Exhaust 36.87 - 37.13 mm
1.4516 - 1.4618 in.)
Length (Overall)
Intake 113.45 - 114.21 mm
(4.4666 - 4.4965)
Exhaust 114.92 - 115.68 mm
(4.5244 - 4.5543 in.)
Stem Diameter
Intake 6.931 - 6.957 mm
(0.2729 - 0.2739 in.)
Exhaust 6.902 - 6.928 mm
(0.2717 - 0.2728 in.)
Stem - to - Guide
Clearance
Intake 0.018 - 0.069 mm
(0.0008 - 0.0028 in.)
Exhaust 0.047 - 0.098 mm
(0.0019 - 0.0039 in.)
Max. Allowable Stem -
to -
Guide Clearance
(Rocking
Method)
Intake 0.069 mm (0.0028 in.)
Exhaust 0.098 mm (0.0039 in.)
Valve Lift (Zero Lash)
Intake 12.00 mm (0.472 in.)
Exhaust 10.90 mm (0.4292 in.)
VALVE SPRING
Free Lenght (Approx)
Intake and Exhaust 48.92 mm (1.9260 in.)
Spring Force (Valve
Closed)
Intake and Exhaust 361.0 - 399.0 N @ 40.12
mm
(81.15 - 89.70 lbs. @
1.5795 in.)
Spring Force (Valve
Open)
Intake and Exhaust 984.0 - 1076.0 N @
28.12 mm
221.2 - 241.9 lbs. @
1.107 in.)
Number of Coils
Intake and Exhaust 7.30
Wire Diameter
Intake and Exhaust 4.77 3.80mm
(0.1878 - 0.1496 in.)
Installed Height (Spring
Seat to Bottom of
Retainer)
Nominal
Intake 41.11 mm (1.619 in.)
Exhaust 41.13 mm (1.619 in.)
CYLINDER HEAD
Gasket Thickness
(Compressed) 0.7 mm (0.0276 in.)
Valve Seat Angle 44.5- 45.0
Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
Valve Seat Width
Intake 1.75 - 2.36 mm
(0.0698 - 0.0928 in.)
Exhaust 1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
Guide Bore Diameter
(Std.)
6.975 - 7.00 mm
(0.2747 - 0.2756 in.)
9 - 14 ENGINE - 3. 7L KJ
Cylinder Head Warpage
(Flatness) 0.0508 mm (0.002 in.)
OIL PUMP
Clearance Over
Rotors/End Face(MAX)
0.035 - 0.095 mm
(0.0014 - 0.0038 in.)
Cover Out - of -Flat
(MAX)
0.025 mm (0.001 in.)
Inner and Outer Rotor
Thickness 12.02 mm (0.4731 in.)
Outer Rotor Diameter
(MAX)
.235 mm (.0093 in.)
Outer Rotor Diameter
(MIN)
85.925 mm (0.400 in.)
Tip Clearance Between
Rotors
(MAX) 0.150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
(MIN)*
25 kPa (4 psi)
@ 3000 rpm 170 - 758 kPa (25 - 110
psi)
* CAUTION: If pressure is zero at curb idle, DO
NOT run engine at 3000 rpm.
SPECIAL TOOLS
3. 7L ENGINE
Spanner Wrench 6958
Adapter Pins 8346
Front Crankshaft Seal Remover 8511
Front Crankshaft Seal Installer 8348
Handle C-4171
KJ ENGINE - 3. 7L 9 - 15
Rear Crankshaft Seal Installer 8349
Rear Crankshaft Seal Remover 8506
Connecting Rod Guides 8507
Crankshaft Damper Installer 8512
Puller 1026
Crankshaft Damper Removal Insert 8513
Chain Tensioner Wedge 8379
Chain Tensioner Pins 8514
9 - 16 ENGINE - 3. 7L KJ
VALVE SPRING COMPRESSOR 8426
ENGINE LIFTING FIXTURE 8427
CAMSHAFT HOLDER 8428
HOLDER SECONDARY CAMSHAFT CHAIN 8429
Remover, Rocker Arm 8516
Idler Shaft Remover 8517
Valve Spring Compressor Adapters 8519
KJ ENGINE - 3. 7L 9 - 17
INSTALLER - REMOVER - COUNTER BALANCE
SHAFT 8641
Valve Spring Tester C-647
Dial Indicator C-3339
Valve Spring Compressor C-3422-B
Bore Size Indicator C-119
Oil Pressure Gauge C-3292
Piston Ring Compressor C-385
Pressure Tester Kit 7700
BlocChekKit C-3685A
9 - 18 ENGINE - 3. 7L KJ
AIR CLEANER ELEMENT
REMOVAL - 3. 7L
Housi ng removal i s not necessary for el ement (fi l -
ter) repl acement.
(1) Pry up 2 spri ng cl i ps (Fi g. 3) from front of
housi ng cover (spri ng cl i ps retai n cover to housi ng).
(2) Rel ease housi ng cover from 4 l ocati ng tabs
l ocated on rear of housi ng, and remove cover.
(3) Remove ai r cl eaner el ement (fi l ter) from hous-
i ng.
(4) Cl ean i nsi de of housi ng before repl aci ng el e-
ment.
(1) I nstal l el ement i nto housi ng.
(2) Posi ti on housi ng cover i nto housi ng l ocati ng
tabs.
(3) Pry up spri ng cl i ps and l ock cover to housi ng.
I f any ai r fi l ter, ai r resonator, ai r i ntake tubes or
ai r fi l ter housi ng cl amps had been l oosened or
removed, ti ghten them to 5 Nm (40 i n. l bs.) torque.
CYLINDER HEAD - LEFT
DESCRIPTION - VALVE GUIDES
The val ve gui des are made of powered metal and
are pressed i nto the cyl i nder head. The gui des are
not repl aceabl e or servi ceabl e, and val ve gui de ream-
i ng i s not recommended. I f the gui des are worn
beyond acceptabl e l i mi ts, repl ace the cyl i nder heads.
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-l i ke noi se may be produced from several
i tems. Check the fol l owi ng i tems.
(1) Engi ne oi l l evel too hi gh or too l ow. Thi s may
cause aerated oi l to enter the adjusters and cause
them to be spongy.
(2) I nsuffi ci ent runni ng ti me after rebui l di ng cyl i n-
der head. Low speed runni ng up to 1 hour may be
requi red.
(3) Turn engi ne off and l et set for a few mi nutes
before restarti ng. Repeat thi s several ti mes after
engi ne has reached normal operati ng temperature.
(4) Low oi l pressure.
(5) The oi l restri ctor i n cyl i nder head gasket or the
oi l passage to the cyl i nder head i s pl ugged wi th
debri s.
(6) Ai r i ngested i nto oi l due to broken or cracked
oi l pump pi ck up.
(7) Worn val ve gui des.
(8) Rocker arm ears contacti ng val ve spri ng
retai ner.
(9) Rocker arm l oose, adjuster stuck or at maxi -
mum extensi on and sti l l l eaves l ash i n the system.
(10) Oi l l eak or excessi ve cam bore wear i n cyl i n-
der head.
(11) Faul ty l ash adjuster.
Check l ash adjusters for spongi ness whi l e
i nstal l ed i n cyl i nder head and cam on camshaft at
base ci rcl e. Depress part of rocker arm over adjuster.
Normal adjusters shoul d feel very fi rm. Spongy
adjusters can be bottomed out easi l y.
Remove suspected l ash adjusters, and repl ace.
Before i nstal l ati on, make sure adjusters are at
l east parti al l y ful l of oi l . Thi s can be veri fi ed by l i ttl e
or no pl unger travel when l ash adjuster i s depressed.
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET
A cyl i nder head gasket l eak can be l ocated between
adjacent cyl i nders or between a cyl i nder and the
adjacent water jacket.
Fig. 3 AIR CLEANER ELEMENT - 3.7L
1 - AIR INTAKE HOSE
2 - HOSE CLAMP
3 - COVER
4 - CLIPS (2)
KJ ENGINE - 3. 7L 9 - 19
Possi bl e i ndi cati ons of the cyl i nder head gasket
l eaki ng between adjacent cyl i nders are:
Loss of engi ne power
Engi ne mi sfi ri ng
Poor fuel economy
l eaki ng between a cyl i nder and an adjacent water
jacket are:
Engi ne overheati ng
Loss of cool ant
Excessi ve steam (whi te smoke) emi tti ng from
exhaust
Cool ant foami ng
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders, fol l ow the proce-
dures i n Cyl i nder Compressi on Pressure Test (Refer
to 9 - ENGI NE - DI AGNOSI S AND TESTI NG). An
engi ne cyl i nder head gasket l eaki ng between adja-
cent cyl i nders wi l l resul t i n approxi matel y a 5070%
reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
Wi th the engi ne cool , remove the cool ant pressure
cap. Start the engi ne and al l ow i t to warm up unti l
thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
I nstal l Cool i ng System Tester 7700 or equi val ent to
pressure cap neck. Start the engi ne and observe the
testers pressure gauge. I f gauge pul sates wi th every
power stroke of a cyl i nder a combusti on pressure
l eak i s evi dent.
CHEMICAL TEST METHOD
Combusti on l eaks i nto the cool i ng system can al so
be checked by usi ng Bl oc-Chek Ki t C-3685-A or
equi val ent. Perform test fol l owi ng the procedures
suppl i ed wi th the tool ki t.
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(2) Rai se the vehi cl e on a hoi st.
(3) Di sconnect the exhaust pi pe at the l eft si de
exhaust mani fol d.
(4) Drai n the engi ne cool ant. Refer to COOLI NG
SYSTEM.
(6) Remove the i ntake mani fol d. Refer to proce-
dure i n thi s secti on.
(7) Remove the cyl i nder head cover. Refer to proce-
dure i n thi s secti on.
(8) Remove the fan shroud and fan bl ade assembl y.
Refer to COOLI NG SYSTEM.
(9) Remove accessory dri ve bel t. Refer to COOL-
I NG SYSTEM.
(10) Remove the power steeri ng pump and set
asi de.
(11) Rotate the crankshaft unti l the damper ti mi ng
mark i s al i gned wi th TDC i ndi cator mark (Fi g. 4).
(12) Veri fy the V6 mark on the camshaft sprocket
i s at the 12 ocl ock posi ti on (Fi g. 5). Rotate the crank-
shaft one turn i f necessary.
(13) Remove the crankshaft damper. Refer to Pro-
cedure.
(14) Remove the ti mi ng chai n cover. Refer to pro-
cedure.
Fig. 4 Engine Top Dead Center
2 - CRANKSHAFT TIMING MARKS
9 - 20 ENGINE - 3. 7L KJ
CYLINDER HEAD - LEFT (Continued)
(15) Lock the secondary ti mi ng chai ns to the i dl er
sprocket usi ng Speci al Tool 8429 Ti mi ng Chai n Hol d-
i ng Fi xture (Fi g. 6).
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(16) Mark the secondary ti mi ng chai n, one l i nk on
each si de of the V6 mark on the camshaft dri ve gear.
(17) Remove the l eft si de secondary chai n ten-
si oner. Refer to Ti mi ng Chai n and Sprockets.
(18) Remove the cyl i nder head access pl ug (Fi g. 7).
(19) Remove the l eft si de secondary chai n gui de.
Refer to Ti mi ng Chai n and Sprockets.
(20) Remove the retai ni ng bol t and the camshaft
dri ve gear.
CAUTION: Do not allow the engine to rotate. Severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
NOTE: The cylinder head is attached to the cylinder
block with twelve bolts.
Fig. 5 Camshaft Sprocket V6 Marks
1 - LEFT CYLINDER HEAD
Fig. 6 Using Special Tool 8429
2 - CAMSHAFT CHAIN
3 - CRANKSHAFT TIMING GEAR
KJ ENGINE - 3. 7L 9 - 21
(21) Remove the cyl i nder head retai ni ng bol ts.
(22) Remove the cyl i nder head and gasket. Di scard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, due to the design of the cylin-
der head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
CLEANING
use of al umi num engi ne components (Fi g. 8). (Refer
to 9 - ENGI NE - STANDARD PROCEDURE)
INSTALLATION
NOTE: The cylinder head bolts are tightened using
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced. The M8 head
bolts, should not be reused. Use new M8 bolts.
Necki ng can be checked by hol di ng a strai ght edge
agai nst the threads. I f al l the threads do not contact
the scal e, the bol t shoul d be repl aced (Fi g. 9).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Cl ean the cyl i nder head and cyl i nder bl ock
mati ng surfaces (Fi g. 10).
(2) Posi ti on the new cyl i nder head gasket on the
l ocati ng dowel s.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
(3) Posi ti on the cyl i nder head onto the cyl i nder
bl ock. Make sure the cyl i nder head seats ful l y over
the l ocati ng dowel s.
NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
Fig. 7 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
Fig. 9 Checking Cylinder Head Bolts for Stretching
(Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
9 - 22 ENGINE - 3. 7L KJ
(4) Lubri cate the cyl i nder head bol t threads wi th
cl ean engi ne oi l and i nstal l the ei ght M11 bol ts.
(5) Coat the four M8 cyl i nder head bol ts wi th
Mopar Lock and Seal Adhesive then i nstal l the
bol ts.
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Ti ghten the bol ts i n sequence usi ng the fol l ow-
i ng steps and torque val ues:
Step 1: Ti ghten bol ts 110, 27 Nm (20 ft. l bs.).
Step 2: Veri fy that bol ts 110, al l reached 27
Nm (20 ft. l bs.), by repeati ng step-1 wi thout l oosen-
i ng the bol ts. Ti ghten bol ts 11 thru 14 to 14 Nm (10
ft. l bs.).
Step 3: Ti ghten bol ts 110, 90 degrees (Fi g. 11).
Step 4: Ti ghten bol ts 110, 90 degrees, agai n.
Ti ghten bol ts 1114, 26 Nm (19 ft. l bs.)
(7) Posi ti on the secondary chai n onto the camshaft
dri ve gear, maki ng sure one marked chai n l i nk i s on
ei ther si de of the V6 mark on the gear then usi ng
Speci al Tool 8428 Camshaft Wrench, posi ti on the
gear onto the camshaft.
CAUTION: Remove excess oil from camshaft
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(8) I nstal l the camshaft dri ve gear retai ni ng bol t.
(9) I nstal l the l eft si de secondary chai n gui de.
(10) I nstal l the cyl i nder head access pl ug.
(11) Re-set and I nstal l the l eft si de secondary
chai n tensi oner.
(12) Remove Speci al Tool 8429.
(13) I nstal l the ti mi ng chai n cover.
(14) I nstal l the crankshaft damper. Ti ghten
damper bol t 175 Nm (130 Ft. Lbs.).
(15) I nstal l the power steeri ng pump.
(16) I nstal l the fan bl ade assembl y and fan
shroud.
(17) I nstal l the cyl i nder head cover.
(19) Refi l l the cool i ng system
(21) I nstal l the exhaust pi pe onto the l eft exhaust
mani fol d.
(23) Connect the negati ve cabl e to the battery.
CAMSHAFT(S)
DESCRIPTION
The camshafts consi st of powdered metal steel
l obes whi ch are si nter-bonded to a steel tube. Four
beari ng journal s are machi ned i nto the camshaft.
Camshaft end pl ay i s control l ed by two thrust wal l s
that border the nose pi ece journal . Engi ne oi l enters
the hol l ow camshafts at the thi rd journal and l ubri -
cates every i ntake l obe rocker through a dri l l ed pas-
sage i n the i ntake l obe.
Fig. 11 CYLINDER HEAD TIGHTENING SEQUENCE
KJ ENGINE - 3. 7L 9 - 23
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use Special Tool
8379 will result in hydraulic tensioner ratchet over
extension, requiring timing chain cover removal to
reset the tensioner ratchet.
(1) Remove cyl i nder head cover. Refer to CYLI N-
DER HEAD COVER i n thi s secti on.
(2) Set engi ne to TDC cyl i nder #1, camshaft
sprocket V6 marks at the 12 ocl ock posi ti on.
(3) Mark one l i nk on the secondary ti mi ng chai n
on both si des of the V6 mark on the camshaft
sprocket to ai d i n i nstal l ati on.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel (Located on the right side camshaft
sprocket) for any reason, Severe damage will occur
to the target wheel resulting in a vehicle no start
condition.
(4) Loosen but DO NOT remove the camshaft
sprocket retai ni ng bol t. Leave the bol t snug agai nst
the sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) Posi ti on Speci al Tool 8379 ti mi ng chai n wedge
between the ti mi ng chai n strands, tap the tool to
securel y wedge the ti mi ng chai n agai nst the ten-
si oner arm and gui de (Fi g. 12).
(6) Hol d the camshaft wi th Speci al Tool 8428 Cam-
shaft Wrench, whi l e removi ng the camshaft sprocket
bol t and sprocket (Fi g. 13).
(7) Usi ng Speci al Tool 8428 Camshaft Wrench,
gentl y al l ow the camshaft to rotate 5 cl ockwi se unti l
the camshaft i s i n the neutral posi ti on (no val ve
l oad).
(8) Starti ng at the outsi de worki ng i nward, l oosen
the camshaft beari ng cap retai ni ng bol ts 1/2 turn at
a ti me. Repeat unti l al l l oad i s off the beari ng caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
Fig. 12 SECURING TIMING CHAIN TENSIONERS
USING TIMING CHAIN WEDGE Typical
2 - CAMSHAFT SPROCKET
3 - CAMSHAFT SPROCKET BOLT
Fig. 13 Special Tool 8428
1 - Camshaft hole
2 - Special Tool 8428
9 - 24 ENGINE - 3. 7L KJ
CAMSHAFT(S) (Continued)
NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
(9) Remove the camshaft beari ng caps and the
camshaft.
INSTALLATION
(1) Lubri cate camshaft journal s wi th cl ean engi ne
oi l .
NOTE: Position the left side camshaft so that the
camshaft sprocket dowel is near the 1 oclock posi-
tion, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
(2) Posi ti on the camshaft i nto the cyl i nder head.
(3) I nstal l the camshaft beari ng caps, hand ti ghten
the retai ni ng bol ts.
NOTE: Caps should be installed so that the
stamped numbers on the caps are in numerical
order, ( 1 thru 4 ) from the front to the rear of the
engine. All caps should be installed so that the
stamped arrows on the caps point toward the front
of the engine.
(4) Worki ng i n turn i ncrements, ti ghten the
beari ng cap retai ni ng bol ts starti ng wi th the mi ddl e
cap worki ng outward (Fi g. 14).
(5) Torque the camshaft beari ng cap retai ni ng
bol ts to 11 Nm (100 i n. l bs.).
(6) Posi ti on the camshaft dri ve gear i nto the ti m-
i ng chai n al i gni ng the V6 mark between the two
marked chai n l i nks (Two l i nks marked duri ng remov-
al ).
rotate the camshaft unti l the camshaft sprocket
dowel i s al i gned wi th the sl ot i n the camshaft
sprocket. I nstal l the sprocket onto the camshaft.
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Remove excess oi l from bol t, then i nstal l the
camshaft sprocket retai ni ng bol t and hand ti ghten.
(9) Remove Speci al Tool 8379 ti mi ng chai n wedge.
(10) Usi ng Speci al Tool 6958 spanner wrench wi th
adapter pi ns 8346, torque the camshaft sprocket
retai ni ng bol t to 122 Nm (90 ft. l bs.).
DESCRIPTION
The cyl i nder head covers are made of si ngl e l ayer
stamped steel , and are not i nterchangabl e from si de-
to-si de (Fi g. 15).
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the resonator assembl e and ai r i nl et
hose.
(3) Di sconnect i njector connectors and un-cl i p the
i njector harness.
(4) Route i njector harness i n front of cyl i nder head
cover.
(5) Di sconnect the l eft si de breather tube and
remove the breather tube.
(6) Remove the cyl i nder head cover mounti ng bol ts
(Fi g. 16).
(7) Remove cyl i nder head cover and gasket.
NOTE: The gasket may be used again, providing no
cuts, tears, or deformation has occurred.
Fig. 14 Camshaft Bearing Caps Tightening
Sequence
KJ ENGINE - 3. 7L 9 - 25
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
NOTE: The gasket may be used again, provided no
(1) Cl ean cyl i nder head cover and both seal i ng sur-
faces. I nspect and repl ace gasket as necessary.
(2) Ti ghten cyl i nder head cover bol ts and doubl e
ended studs to 12 Nm (105 i n. l bs.).
(3) I nstal l l eft si de breather and connect breather
tube.
(4) Connect i njector el ectri cal connectors and i njec-
tor harness retai ni ng cl i ps.
(5) I nstal l the resonator and ai r i nl et hose.
(6) Connect negati ve cabl e to battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Each
val ve i s actuated by a rol l er rocker arm whi ch pi vots
on a stati onary l ash adjuster. Al l val ves use three
bead l ock keepers to retai n the spri ngs and promote
val ve rotati on.
STANDARD PROCEDURE - REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Usi ng a sui tabl e di al i ndi cator measure the
center of the val ve seat Total run out must not
exceed 0.051 mm (0.002 i n).
(2) Appl y a smal l amount of Prussi an bl ue to the
val ve seat, i nsert the val ve i nto the cyl i nder head,
whi l e appl yi ng l i ght pressure on the val ve rotate the
Fig. 15 CYLINDER HEAD COVERS
1 - LEFT SIDE CYLINDER HEAD COVER
2 - RIGHT SIDE CYLINDER HEAD COVER
Fig. 16 CYLINDER HEAD COVER -TYPICAL
1 - SCREWS
2 - CYLINDER HEAD COVER
9 - 26 ENGINE - 3. 7L KJ
CYLINDER HEAD COVER(S) (Continued)
val ve. Remove the val ve and exami ne the val ve face.
I f the bl ue i s transferred bel ow the top edge of the
val ve face, l ower the val ve seat usi ng a 15 degree
stone. I f the bl ue i s transferred to the bottom edge of
the val ve face, rai se the val ve seat usi ng a 65 degree
stone.
(3) When the seat i s properl y posi ti oned the wi dth
of the i ntake seat must be 1.75 2.36 mm (0.0689
0.0928 i n.) and the exhaust seat must be 1.71 2.32
mm (0.0673 0.0911 i n.).
(4) Check the val ve spri ng i nstal l ed hei ght after
refaci ng the val ve and seat. The i nstal l ed hei ght for
both i ntake and exhaust val ve spri ngs must not
exceed 41.44 mm (1.6315 i n.).
(5) The val ve seat and val ve face must mai ntai n a
face angl e of 44.5 45 degrees angl e (Fi g. 17).
REMOVAL
NOTE: The cylinder heads must be removed in
order to perform this procedure.
(1) Remove rocker arms and l ash adjusters. Refer
to procedures i n thi s secti on (Fi g. 18).
camshaft.
NOTE: All six valve springs and valves are removed
in the same manner; this procedure only covers
one valve and valve spring.
(3) Usi ng Speci al Tool C-3422B or C-3422C
Val ve Spri ng Compressor and Speci al tool 8519
Adapter, compress the val ve spri ng.
NOTE: It may be necessary to tap the top of the
valve spring to loosen the spring retainers locks
enough to be removed.
(4) Remove the two spri ng retai ner l ock hal ves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
(5) Remove the val ve spri ng compressor.
(6) Remove the spri ng retai ner, and the spri ng.
NOTE: Check for sharp edges on the keeper
grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Remove the val ve from the cyl i nder head.
NOTE: The valve stem seals are common between
intake and exhaust.
(8) Remove the val ve stem seal . Mark the val ve for
proper i nstal l ati on.
Fig. 17 Valve Assembly Configuration
1 - VALVE LOCKS (3BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 18 Rocker Arm Removal
1 - CAMSHAFT
KJ ENGINE - 3. 7L 9 - 27
INTAKE/EXHAUST VALVES & SEATS (Continued)
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.
I nspect the val ve spri ngs for physi cal si gns of wear
or damage. Turn tabl e of tool C-647 unti l surface i s
i n l i ne wi th the 40.69 mm (1.602 i n.) mark on the
threaded stud and the zero mark on the front. Pl ace
spri ng over the stud on the tabl e and l i ft compress-
i ng l ever to set tone devi ce. Pul l on torque wrench
unti l Pi ng i s heard. Take readi ng on torque wrench
at thi s i nstant. Mul ti pl y thi s readi ng by two. Thi s
wi l l gi ve the spri ng l oad at test l ength. Fracti onal
measurements are i ndi cated on the tabl e for fi ner
adjustments. Refer to Speci fi cati ons Secti on to obtai n
speci fi ed hei ght and al l owabl e tensi ons. Repl ace any
spri ngs that do not meet speci fi cati ons (Fi g. 19).
INSTALLATION
(1) coat the val ve stem wi th cl ean engi ne oi l and
i nsert i t i nto the cyl i nder head.
(2) I nstal l the val ve stem seal . make sure the seal
i s ful l y seated and that the garter spri ng at the top
of the seal i s i ntact.
(3) I nstal l the spri ng and the spri ng retai ner (Fi g.
20).
(4) Usi ng the val ve spri ng compressor, compress
the spri ng and i nstal l the two val ve spri ng retai ner
hal ves.
(5) Rel ease the val ve spri ng compressor and make
sure the two spri ng retai ner hal ves and the spri ng
retai ner are ful l y seated.
(6) l ubri cate the camshaft journal wi th cl ean
engi ne oi l then Posi ti on the camshaft (wi th the
sprocket dowel on the l eft camshaft at 11 ocl ock and
the ri ght camshaft at 12 ocl ock), then posi ti on the
camshaft beari ng caps.
(7) I nstal l the camshaft beari ng cap retai ni ng
bol ts. Ti ghten the bol ts 913 Nm (100 i n. l bs.) i n
turn i ncrements i n the sequence shown (Fi g. 21).
(8) Posi ti on the hydraul i c l ash adjusters and
rocker arms.
Fig. 19 Testing Valve Springs
1 - SPECIAL TOOL C-647
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
9 - 28 ENGINE - 3. 7L KJ
ROCKER ARM
DESCRIPTION
The rocker arms are steel stampi ngs wi th an i nte-
gral rol l er beari ng. The rocker arms i ncorporate a 2.8
mm (0.11 i nch) oi l hol e i n the l ash adjuster socket for
rol l er and camshaft l ubri cati on.
VALVE GUIDE SEALS
DESCRIPTION
The val ve gui de seal s are made of rubber and
i ncorporate an i ntegral steel val ve spri ng seat. The
i ntegral garter spri ng mai ntai ns consi stent l ubri ca-
ti on control to the val ve stems.
VALVE SPRINGS
DESCRIPTION
The val ve spri ngs are made from hi gh strength
chrome si l i con steel . The spri ngs are common for
i ntake and exhaust appl i cati ons. The val ve spri ng
seat i s i ntegral wi th the val ve stem seal , whi ch i s a
posi ti ve type seal to control l ubri cati on.
REMOVAL
(1) Remove the cyl i nder head cover. Refer to Cyl -
i nder Head Cover i n thi s Secti on.
(2) Usi ng Speci al Tool 8516 Val ve Spri ng Compres-
sor, remove the rocker arms and the hydraul i c l ash
adjusters.
(3) Remove the spark pl ug for the cyl i nder the
val ve spri ng and seal are to be removed from.
(4) Appl y shop ai r to the cyl i nder to hol d the
val ves i n pl ace when the spri ng i s removed.
NOTE: All six valve springs and seals are removed
one valve seal and valve spring.
sor, compress the val ve spri ng.
(9) Remove the val ve stem seal .
intake and exhaust.
INSTALLATION
val ves i n pl ace whi l e the spri ng i s i nstal l ed.
intake and exhaust.
(2) I nstal l the val ve stem seal .
(3) I nstal l the spri ng retai ner, and the spri ng.
(5) I nstal l the two spri ng retai ner l ock hal ves.
(7) Di sconnect the shop ai r to the cyl i nder.
(8) I nstal l the spark pl ug for the cyl i nder the val ve
spri ng and seal was i nstal l ed on.
Sequence
KJ ENGINE - 3. 7L 9 - 29
sor, i nstal l the rocker arms and the hydraul i c l ash
adjusters.
(10) I nstal l the cyl i nder head cover. Refer to Cyl i n-
der Head Cover i n thi s Secti on.
CYLINDER HEAD - RIGHT
DESCRIPTION
DESCRIPTION - CYLINDER HEAD
The cyl i nder heads are made of an al umi num al l oy.
The cyl i nder head features two val ves per cyl i nder
wi th pressed i n powdered metal val ve gui des. The
cyl i nder heads al so provi de encl osures for the ti mi ng
chai n drai n, necessi tati ng uni que l eft and ri ght cyl i n-
der heads.
DESCRIPTION - VALVE GUIDES
The val ve gui des are made of powered metal and
are pressed i nto the cyl i nder head. The gui des are
not repl aceabl e or servi ceabl e, and val ve gui de ream-
i ng i s not recommended. I f the gui des are worn
beyond acceptabl e l i mi ts, repl ace the cyl i nder heads.
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Each
val ve i s actuated by a rol l er rocker arm whi ch pi vots
on a stati onary l ash adjuster. Al l val ves use three
bead l ock keepers to retai n the spri ngs and promote
val ve rotati on.
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-l i ke noi se may be produced from several
i tems. Check the fol l owi ng i tems.
(1) Engi ne oi l l evel too hi gh or too l ow. Thi s may
cause aerated oi l to enter the adjusters and cause
them to be spongy.
(2) I nsuffi ci ent runni ng ti me after rebui l di ng cyl i n-
der head. Low speed runni ng up to 1 hour may be
requi red.
(3) Turn engi ne off and l et set for a few mi nutes
before restarti ng. Repeat thi s several ti mes after
engi ne has reached normal operati ng temperature.
(4) Low oi l pressure.
(5) The oi l restri ctor i n cyl i nder head gasket or the
oi l passage to the cyl i nder head i s pl ugged wi th
debri s.
(6) Ai r i ngested i nto oi l due to broken or cracked
oi l pump pi ck up.
(7) Worn val ve gui des.
(8) Rocker arm ears contacti ng val ve spri ng
retai ner.
(9) Rocker arm l oose, adjuster stuck or at maxi -
mum extensi on and sti l l l eaves l ash i n the system.
(10) Oi l l eak or excessi ve cam bore wear i n cyl i n-
der head.
(11) Faul ty l ash adjuster.
Check l ash adjusters for spongi ness whi l e
i nstal l ed i n cyl i nder head and cam on camshaft at
base ci rcl e. Depress part of rocker arm over adjuster.
Normal adjusters shoul d feel very fi rm. Spongy
adjusters can be bottomed out easi l y.
Remove suspected l ash adjusters, and repl ace.
Before i nstal l ati on, make sure adjusters are at
l east parti al l y ful l of oi l . Thi s can be veri fi ed by l i ttl e
or no pl unger travel when l ash adjuster i s depressed.
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET
A cyl i nder head gasket l eak can be l ocated between
adjacent cyl i nders or between a cyl i nder and the
adjacent water jacket.
l eaki ng between adjacent cyl i nders are:
Loss of engi ne power
Engi ne mi sfi ri ng
Poor fuel economy
l eaki ng between a cyl i nder and an adjacent water
jacket are:
Engi ne overheati ng
Loss of cool ant
Excessi ve steam (whi te smoke) emi tti ng from
exhaust
Cool ant foami ng
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders, fol l ow the proce-
dures i n Cyl i nder Compressi on Pressure Test (Refer
to 9 - ENGI NE - DI AGNOSI S AND TESTI NG). An
engi ne cyl i nder head gasket l eaki ng between adja-
cent cyl i nders wi l l resul t i n approxi matel y a 5070%
reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
9 - 30 ENGINE - 3. 7L KJ
VALVE SPRINGS (Continued)
VISUAL TEST METHOD
Wi th the engi ne cool , remove the cool ant pressure
cap. Start the engi ne and al l ow i t to warm up unti l
thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
I nstal l Cool i ng System Tester 7700 or equi val ent to
pressure cap neck. Start the engi ne and observe the
testers pressure gauge. I f gauge pul sates wi th every
power stroke of a cyl i nder a combusti on pressure
l eak i s evi dent.
CHEMICAL TEST METHOD
Combusti on l eaks i nto the cool i ng system can al so
be checked by usi ng Bl oc-Chek Ki t C-3685-A or
equi val ent. Perform test fol l owi ng the procedures
suppl i ed wi th the tool ki t.
REMOVAL
(2) Rai se the vehi cl e on a hoi st.
(3) Di sconnect the exhaust pi pe at the ri ght si de
exhaust mani fol d.
(4) Drai n the engi ne cool ant. Refer to COOLI NG
SYSTEM.
(6) Remove the i ntake mani fol d. Refer to proce-
dure.
(7) Remove the cyl i nder head cover. Refer to proce-
dure.
(8) Remove the fan shroud. Refer to COOLI NG
SYSTEM.
(9) Remove oi l fi l l housi ng from cyl i nder head.
(10) Remove accessory dri ve bel t. Refer to COOL-
I NG SYSTEM.
(11) Rotate the crankshaft unti l the damper ti mi ng
mark i s al i gned wi th TDC i ndi cator mark.
(12) Veri fy the V6 mark on the camshaft sprocket
i s at the 12 ocl ock posi ti on. Rotate the crankshaft
one turn i f necessary.
(13) Remove the crankshaft damper. Refer to pro-
cedure.
(14) Remove the ti mi ng chai n cover. Refer to pro-
cedure.
(15) Lock the secondary ti mi ng chai ns to the i dl er
sprocket usi ng Speci al Tool 8429 Ti mi ng Chai n Hol d-
i ng Fi xture.
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(16) Mark the secondary ti mi ng chai n, one l i nk on
each si de of the V6 mark on the camshaft dri ve gear.
(17) Remove the ri ght si de secondary chai n ten-
si oner. Refer to Ti mi ng Chai n and Sprockets i n thi s
secti on.
(18) Remove the cyl i nder head access pl ug.
(19) Remove the ri ght si de secondary chai n gui de.
Refer to Ti mi ng Chai n and Sprockets i n thi s secti on.
CAUTION: The nut on the right side camshaft
sprocket should not be removed for any reason, as
the sprocket and camshaft sensor target wheel is
serviced as an assembly. If the nut was removed
retorque nut to 5 Nm (44 in. lbs.).
(20) Remove the retai ni ng bol t and the camshaft
dri ve gear.
CAUTION: Do not allow the engine to rotate. severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
NOTE: The cylinder head is attached to the cylinder
block with twelve bolts.
(21) Remove the cyl i nder head retai ni ng bol ts.
(22) Remove the cyl i nder head and gasket. Di scard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, do to the design of the cylinder
head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
CLEANING
use of al umi num engi ne components (Fi g. 22). (Refer
to 9 - ENGI NE - STANDARD PROCEDURE)
KJ ENGINE - 3. 7L 9 - 31
CYLINDER HEAD - RIGHT (Continued)
INSPECTION
(1) I nspect the cyl i nder head for out-of-fl atness,
usi ng a strai ghtedge and a feel er gauge. I f measure-
ments exceed 0.0508 mm (0.002 i n.) repl ace the cyl -
i nder head.
(2) I nspect the val ve seats for damage. Servi ce the
val ve seats as necessary.
(3) I nspect the val ve gui des for wear, cracks or
l ooseness. I f ei ther condi ti on exi st, repl ace the cyl i n-
der head.
INSTALLATION
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Necki ng can be checked by hol di ng a strai ght edge
agai nst the threads. I f al l the threads do not contact
the scal e, the bol t shoul d be repl aced.
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Cl ean the cyl i nder head and cyl i nder bl ock
mati ng surfaces.
(2) Posi ti on the new cyl i nder head gasket on the
l ocati ng dowel s.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
(3) Posi ti on the cyl i nder head onto the cyl i nder
bl ock. Make sure the cyl i nder head seats ful l y over
the l ocati ng dowel s.
NOTE: The four M8 cylinder head mounting bolts
require sealant to be added to them before install-
ing. Failure to do so may cause leaks. Do not reuse
the old M8 bolts, use new M8 bolts.
(4) Lubri cate the cyl i nder head bol t threads wi th
cl ean engi ne oi l and i nstal l the ei ght M10 bol ts.
(5) Coat the four M8 cyl i nder head bol ts wi th
Mopar Lock and Seal Adhesive then i nstal l the
bol ts.
The cyl i nder head bol ts are ti ghtened usi ng an
angl e torque procedure, however, the bol ts are not a
torque-to-yi el d desi gn.
(6) Ti ghten the bol ts i n sequence usi ng the fol l ow-
i ng steps and torque val ues:
Ti ghten bol ts 1114, 25 Nm (18 ft. l bs.).
Step 3: Ti ghten bol ts 110, 90 degrees. Ti ghten
bol ts 1114, 30 Nm (22 ft. l bs.).
(7) Posi ti on the secondary chai n onto the camshaft
dri ve gear, maki ng sure one marked chai n l i nk i s on
ei ther si de of the V6 mark on the gear then usi ng
Speci al Tool 8428 Camshaft Wrench, posi ti on the
gear onto the camshaft.
ure to do so may cause over-torquing of bolt result-
ing in bolt failure.
(8) I nstal l the camshaft dri ve gear retai ni ng bol t.
(9) I nstal l the ri ght si de secondary chai n gui de.
(10) I nstal l the cyl i nder head access pl ug.
(11) Re-set and i nstal l the ri ght si de secondary
chai n tensi oner.
(13) I nstal l the ti mi ng chai n cover.
(14) I nstal l the crankshaft damper.Ti ghten damper
bol t 175 Nm (130 Ft. Lbs.).
(15) I nstal l accessory dri ve bel t.
(16) I nstal l the fan shroud.
9 - 32 ENGINE - 3. 7L KJ
(19) I nstal l oi l fi l l housi ng onto cyl i nder head.
(20) Refi l l the cool i ng system.
(22) I nstal l the exhaust pi pe onto the ri ght
exhaust mani fol d.
(24) Reconnect battery negi ti ve cabl e.
CAMSHAFT(S)
DESCRIPTION
The camshafts consi st of powdered metal steel
l obes whi ch are si nter-bonded to a steel tube. Four
beari ng journal s are machi ned i nto the camshaft.
Camshaft end pl ay i s control l ed by two thrust wal l s
that border the nose pi ece journal . Engi ne oi l enters
the hol l ow camshafts at the thi rd journal and l ubri -
cates every i ntake l obe rocker through a dri l l ed pas-
sage i n the i ntake l obe.
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use special tool 8379
will result in hydraulic tensioner ratchet over exten-
sion, Requiring timing chain cover removal to re-set
the tensioner ratchet.
(1) Remove the cyl i nder head cover. Refer to CYL-
I NDER HEAD COVER i n thi s secti on.
(2) Set engi ne to TDC cyl i nder #1, camshaft
sprocket V6 marks at the 12 ocl ock posi ti on.
(3) Mark one l i nk on the secondary ti mi ng chai n
on both si des of the V6 mark on the camshaft
sprocket to ai d i n i nstal l ati on.
get wheel for any reason, Severe damage will occur
to the target wheel. A damaged target wheel could
cause a vehicle no start condition.
(4) Loosen but DO NOT remove the camshaft
sprocket retai ni ng bol t. Leave bol t snug agai nst
sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) Posi ti on Speci al Tool 8379 ti mi ng chai n wedge
between the ti mi ng chai n strands. Tap the tool to
securel y wedge the ti mi ng chai n agai nst the ten-
si oner arm and gui de.
(6) Remove the camshaft posi ti on sensor.
(7) Hol d the camshaft wi th Speci al Tool 8428 Cam-
shaft Wrench, whi l e removi ng the camshaft sprocket
bol t and sprocket.
(8) Starti ng at the outsi de worki ng i nward, l oosen
the camshaft beari ng cap retai ni ng bol ts 1/2 turn at
a ti me. Repeat unti l al l l oad i s off the beari ng caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
camshaft.
INSTALLATION
(1) Lubri cate camshaft journal s wi th cl ean engi ne
oi l .
NOTE: Position the right side camshaft so that the
camshaft sprocket dowel is near the 10 oclock
position, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
(2) Posi ti on the camshaft i nto the cyl i nder head.
(3) I nstal l the camshaft beari ng caps, hand ti ghten
the retai ni ng bol ts.
NOTE: Caps should be installed so that the
stamped numbers on the caps are in numerical
order, ( 1 thru 4 ) from the front to the rear of the
engine. All caps should be installed so that the
stamped arrows on the caps point toward the front
of the engine.
(4) Worki ng i n 1/2 turn i ncrements, ti ghten the
beari ng cap retai ni ng bol ts starti ng wi th the mi ddl e
cap worki ng outward (Fi g. 23).
(5) Torque the camshaft beari ng cap retai ni ng
KJ ENGINE - 3. 7L 9 - 33
(6) Posi ti on the camshaft dri ve gear i nto the ti m-
i ng chai n al i gni ng the V6 mark between the two
marked chai n l i nks (Two l i nks marked duri ng remov-
al ).
rotate the camshaft unti l the camshaft sprocket
dowel i s al i gned wi th the sl ot i n the camshaft
sprocket. I nstal l the sprocket onto the camshaft.
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Remove excess oi l from camshaft sprocket bol t,
then i nstal l the camshaft sprocket retai ni ng bol t and
hand ti ghten.
(9) Remove ti mi ng chai n wedge speci al tool 8379.
(10) Usi ng Speci al Tool 6958 spanner wrench wi th
adapter pi ns 8346, torque the camshaft sprocket
retai ni ng bol t to 122 Nm (90 ft. l bs.).
(11) I nstal l the camshaft posi ti on sensor.
REMOVAL
(2) Remove ai r cl eaner assembl y, resonator assem-
bl y and ai r i nl et hose.
(3) Drai n cool i ng system, bel ow the l evel of the
heater hoses. Refer to COOLI NG SYSTEM.
(4) Remove accessory dri ve bel t.
(5) Remove ai r condi ti oni ng compressor retai ni ng
bol ts and move compressor to the l eft.
(6) Remove heater hoses.
(7) Di sconnect i njector and i gni ti on coi l connectors.
(8) Di sconnect and remove posi ti ve crankcase ven-
ti l ati on (PCV) hose.
(9) Remove oi l fi l l tube.
(10) Un-cl i p i njector and i gni ti on coi l harness and
move away from cyl i nder head cover.
(11) Remove ri ght rear breather tube and fi l ter
assembl y.
(12) Remove cyl i nder head cover retai ni ng bol ts.
(13) Remove cyl i nder head cover.
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
NOTE: The gasket may be used again, provided no
(1) Cl ean cyl i nder head cover and both seal i ng sur-
faces. I nspect and repl ace gasket as necessary.
(2) Ti ghten cyl i nder head cover bol ts and doubl e
ended studs to 12 Nm (105 i n. l bs).
(3) I nstal l ri ght rear breather tube and fi l ter
assembl y.
(4) Connect i njector, i gni ti on coi l el ectri cal connec-
tors and harness retai ni ng cl i ps.
(5) I nstal l the oi l fi l l tube.
(6) I nstal l PCV hose.
(7) I nstal l heater hoses.
(8) I nstal l ai r condi ti oni ng compressor retai ni ng
bol ts.
(9) I nstal l accessory dri ve bel t
(10) Fi l l Cool i ng system
(11) I nstal l ai r cl eaner assembl y, resonator assem-
bl y and ai r i nl et hose.
INTAKE/EXHAUST VALVES &
SEATS
STANDARD PROCEDURE - REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
Sequence
9 - 34 ENGINE - 3. 7L KJ
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Usi ng a sui tabl e di al i ndi cator measure the
center of the val ve seat Total run out must not
exceed 0.051 mm (0.002 i n).
(2) Appl y a smal l amount of Prussi an bl ue to the
val ve seat, i nsert the val ve i nto the cyl i nder head,
whi l e appl yi ng l i ght pressure on the val ve rotate the
val ve. Remove the val ve and exami ne the val ve face.
I f the bl ue i s transferred bel ow the top edge of the
val ve face, l ower the val ve seat usi ng a 15 degree
stone. I f the bl ue i s transferred to the bottom edge of
the val ve face, rai se the val ve seat usi ng a 65 degree
stone.
(3) When the seat i s properl y posi ti oned the wi dth
of the i ntake seat must be 1.75 2.36 mm (0.0689
0.0928 i n.) and the exhaust seat must be 1.71 2.32
mm (0.0673 0.0911 i n.).
(4) Check the val ve spri ng i nstal l ed hei ght after
refaci ng the val ve and seat. The i nstal l ed hei ght for
both i ntake and exhaust val ve spri ngs must not
exceed 41.44 mm (1.6315 i n.).
(5) The val ve seat and val ve face must mai ntai n a
face angl e of 44.5 45 degrees angl e (Fi g. 24).
REMOVAL
NOTE: The cylinder heads must be removed in
order to perform this procedure.
(1) Remove rocker arms and l ash adjusters. Refer
to procedures i n thi s secti on (Fi g. 25).
camshaft.
NOTE: All six valve springs and valves are removed
one valve and valve spring.
(3) Usi ng Speci al Tool C-3422B or C-3422C
Val ve Spri ng Compressor and Speci al tool 8519
Adapter, compress the val ve spri ng.
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 25 Rocker Arm Removal
1 - CAMSHAFT
KJ ENGINE - 3. 7L 9 - 35
NOTE: Check for sharp edges on the keeper
grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Remove the val ve from the cyl i nder head.
intake and exhaust.
(8) Remove the val ve stem seal . Mark the val ve for
proper i nstal l ati on.
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.
I nspect the val ve spri ngs for physi cal si gns of wear
or damage. Turn tabl e of tool C-647 unti l surface i s
i n l i ne wi th the 40.69 mm (1.602 i n.) mark on the
threaded stud and the zero mark on the front. Pl ace
spri ng over the stud on the tabl e and l i ft compress-
i ng l ever to set tone devi ce. Pul l on torque wrench
unti l Pi ng i s heard. Take readi ng on torque wrench
at thi s i nstant. Mul ti pl y thi s readi ng by two. Thi s
wi l l gi ve the spri ng l oad at test l ength. Fracti onal
measurements are i ndi cated on the tabl e for fi ner
adjustments. Refer to Speci fi cati ons Secti on to obtai n
speci fi ed hei ght and al l owabl e tensi ons. Repl ace any
spri ngs that do not meet speci fi cati ons (Fi g. 26).
INSTALLATION
(1) coat the val ve stem wi th cl ean engi ne oi l and
i nsert i t i nto the cyl i nder head.
(2) I nstal l the val ve stem seal . make sure the seal
i s ful l y seated and that the garter spri ng at the top
of the seal i s i ntact.
(3) I nstal l the spri ng and the spri ng retai ner.
(4) Usi ng the val ve spri ng compressor, compress
the spri ng and i nstal l the two val ve spri ng retai ner
hal ves (Fi g. 27).
(5) Rel ease the val ve spri ng compressor and make
sure the two spri ng retai ner hal ves and the spri ng
retai ner are ful l y seated.
(6) l ubri cate the camshaft journal wi th cl ean
engi ne oi l then Posi ti on the camshaft (wi th the
sprocket dowel on the l eft camshaft at 11 ocl ock and
the ri ght camshaft at 12 ocl ock), then posi ti on the
camshaft beari ng caps.
(7) I nstal l the camshaft beari ng cap retai ni ng
bol ts. Ti ghten the bol ts 913 Nm (100 i n. l bs.) i n
turn i ncrements i n the sequence shown (Fi g. 28).
(8) Posi ti on the hydraul i c l ash adjusters and
rocker arms.
Fig. 26 Testing Valve Springs
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
9 - 36 ENGINE - 3. 7L KJ
ROCKER ARM
DESCRIPTION
The rocker arms are steel stampi ngs wi th an i nte-
gral rol l er beari ng. The rocker arms i ncorporate a 2.8
mm (0.11 i nch) oi l hol e i n the l ash adjuster socket for
rol l er and camshaft l ubri cati on.
REMOVAL
NOTE: Disconnect the battery negative cable to pre-
vent accidental starter engagement.
(1) Remove the cyl i nder head cover (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - REMOVAL).
(2) For rocker arm removal on cyl i nder #4, Rotate
the crankshaft unti l cyl i nder #1 i s at TDC exhaust
stroke.
(3) For rocker arm removal on cyl i nder #1, Rotate
the crankshaft unti l cyl i nder #1 i s at TDC compres-
si on stroke.
(4) For rocker arm removal on cyl i nders #2 and #3,
Rotate the crankshaft unti l cyl i nder #1 i s at BDC
compressi on stroke.
(5) For rocker arm removal on cyl i nders #5 and #6,
Rotate the crankshaft unti l cyl i nder #1 i s at BDC
exhaust stroke.
(6) Usi ng speci al tool 8516 Rocker Arm Remover,
press downward on the val ve spri ng, remove rocker
arm (Fi g. 29).
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
(1) For rocker arm i nstal l ati on on cyl i nders #4,
Rotate the crankshaft unti l cyl i nder #1 i s at TDC
exhaust stroke.
(2) For rocker arm i nstal l ati on on cyl i nder #1,
Rotate the crankshaft unti l cyl i nder #1 i s at TDC
(3) For rocker arm i nstal l ati on on cyl i nders #2 and
#3, Rotate the crankshaft unti l cyl i nder #1 i s at BDC
(4) For rocker arm i nstal l ati on on cyl i nders #5 and
#6, Rotate the crankshaft unti l cyl i nder #1 i s at BDC
exhaust stroke.
(5) Usi ng speci al tool 8516 press downward on the
val ve spri ng, i nstal l rocker arm (Fi g. 30).
(6) I nstal l the cyl i nder head cover (Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - I NSTALLATI ON).
Sequence
Fig. 29 Rocker Arm - Removal
1 - CAMSHAFT
KJ ENGINE - 3. 7L 9 - 37
VALVE GUIDE SEALS
DESCRIPTION
The val ve gui de seal s are made of rubber and
i ncorporate an i ntegral steel val ve spri ng seat. The
i ntegral garter spri ng mai ntai ns consi stent l ubri ca-
ti on control to the val ve stems.
VALVE SPRINGS
DESCRIPTION
The val ve spri ngs are made from hi gh strength
chrome si l i con steel . The spri ngs are common for
i ntake and exhaust appl i cati ons. The val ve spri ng
seat i s i ntegral wi th the val ve stem seal , whi ch i s a
posi ti ve type seal to control l ubri cati on.
REMOVAL
(1) Remove the cyl i nder head cover. Refer to Cyl -
i nder Head Cover i n thi s Secti on.
sor, remove the rocker arms and the hydraul i c l ash
adjusters.
(3) Remove the spark pl ug for the cyl i nder the
val ve spri ng and seal are to be removed from.
val ves i n pl ace when the spri ng i s removed.
(9) Remove the val ve stem seal .
intake and exhaust.
INSTALLATION
val ves i n pl ace whi l e the spri ng i s i nstal l ed.
intake and exhaust.
(2) I nstal l the val ve stem seal .
(3) I nstal l the spri ng retai ner, and the spri ng.
(5) I nstal l the two spri ng retai ner l ock hal ves.
(7) Di sconnect the shop ai r to the cyl i nder.
(8) I nstal l the spark pl ug for the cyl i nder the val ve
spri ng and seal was i nstal l ed on.
sor, i nstal l the rocker arms and the hydraul i c l ash
adjusters.
(10) I nstal l the cyl i nder head cover. Refer to Cyl i n-
der Head Cover i n thi s Secti on.
Fig. 30 Rocker Arm - Installation
1 - CAMSHAFT
9 - 38 ENGINE - 3. 7L KJ
ROCKER ARM (Continued)
ENGINE BLOCK
DESCRIPTION
The cyl i nder bl ock i s made of cast i ron. The bl ock
i s a cl osed deck desi gn wi th the l eft bank forward. To
provi de hi gh ri gi di ty and i mproved NVH an
enhanced compacted graphi te bedpl ate (Fi g. 31) i s
bol ted to the bl ock. The bl ock desi gn al l ows cool ant
fl ow between the cyl i nders bores, and an i nternal
cool ant bypass to a si ngl e poppet i nl et thermostat i s
i ncl uded i n the cast al umi num front cover.
STANDARD PROCEDURE - CYLINDER BORE
HONING
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823, equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round, as wel l as removi ng l i ght
scuffi ng, scori ng and scratches. Usual l y, a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). about 20-60
strokes, dependi ng on the bore condi ti on, wi l l be suf-
fi ci ent to provi de a sati sfactory surface. Usi ng honi ng
oi l C-3501-3880, or a l i ght honi ng oi l , avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50 to 60
for proper seati ng of ri ngs (Fi g. 32).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e.
The front and rear oi l gal l ey hol es.
The feed hol es for the crankshaft mai n beari ngs.
Fig. 31 CYLINDER BLOCK BEDPLATE
1 - Cylinder Block Bedplate
2 - Crankshaft Position Sensor
3 - Crankshaft Main Bearing Caps
Fig. 32 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
KJ ENGINE - 3. 7L 9 - 39
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 34 Nm (25 ft. l bs.) torque.
INSPECTION
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter. To correctl y
sel ect the proper si ze pi ston, a cyl i nder bore gauge,
capabl e of readi ng i n 0.003 mm (.0001 i n.) I NCRE-
MENTS i s requi red. I f a bore gauge i s not avai l abl e,
do not use an i nsi de mi crometer (Fi g. 33).
(2) Measure the i nsi de di ameter of the cyl i nder
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90 and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
bl ock must be repl aced. A sl i ght amount of taper
al ways exi sts i n the cyl i nder bore after the engi ne
has been i n use for a peri od of ti me.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING ROD
BEARING - FITTING
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 34) (Fi g. 35). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 36). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
Fig. 33 Bore GaugeTypical
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
Fig. 34 Connecting Rod Bearing Inspection
1 - UPPER BEARING HALF
2 - MATING EDGES
3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 - WEAR PATTERN ALWAYS GREATER ON UPPER
BEARING
5 - LOWER BEARING HALF
9 - 40 ENGINE - 3. 7L KJ
ENGINE BLOCK (Continued)
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(3) Use pi ston ri ng compressor and Gui de Pi ns
Speci al Tool 8507 (Fi g. 37) to i nstal l the rod and pi s-
ton assembl i es. The oi l sl i nger sl ots i n the rods must
face front of the engi ne. The Fs near the pi ston
wri st pi n bore shoul d poi nt to the front of the engi ne.
(4) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(5) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us a
90 turn. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(6) Remove the beari ng cap and determi ne amount
of beari ng-to-journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 38). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(7) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(8) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, determi n whi ch servi ces beari ng set to
use the beari ng si zes are as fol l ows:
Fig. 35 Locking Tab Inspection
1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 36 Scoring Caused by Insufficient Lubrication
or Damaged Crankshaft Journal
Fig. 37 Piston and Connecting Rod -Installation -
Typical
1 - F TOWARD FRONT OF ENGINE
2 - OIL SLINGER SLOT
3 - RING COMPRESSOR
KJ ENGINE - 3. 7L 9 - 41
CONNECTING ROD BEARINGS (Continued)
Bearing
Mark
SIZE USED WITH
JOURNAL SIZE
.025 US .025 mm 50.983-50.967 mm
(.001 in.) (2.0073-2.0066 in.)
Std. STANDARD 50.992-51.008 mm
(2.0076-2.0082 in.)
.250 US .250 mm 50.758-50.742 mm
(.010 in.) (1.9984-1.9978 in.)
(9) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(10) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 27 Nm (20 ft. l bs.) pl us a 90 turn.
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 39).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
CRANKSHAFT
DESCRIPTION
The crankshaft (Fi g. 40) i s constructed of nodul ar
cast i ron. The crankshaft i s a three throw spl i t pi n
desi gn wi th si x counterwei ghts for bal anci ng pur-
poses. The crankshaft i s supported by four sel ect fi t
mai n beari ngs wi th the number two servi ng as the
thrust washer l ocati on. The mai n journal s of the
crankshaft are cross dri l l ed to i mprove rod beari ng
l ubri cati on. The number si x counterwei ght has provi -
si ons for crankshaft posi ti on sensor target wheel
mounti ng. The sel ect fi t mai n beari ng marki ngs are
l ocated on the rear si de of the target wheel . The
crankshaft oi l seal s are one pi ece desi gn. The front
oi l seal i s retai ned i n the ti mi ng chai n cover, and the
rear seal i s pressed i n to a bore formed by the cyl i n-
der bl ock and the bedpl ate assembl y.
Fig. 38 Measuring Bearing Clearance with
Plastigage
1 - PLASTIGAGE SCALE
2 - COMPRESSED PLASTIGAGE
Fig. 39 Checking Connecting Rod Side Clearance -
Typical
Fig. 40 CRANKSHAFT AND TARGET RING
1 - CRANKSHAFT
2 - CRANKSHAFT POSITION SENSOR TARGET RING
9 - 42 ENGINE - 3. 7L KJ
CONNECTING ROD BEARINGS (Continued)
REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.
(1) Remove the engi ne. Refer to Engi ne Assembl y
i n thi s secti on for procedure.
(2) Remove the engi ne oi l pump. Refer to Oi l
Pump i n thi s secti on for procedure.
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.
(3) Remove oi l pan bol ts and oi l pan.
(4) Remove the oi l pump pi ckup tube and oi l pan
gasket /wi ndage tray.
(5) Remove the bedpl ate mounti ng bol ts. Note the
l ocati on of the two stud bol ts for i nstal l ati on.
(6) Remove the connecti ng rods from the crank-
shaft.
CAUTION: The bedplate to cylinder block mating
surface is a critical sealing surface. Do not pry on
or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear-
ing halves. Use care when handling bedplate as not
to drop or damage bearing halves. Installing main
bearing halves in the wrong position will cause
sever damage to the crankshaft.
NOTE: The bedplate has pry points cast into it. Use
these points only. The pry points are shown below.
(7) Careful l y pry on the pry poi nts (Fi g. 41) to
l oosen the bedpl ate then remove the bedpl ate.
CAUTION: When removing the crankshaft, use care
not to damage bearing surfaces on the crankshaft.
(8) Remove the crankshaft.
(9) Remove the crankshaft tone wheel .
INSPECTION
NOTE: Thoroughly inspect the connecting rod bear-
ing bores and main bearing bores for scoring, blue-
ing or severe scratches. Further disassembly may
be required.
I f connecti ng rod beari ng bores show damage, the
cyl i nder heads must be removed to servi ce the pi ston
and rod assembl i es. I f the bedpl ate or the cyl i nder
bl ock mai n beari ng bores show damage the engi ne
must be repl aced.
(1) I f requi red, remove the mai n beari ng hal ves
from the cyl i nder bl ock and bedpl ate.
(2) Thoroughl y cl ean the bedpl ate to cyl i nder bl ock
seal i ng surfaces and mai n beari ng bores. Remove al l
oi l and seal ant resi due.
(3) I nspect the bedpl ate mai n beari ng bores for
cracks, scori ng or severe bl uei ng. I f ei ther condi ti on
exi sts the engi ne must be repl aced.
(4) I nspect the crankshaft thrust washer for scor-
i ng, scratches or bl uei ng. I f ei ther condi ti on exi st
repl ace the thrust washer.
(5) I nspect the oi l pan gasket/wi ndage tray for
spl i ts, tears or cracks i n the gasket seal i ng surfaces.
Repl ace gasket as necessary.
INSTALLATION
CAUTION: Main bearings are select fit. Refer to
Crankshaft Main Bearings in this section for proper
bearing selections.
CAUTION: When installing crankshaft, use care not
to damage bearing surfaces on the crankshaft.
NOTE: Apply sealant to the tone wheel retaining
screws prior to installation.
(1) Lubri cate upper mai n beari ng hal ves wi th
cl ean engi ne oi l .
(2) I nstal l the crankshaft tone wheel . Torque the
mounti ng screws to 22 Nm (21 ft. l bs.).
(3) Posi ti on crankshaft i n cyl i nder bl ock.
(4) I nstal l the thrust washers (Fi g. 42).
CAUTION: The bedplate to cylinder block mating
surface must be coated with Mopar Engine RTV
sealant prior to installation. Failure to do so will
cause severe oil leaks.
NOTE: Make sure that the bedplate and cylinder
block sealing surfaces are clean and free of oil or
other contaminants. Contaminants on the sealing
surfaces may cause main bearing distortion and/or
oil leaks.
(5) Appl y a 2.5mm (0.100 i nch) bead of Mopar
Engi ne RTV seal ant to the cyl i nder bl ock-to-bedpl ate
mati ng surface as shown.
(6) Coat the crankshaft mai n beari ng journal s
wi th cl ean engi ne oi l and posi ti on the bedpl ate onto
the cyl i nder bl ock.
KJ ENGINE - 3. 7L 9 - 43
CRANKSHAFT (Continued)
NOTE: Lubricate the bedplate retaining bolts with
clean engine oil prior to installation.
(7) I nstal l the bedpl ate retai ni ng bol ts, maki ng
sure to pl ace the stud bol ts i n the correct l ocati on,
Torque the bol ts i n the sequence shown (Fi g. 43).
Hand ti ghten bol ts 1D,1G and 1F unti l the bed-
pl ate contacts the bl ock.
Ti ghten bol ts 18 to 27 Nm (20 ft. l bs.)
Ti ghten bol ts 1A1J to 20 Nm (15 ft. l bs.)
Ti ghten bol ts AE 8 Nm ( 6 ft. l bs.).
Turn bol ts 18 an addi ti onal 66.
Turn bol ts 1D,1G, and 1F an addi ti onal 42.
Turn bol ts 1A,1B,1C,1E,1H,1I,and 1J an addi -
ti onal 36.
Turn bol ts AE an addi ti onal 32.
(8) Measure crankshaft end pl ay. Refer to Crank-
shaft Mai n Beari ngs i n thi s secti on for procedure.
(9) I nstal l the connecti ng rods and measure si de
cl earance. Refer to Connecti ng Rod Beari ngs i n thi s
secti on for procedure.
(10) Posi ti on the oi l pan gasket/wi ndage tray,
usi ng a new o-ri ng, i nstal l the oi l pi ckup tube.
Torque the bol t to 28Nn (20 ft. l bs.) torque the nuts
to 28Nm (20 ft. l bs.).
(11) I nstal l the oi l pan. Torque the retai ni ng bol ts
to 15 Nm (11 ft. l bs.) i n the sequence shown.
(12) I nstal l the engi ne.
Fig. 41 BEDPLATE PRY POINT LOCATION
Fig. 42 Crankshaft Thrust Washer Installation
1 - CRANKSHAFT THRUST WASHER
9 - 44 ENGINE - 3. 7L KJ
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE
MAIN BEARING - FITTING
SELECT FIT IDENTIFICATION
The mai n beari ngs are sel ect fi t to achi eve proper
oi l cl earances. For mai n beari ng sel ecti on, the crank-
shaft posi ti on sensor target wheel has grade i denti fi -
cati on marks stamped i nto i t (Fi g. 44). These marks
are read from l eft to ri ght, correspondi ng wi th jour-
nal number 1, 2, 3, 4 and 5. The crankshaft posi ti on
sensor target wheel i s mounted to the number 8
counter wei ght on the crankshaft.
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
Fig. 43 BEDPLATE TIGHTENING SEQUENCE
Fig. 44 Main Bearing Markings on Target Wheel
-Typical
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
KJ ENGINE - 3. 7L 9 - 45
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock.
Refer to CRANKSHAFT.
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper i s 0.008mm (0.0004
i nch.) and maxi mum out of round i s 0.005mm (0.002
i nch). Compare the measured di ameter wi th the jour-
nal di ameter speci fi cati on (Mai n Beari ng Fi tti ng
Chart). Sel ect i nserts requi red to obtai n the speci fi ed
beari ng-to-journal cl earance.
I nstal l the crankshaft i nto the cyl i nder bl ock. Refer
to CRANKSHAFT.
Check crankshaft end pl ay. Refer to CHECKI NG
CRANKSHAFT END PLAY.
CRANKSHAFT MAIN BEARING SELECTION
(1) Servi ce mai n beari ngs are avai l abl e i n three
grades. The chart bel ow i denti fi es the three servi ce
grades avai l abl e.
Crankshaft JOURNAL SIZE
SIZE mm(in.)
MARKING
R Size 63.488 - 63.496 mm
(2.4995 - 2.4998 in.)
S Size 63.496 - 63.500 mm (2.4998 - 2.4999 in.
T Size 63.500 - 63.504 mm (2.4999 - 2.501 in.)
Bearing size and application
Bearing
Code
SIze Application
Upper Bearing
A .2.443 - 2.447
mm
Use with
Cankshaft size R
(.0961 - .0963 in.)
B 2.439 - 2.443 mm Use with
crankshaft S, T
(0.960 -.o961 in.)
C 2.435 - 2.439 mm Use with
carnkshaft U
(.0958 - .0960 in.)
Lower Bearing Main 1 and 4
1 2.441 - 2.447 mm Use with
carnkshaft R, S
(.0961 -.0963 in.)
2 2.435 - 2.441 mm Use with
crankshaft T, U
(.0958 - .0962 in.)
Crankshaft JOURNAL SIZE
SIZE mm(in.)
MARKING
Lower Main Bearing 2 and 3
3 2.429 - 2.435 mm Use with
crankshaft R, S
(.0956 - .0958 in.)
4 2.423 - 2.429 mm Use with
crankshaft T, U
(.0953 - .0956 in.)
Bearing Clearances
Main 1, 4
Crankshaft
R
.004 - .034 mm ( .00015 - .0013 in.)
Crankshaft
S
.004 - .030 mm ( .00015 - .0011 in.)
Crankshaft
T
.006 - .032 mm (.0002 - .0012 in.)
Crankshaft
U
.002 - .032 mm (.00007 -. 0012 in.)
Main 2, 3
Crankshaft
R
.016 - .064 mm (.0 062 - .0025 in.)
Crankshaft
S
.016 - .042 mm (.00062 - .016 in.)
Crankshaft
T
.018 - .044 mm (.0007 - .0017 in.)
Crankshaft
U
.014 - .044 mm (.0005 - .0017 in.)
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
REMOVAL).
(3) Remove A/C compressor mouni ng fasteners and
set asi de.
(5) Remove upper radi ator hose.
(6) Di sconnect el ectri cal connector for fan mounted
i nsi de radi ator shroud.
(7) Remove radi ator shroud attachi ng fasteners.
(8) Remove radi ator cool i ng fan and shroud (Refer
to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
REMOVAL).
(9) Remove crankshaft damper bol t.
9 - 46 ENGINE - 3. 7L KJ
CRANKSHAFT MAIN BEARINGS (Continued)
(10) Remove damper usi ng Speci al Tool s 8513
I nsert and 1026 Three Jaw Pul l er (Fi g. 45).
(11) Usi ng Speci al Tool 8511, remove crankshaft
front seal (Fi g. 46).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Usi ng Speci al Tool 8348 and 8512, i nstal l
crankshaft front seal (Fi g. 47).
(2) I nstal l vi brati on damper (Refer to 9 - ENGI NE/
ENGI NE BLOCK/VI BRATI ON DAMPER - I NSTAL-
LATI ON).
(3) I nstal l radi ator cool i ng fan and shroud (Refer
to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
I NSTALLATI ON).
(4) I nstal l upper radi ator hose.
(5) I nstal l A/C compressor and ti ghten fasteners to
54 Nm (40 ft. l bs.).
(6) I nstal l accessory dri ve bel t refer (Refer to 7 -
I NSTALLATI ON).
(7) Refi l l cool i ng system (Refer to 7 - COOLI NG -
Fig. 45 Crankshaft DamperRemoval
1 - SPECIAL TOOL 8513 INSERT
Fig. 46 Crankshaft Front SealRemoval
Fig. 47 Crankshaft Front SealInstallation
KJ ENGINE - 3. 7L 9 - 47
CRANKSHAFT OIL SEAL - FRONT (Continued)
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) I f bei ng preformed i n vehi cl e, remove the
transmi ssi on.
(2) Remove the fl expl ate (Refer to 9 - ENGI NE/
ENGI NE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Usi ng Speci al Tool 8506 (Fi g. 48), remove the
crankshaft rear oi l seal .
INSTALLATION
(1) Posi ti on the magneti c seal gui de Speci al Tool
83492 (Fi g. 49) onto the crankshaft rear face. Then
posi ti on the crankshaft rear oi l seal onto the gui de.
(2) Usi ng Speci al Tool s 8349 Crankshaft Rear Oi l
Seal I nstal l er and C-4171 Dri ver Handl e (Fi g. 50),
wi th a hammer, tap the seal i nto pl ace. Conti nue to
tap on the dri ver handl e unti l the seal i nstal l er seats
agai nst the cyl i nder bl ock crankshaft bore.
(3) I nstal l the fl expl ate.
Fig. 48 Crankshaft Rear Oil Seal Removal
1 - REAR CRANKSHAFT SEAL
Fig. 49 Crankshaft Rear Oil Seal Guide Special Tool
83492 and Oil
2 - SPECIAL TOOL 83492 GUIDE
Fig. 50 Crankshaft Rear Oil Seal Installation
2 - SPECIAL TOOL 83491 INSTALLER
3 - SPECIAL TOOL C-4171 HANDLE
9 - 48 ENGINE - 3. 7L KJ
FLEX PLATE
REMOVAL
(1) Remove the transmi ssi on.
(2) Remove the bol ts and fl expl ate.
INSTALLATION
(1) Posi ti on the fl expl ate onto the crankshaft and
i nstal l the bol ts hand ti ght.
(2) Ti ghten the fl expl ate retai ni ng bol ts to 95 Nm
(70 ft. l bs.) i n the sequence shown (Fi g. 51).
PISTON & CONNECTING ROD
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
The pi stons are made of a hi gh strength al umi num
al l oy. The top ri ng groove i s coated wi th a anti -sei ze
coati ng. The connecti ng rods are made of forged pow-
dered metal , wi th a fractured cap desi gn. A ful l
fl oati ng pi ston pi n i s used to attach the pi ston to the
connecti ng rod (Fi g. 52).
1 Connecting Rod
2 Piston
3 Piston Pin
4 Oil Slinger Slot
STANDARD PROCEDURE
CONNECTING ROD BEARING - FITTING
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs. Check the beari ngs for normal
wear patterns, scori ng, groovi ng, fati gue and pi tti ng.
Repl ace any beari ng that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(3) Use pi ston ri ng compressor and Gui de Pi ns
Speci al Tool 8507 to i nstal l the rod and pi ston assem-
bl i es. The oi l sl i nger sl ots i n the rods must face front
of the engi ne. The Fs near the pi ston wri st pi n
bore shoul d poi nt to the front of the engi ne.
(4) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(5) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us a
Fig. 51 Flexplate Tightening Sequence
1 - FLEXPLATE
Fig. 52 PISTON AND ROD ASSEMBLY
KJ ENGINE - 3. 7L 9 - 49
90 turn. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(6) Remove the beari ng cap and determi ne amount
of beari ng-to-journal cl earance by measuri ng the
wi dth of compressed Pl asti gage. Refer to Engi ne
Speci fi cati ons for the proper cl earance. Plastigage
should indicate the same clearance across the
entire width of the insert. If the clearance var-
ies, it may be caused by either a tapered jour-
nal, bent connecting rod or foreign material
trapped between the insert and cap or rod.
(7) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(8) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, determi n whi ch servi ces beari ng set to
use the beari ng si zes are as fol l ows:
Bearing
Mark
SIZE USED WITH
JOURNAL SIZE
.025 US .025 mm 57.871-57.879 mm
(.001 in.) (2.2783-2.2786 in.)
Std. STANDARD 57.896-57.904 mm
(2.2793-2.2810 in.)
.250 US .250 mm 57.646-57.654 mm
(.010 in.) (2.2695-2.2698 in.)
(9) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(10) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 27 Nm (20 ft. l bs.) pl us a 90 turn.
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange. Refer to
Engi ne Speci fi cati ons for the proper cl earance.
Repl ace the connecti ng rod i f the si de cl earance i s
not wi thi n speci fi cati on.
STANDARD PROCEDURE - PISTON FITTING
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm (
.0001 i n.) I NCREMENTS i s requi red. I f a bore gauge
i s not avai l abl e, do not use an i nsi de mi crometer.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at a poi nt 38.0 mm (1.5 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 54).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 53). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
REMOVAL
(2) Remove the fol l owi ng components:
Oi l pan and gasket/wi ndage tray (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
Cyl i nder head covers (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CYLI NDER HEAD COVER(S) -
REMOVAL) and (Refer to 9 - ENGI NE/CYLI NDER
HEAD/CYLI NDER HEAD COVER(S) - REMOVAL).
Ti mi ng chai n cover (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT / CHAI N COVER(S)
- REMOVAL).
Cyl i nder head(s) (Refer to 9 - ENGI NE/CYLI N-
DER HEAD - REMOVAL) and (Refer to 9 - ENGI NE/
CYLI NDER HEAD - REMOVAL).
(3) I f necessary, remove top ri dge of cyl i nder bores
wi th a rel i abl e ri dge reamer before removi ng pi stons
from cyl i nder bl ock. Be sure to keep tops of pis-
tons covered during this operation. Pi stons and
connecti ng rods must be removed from top of cyl i nder
bl ock. When removi ng pi ston and connecti ng rod
Fig. 53 Moly Coated Piston - Typical
1 - MOLY COATED
2 - MOLY COATED
9 - 50 ENGINE - 3. 7L KJ
PISTON & CONNECTING ROD (Continued)
assembl i es from the engi ne, rotate crankshaft so the
each connecti ng rod i s centered i n cyl i nder bore.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods or caps, as damage to
connecting rods could occur
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
removing to ensure correct reassembly.
(4) Mark connecti ng rod and beari ng cap posi ti ons
usi ng a permanent i nk marker or scri be tool .
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
(5) Remove connecti ng rod cap. I nstal l Speci al Tool
8507 Connecti ng Rod Gui des i nto the connecti ng rod
bei ng removed. Remove pi ston from cyl i nder bore.
Repeat thi s procedure for each pi ston bei ng removed.
CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) I mmedi atel y after pi ston and connecti ng rod
removal , i nstal l beari ng cap on the mati ng connect-
i ng rod to prevent damage to the fractured cap and
rod surfaces.
CLEANING
CAUTION: DO NOT use a wire wheel or other abra-
sive cleaning devise to clean the pistons or con-
necting rods. The pistons have a Moly coating, this
coating must not be damaged.
(1) Usi ng a sui tabl e cl eani ng sol vent cl ean the pi s-
tons i n warm water and towel dry.
(2) Use a wood or pl asti c scraper to cl ean the ri ng
l and grooves.
CAUTION: DO NOT remove the piston pin from the
piston and connecting rod assembly.
INSPECTION
Check the connecti ng rod journal for excessi ve
wear, taper and scori ng (Refer to 9 - ENGI NE/EN-
GI NE BLOCK/CONNECTI NG ROD BEARI NGS -
Check the connecti ng rod for si gns of twi st or bend-
i ng.
Check the pi ston for taper and el l i pti cal shape
before i t i s fi tted i nto the cyl i nder bore (Refer to 9 -
ENGI NE/ENGI NE BLOCK/PI STON & CONNECT-
I NG ROD - STANDARD PROCEDURE).
Check the pi ston for scori ng, or scrapi ng marks i n
the pi ston ski rts. Check the ri ng l ands for cracks
and/or deteri orati on.
INSTALLATION
(1) Before i nstal l i ng pi ston and connecti ng rod
assembl i es i nto the bore, i nstal l the pi ston ri ngs.
(2) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l . Posi ti on a ri ng compressor over the pi ston
and ri ngs. Ti ghten ri ng compressor. Ensure posi-
tion of rings do not change during this opera-
tion.
(3) Posi ti on beari ng onto connecti ng rod. Ensure
that tabs i n beari ng shel l al i gns wi th sl ots i n con-
necti ng rod. Veri fy that parti ng l i ne of beari ng i s
al i gned wi th parti ng l i ne of connecti ng rod.
(4) Lubri cate beari ng surface wi th cl ean engi ne oi l .
(5) I nstal l Speci al Tool 8507 Connecti ng Rod
Gui des i nto connecti ng rod bol t threads (Fi g. 55).
(6) The pi stons are marked on the pi ston pi n bore
surface wi th an rai sed F i ndi cati ng i nstal l ati on
posi ti on. Thi s mark must be poi nti ng toward the
front of engi ne on both cyl i nder banks. The connect-
i ng rod oi l sl i nger sl ot faces the front of the engi ne
(Fi g. 56).
(7) Wi pe cyl i nder bore cl ean and l ubri cate wi th
engi ne oi l .
(8) Rotate crankshaft unti l connecti ng rod journal
i s on the center of cyl i nder bore. I nsert rod and pi s-
Fig. 54 Bore Gauge - Typical
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
KJ ENGINE - 3. 7L 9 - 51
ton i nto cyl i nder bore and careful l y posi ti on connect-
i ng rod gui des over crankshaft journal .
(9) Tap pi ston down i n cyl i nder bore usi ng a ham-
mer handl e. Whi l e at the same ti me, gui de connect-
i ng rod i nto posi ti on on rod journal .
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
(10) Lubri cate rod bol ts and beari ng surfaces wi th
engi ne oi l . I nstal l connecti ng rod cap and beari ng.
Ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us 90.
(11) I nstal l the fol l owi ng components:
Cyl i nder head(s). (Refer to 9 - ENGI NE/CYLI N-
DER HEAD - I NSTALLATI ON).
Ti mi ng chai n and cover. (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT / CHAI N COVER(S)
- I NSTALLATI ON).
Cyl i nder head covers (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CYLI NDER HEAD COVER(S) -
I NSTALLATI ON).
Oi l pan and gasket/wi ndage tray. (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
(12) Fi l l crankcase wi th proper engi ne oi l to cor-
rect l evel .
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
Before rei nstal l i ng used ri ngs or i nstal l i ng new
ri ngs, the ri ng cl earances must be checked.
(1) Wi pe the cyl i nder bore cl ean.
(2) I nsert the ri ng i n the cyl i nder bore.
NOTE: The ring gap measurement must be made
with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore.
(3) Usi ng a pi ston, to ensure that the ri ng i s
squared i n the cyl i nder bore, sl i de the ri ng downward
i nto the cyl i nder.
(4) Usi ng a feel er gauge check the ri ng end gap
(Fi g. 57). Repl ace any ri ngs not wi thi n speci fi cati on.
PISTON RING SIDE CLEARANCE
Fig. 55 Piston and Connecting Rod - Installation -
Typical
1 - F TOWARD FRONT OF ENGINE
3 - RING COMPRESSOR
Fig. 56 Piston and Connecting Rod Orientation
1 - MAJOR THRUST SIDE OF PISTON
9 - 52 ENGINE - 3. 7L KJ
NOTE: Make sure the piston ring grooves are clean
and free of nicks and burrs.
(5) Measure the ri ng si de cl earance as shown (Fi g.
58)make sure the feel er gauge fi ts snugl y between
the ri ng l and and the ri ng. Repl ace any ri ng not
wi thi n speci fi cati on.
(6) Rotate the ri ng around the pi ston, the ri ng
must rotate i n the groove wi th out bi ndi ng.
PISTON RING SPECIFICATION CHART
Ring Position Groove Maximum
Clearance Clearance
Upper Ring .051-.094mm 0.11mm
(0.0020- .0037
in.)
(0.004 in.)
Intermediate
Ring
0.04-0.08mm 0.10mm
(0.0016-0.0031
in.)
(0.004 in.)
Oil Control Ring .019-.229mm .25mm
(Steel Rails) (.0007-.0090
in.)
(0.010 in.)
Ring Position Ring Gap Wear Limit
Upper Ring 0.23-0.39mm 0.43mm
(0.009-0.015
in.)
(0.0017 in.)
Intermediate
Ring
0.40-0.66mm 0.74mm
(0.015-0.026
in.)
(0.029 in.)
Oil Control Ring 0.028-0.79mm 1.55mm
(Steel Rail) (0.011- 0.031
in.)
(0.061 in.)
(7) The No. 1 and No. 2 pi ston ri ngs have a di ffer-
ent cross secti on. Ensure No. 2 ri ng i s i nstal l ed wi th
manufacturers I .D. mark (Dot) faci ng up, towards top
of the pi ston.
NOTE: Piston rings are installed in the following
order:
Oil ring expander.
Upper oil ring side rail.
Lower oil ring side rail.
No. 2 Intermediate piston ring.
No. 1 Upper piston ring.
(8) I nstal l the oi l ri ng expander.
(9) I nstal l upper si de rai l (Fi g. 59) by pl aci ng one
end between the pi ston ri ng groove and the expander
ri ng. Hol d end fi rml y and press down the porti on to
be i nstal l ed unti l si de rai l i s i n posi ti on. Repeat thi s
step for the l ower si de rai l .
(10) I nstal l No. 2 i ntermedi ate pi ston ri ng usi ng a
pi ston ri ng i nstal l er (Fi g. 60).
(11) I nstal l No. 1 upper pi ston ri ng usi ng a pi ston
ri ng i nstal l er (Fi g. 60).
(12) Posi ti on pi ston ri ng end gaps as shown i n
(Fi g. 61). I t i s i mportant that expander ri ng gap i s at
l east 45 from the si de rai l gaps, but not on the pi s-
ton pi n center or on the thrust di recti on.
Fig. 57 Ring End Gap Measurement - Typical
1 - FEELER GAUGE
Fig. 58 Measuring Piston Ring Side Clearance
1 - FEELER GAUGE
KJ ENGINE - 3. 7L 9 - 53
PISTON RINGS (Continued)
VIBRATION DAMPER
REMOVAL
REMOVAL).
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(3) Remove crankshaft damper bol t.
(4) Remove damper usi ng Speci al Tool s 8513
I nsert and 1026 Three Jaw Pul l er (Fi g. 62).
Fig. 59 Side RailInstallation
1 - SIDE RAIL END
Fig. 60 Upper and Intermediate RingsInstallation
Fig. 61 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 62 Crankshaft DamperRemoval
1 - SPECIAL TOOL 8513 INSERT
9 - 54 ENGINE - 3. 7L KJ
PISTON RINGS (Continued)
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Al i gn crankshaft damper sl ot wi th key i n
crankshaft. Sl i de damper onto crankshaft sl i ghtl y.
CAUTION: Special Tool 8512A, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(2) Assembl e Speci al Tool 8512A as fol l ows, The
nut i s threaded onto the shaft fi rst. Then the rol l er
beari ng i s pl aced onto the threaded rod (The hard-
ened beari ng surface of the beari ng MUSTface the
nut). Then the hardened washer sl i des onto the
threaded rod (Fi g. 63). Once assembl ed coat the
threaded rods threads wi th Mopar Ni ckel Anti -
Sei ze or (Locti te No. 771).
(3) Usi ng Speci al Tool 8512A, press damper onto
crankshaft (Fi g. 64).
(4) I nstal l then ti ghten crankshaft damper bol t to
175 Nm (130 ft. l bs.).
(5) I nstal l accessory dri ve bel t (Refer to 7 - COOL-
LATI ON).
STRUCTURAL COVER
DESCRIPTION
The structural dust cover i s made of di e cast al u-
mi num and joi ns the l ower hal f of the transmi ssi on
bel l housi ng to the engi ne bedpl ate.
OPERATION
The structural cover provi des addi ti onal power-
trai n sti ffness and reduces noi se and vi brati on.
REMOVAL
(2) Remove the bol ts retai ni ng structural cover
(Fi g. 65).
(3) Remove the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Posi ti on the structural cover i n the vehi cl e.
(2) I nstal l al l bol ts retai ni ng the cover-to-engi ne.
DO NOT ti ghten the bol ts at thi s ti me.
(3) I nstal l the cover-to-transmi ssi on bol ts. Do NOT
ti ghten at thi s ti me.
Fig. 63 Proper Assembly Method for Special Tool
8512A
1 - BEARING
2 - NUT
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
5 - HARDENED WASHER
Fig. 64 Crankshaft Damper Installation
1 - SPECIAL TOOL 8512A
KJ ENGINE - 3. 7L 9 - 55
VIBRATION DAMPER (Continued)
CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starti ng wi th the two rear cover-to-engi ne
bol ts, ti ghten bol ts (1) (Fi g. 66) to 54 Nm (40 ft. l bs.),
then ti ghten bol ts (2) (Fi g. 66) and (3) to 54 Nm ( 40
ft. l bs.) i n the sequence shown.
FRONT MOUNT
REMOVAL
CAUTION: Remove the fan blade, fan clutch and fan
shroud before raising engine. Failure to do so may
cause damage to the fan blade, fan clutch and fan
shroud.
(2) Remove the fan bl ade, fan cl utch and fan
shroud. Refer to COOLI NG SYSTEM for procedure.
(3) Remove the engi ne oi l fi l ter.
(4) Support the engi ne wi th a sui tabl e jack and a
bl ock of wood across the ful l wi dth of the engi ne oi l
pan.
(5) Remove the four (4) cyl i nder bl ock-to-i nsul ator
mount bol ts and the nut from the engi ne i nsul ator
mount through bol t.
(6) Usi ng the jack, rai se the engi ne hi gh enough to
remove the engi ne i nsul ator mount through bol t and
the i nsul ator mount (Fi g. 67) and (Fi g. 68).
Fig. 65 Structural Cover
1 - BOLT
2 - BOLT
3 - BOLT
Fig. 66 Structural Cover
1 - BOLT
2 - BOLT
3 - BOLT
Fig. 67 Engine Insulator Mount 3.7 Left
1 -MOUNT
2 - NUT
3 - WIRE RETAINER
4 - FASTENER
5 - BOLT
6 - THRU BOLT
9 - 56 ENGINE - 3. 7L KJ
STRUCTURAL COVER (Continued)
INSTALLATION
(1) Posi ti on the i nsul ator mount and i nstal l the
i nsul ator mount through bol t.
(2) Lower the engi ne unti l the cyl i nder bl ock-to-i n-
sul ator mount bol ts can be i nstal l ed.
(3) Remove the jack and bl ock of wood.
(4) Torque the cyl i nder bl ock-to-i nsul ator mount
bol ts to 61 Nm ( 45 ft. l bs.).
(5) I nstal l and torque the through bol t retai ni ng
nut to 61 Nm (45 ft. l bs.).
(6) I nstal l the fan bl ade, fan cl utch and fan
shroud.
REAR MOUNT
REMOVAL
NOTE: A resilient rubber cushion supports the
transmission at the rear between the transmission
extension housing and the rear support crossmem-
ber or skid plate.
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the nuts hol di ng the support cushi on
to the crossmember. Remove the crossmember.
MANUAL TRANSMISSION
Remove the support cushi on nuts and remove
the cushi on.
Remove the transmi ssi on support bracket bol ts
and remove the bracket from the transmi ssi on.
AUTOMATIC TRANSMISSION
Remove the support cushi on bol ts and remove
the cushi on and the support bracket from the trans-
mi ssi on (4WD) or from the adaptor bracket (2WD).
On 2WD vehi cl es, remove the bol ts hol di ng the
transmi ssi on support adaptor bracket to the trans-
mi ssi on. Remove the adaptor bracket.
INSTALLATION
MANUAL TRANSMISSION:
(1) I nstal l the transmi ssi on support bracket to the
transmi ssi on. I nstal l the bol ts and ti ghten to 46 Nm
(34 ft. l bs.) torque.
(2) I nstal l the support cushi on to the support
bracket. I nstal l the nuts and ti ghten to 75 Nm (55
ft. l bs.) torque.
(3) Posi ti on the crossmember onto the support
cushi on studs. I nstal l the stud nuts and ti ghten to 22
Nm (192 i n. l bs) torque.
(4) I nstal l crossmember-to-si l l bol ts and ti ghten to
41 Nm (30 ft. l bs.) torque.
(5) Remove the transmi ssi on support.
AUTOMATIC TRANSMISSION:
(1) On 2WD vehi cl es, posi ti on the transmi ssi on
support adaptor bracket to the transmi ssi on. I nstal l
the bol ts and ti ghten to 75 Nm (55 ft. l bs.) torque.
(2) Posi ti on the transmi ssi on support bracket and
support cushi on to the adaptor bracket (2WD) or the
transmi ssi on (4WD). I nstal l the bol ts and ti ghten to
(3) Posi ti on the crossmember onto the support
cushi on studs. I nstal l the stud nuts and ti ghten to 22
Nm (192 i n. l bs) torque.
(4) I nstal l crossmember-to-si l l bol ts and ti ghten to
(5) Remove the transmi ssi on support.
LUBRICATION
DESCRIPTION
The l ubri cati on system i s a ful l fl ow fi l trati on pres-
sure feed type.
Fig. 68 Engine Insulator Mount 3.7 Right
1 - MOUNT
2 - THRU BOLT
3 - BOLT
4 - NUT
KJ ENGINE - 3. 7L 9 - 57
FRONT MOUNT (Continued)
OPERATION
Oi l from the oi l pan i s pumped by a gerotor type oi l
pump di rectl y mounted to the crankshaft nose. Oi l
pressure i s control l ed by a rel i ef val ve mounted
i nsi de the oi l pump housi ng. For l ubri cati on fl ow
refer to (Fi g. 69)
The camshaft exhaust val ve l obes and rocker arms
are l ubri cated through a smal l hol e i n the rocker
arm; oi l fl ows through the l ash adjuster then through
the rocker arm and onto the camshaft l obe. Due to
the orentati on of the rocker arm, the camshaft i ntake
l obes are not l ubed i n the same manner as the
exhaust l obes. The i ntake l obes are l ubed through
i nternal passages i n the camshaft. Oi l fl ows through
a bore i n the number 3 camshaft beari ng bore, and
as the camshaft turns, a hol e i n the camshaft al i gns
wi th the hol e i n the camshaft bore al l owi ng engi ne
oi l to enter the camshaft tube. The oi l then exi ts
through 1.6mm (0.063 i n.) hol es dri l l ed i nto the
i ntake l obes, l ubri cati ng the l obes and the rocker
arms.
ENGINE LUBRICATION FLOW CHART - BLOCK: TABLE 1
FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
Block Main Oil Gallery 1. Crankshaft Main Journal
2. Left Cylinder Head*
3. Right Cylinder Head*
4. Counterbalance Shaft Rear Journal
Crankshaft Main Journals Crankshaft Rod Journals
Crankshaft Number One Main Journal 1. Front Timing Chain Idler Shaft
2. Counterbalance Shaft - Front Journal
3. Both Secondary Chain Tensioners
Left Cylinder Head Refer to Engine Lubrication Flow Chart - Cylinder
Heads: Table 2
Right Cylinder Head Refer to Engine Lubrication Flow Chart - Cylinder
Heads: Table 2
* The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads
ENGINE LUBRICATION FLOW CHART - CYLINDER HEADS: TABLE 2
FROM TO
Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to
front)
1. Base of Camshaft Towers
2. Lash Adjuster Towers
Base of Camshaft Towers Vertical Drilling Through Tower to Camshaft Bearings**
Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets
** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
lobes, which have oil passages drilled into them to lubricate the rocker arms.
9 - 58 ENGINE - 3. 7L KJ
LUBRICATION (Continued)
Fig. 69 LUBRICATION OIL FLOW
1 - OIL FLOW TO RIGHT CYLINDER HEAD
2 - CYLINDER BLOCK MAIN OIL GALLERY
3 - LEFT CYLINDER HEAD OIL GALLERY
4 - OIL FLOW TO BOTH SECONDARY TENSIONERS
5 - OIL FLOW TO LEFT CYLINDER HEAD
6 - OIL PRESSURE SENSOR LOCATION
7 - OIL FLOW TO COUNTER BALANCE SHAFT
8 - OIL PUMP OUTLET TO CYLINDER BLOCK
9 - OIL PUMP
10 - OIL FLOW TO CRANKSHAFT MAIN JOURNALS
11 - CRANKSHAFT MAIN BEARING JOURNALS
12 - RIGHT CYLINDER HEAD OIL GALLERY
KJ ENGINE - 3. 7L 9 - 59
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.If the oil leak source is not pos-
itively identified at this time, proceed wi th the ai r
l eak detecti on test method.
Air Leak Detection Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, camshaft bore
cup pl ugs oi l gal l ey pi pe pl ugs, oi l fi l ter runoff, and
mai n beari ng cap to cyl i nder bl ock mati ng sur-
faces.
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
PRESSURE
(1) Remove oi l pressure sendi ng uni t (Fi g. 70)and
i nstal l gauge assembl y C-3292.
(2) Run engi ne unti l thermostat opens.
(3) Oi l Pressure:
Curb I dl e25 Kpa (4 psi ) mi ni mum
3000 rpm170 - 550 KPa (25 - 80 psi )
(4) I f oi l pressure i s 0 at i dl e, shut off engi ne.
Check for a cl ogged oi l pi ck-up screen or a pressure
rel i ef val ve stuck open.
9 - 60 ENGINE - 3. 7L KJ
DIAGNOSIS AND TESTING - REAR SEAL AREA
LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, camshaft bore
cup pl ugs, oi l gal l ey pi pe pl ugs, oi l fi l ter runoff,
and mai n beari ng cap to cyl i nder bl ock mati ng sur-
faces. See Engi ne, for proper repai r procedures of
these i tems.
(4) I f no l eaks are detected, pressuri zed the crank-
case as outl i ned i n the secti on, I nspecti on (Engi ne oi l
Leaks i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed. (Refer to 9 - ENGI NE - DI AGNOSI S AND
TESTI NG), under the Oi l Leak row, for components
i nspecti ons on possi bl e causes and correcti ons.
(7) After the oi l l eak root cause and appropri ate
correcti ve acti on have been i denti fi ed, (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT OI L
SEAL - REAR - REMOVAL).
OIL
STANDARD PROCEDURE - ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engi ne oi l that i s API Servi ce Grade Certi -
fi ed. MOPAR provi des engi ne oi l s that conform to
thi s servi ce grade.
SAE VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . Use onl y engi ne oi l s wi th mul ti -
Fig. 70 Oil Pressure Sending Unit -Typical
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
KJ ENGINE - 3. 7L 9 - 61
pl e vi scosi ti es such as 5W-30 or 10W-30 i n the 3.7L
engi nes. These are speci fi ed wi th a dual SAE vi scos-
i ty grade whi ch i ndi cates the col d-to-hot temperature
vi scosi ty range. Sel ect an engi ne oi l that i s best
sui ted to your parti cul ar temperature range and vari -
ati on (Fi g. 71).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. The desi gnati on of ENERGY CON-
SERVI NG i s l ocated on the l abel of an engi ne oi l con-
tai ner.
CONTAINER IDENTIFICATION
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 72).
OIL LEVEL INDICATOR (DIPSTICK)
The engi ne oi l l evel i ndi cator i s l ocated on the
ri ght si de of the the 3.7L engi ne.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
pressure loss or oil foaming can result.
I nspect engi ne oi l l evel approxi matel y every 800
ki l ometers (500 mi l es). Unl ess the engi ne has exhi b-
i ted l oss of oi l pressure, run the engi ne for about fi ve
mi nutes before checki ng oi l l evel . Checki ng engi ne oi l
l evel on a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck.
(1) Posi ti on vehi cl e on l evel surface.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, take oi l l evel readi ng.
(6) Add oi l i f l evel i s bel ow the SAFE ZONE on
di psti ck.
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Remove oi l fi l l cap.
(3) Hoi st and support vehi cl e on safety stands.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Remove oi l fi l ter (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L FI LTER - REMOVAL).
(8) I nstal l a new oi l fi l ter.
(9) Lower vehi cl e and fi l l crankcase wi th 5 quarts
of the speci fi ed type of engi ne oi l descri bed i n thi s
secti on.
(10) I nstal l oi l fi l l cap.
(11) Start engi ne and i nspect for l eaks.
(12) Stop engi ne and i nspect oi l l evel .
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
Fig. 71 Temperature/Engine Oil Viscosity - 3.7L
Engine
Fig. 72 Engine Oil Container Standard Notations
9 - 62 ENGINE - 3. 7L KJ
OIL (Continued)
OIL FILTER
REMOVAL
Al l engi nes are equi pped wi th a hi gh qual i ty ful l -
fl ow, di sposabl e type oi l fi l ter. Dai ml erChrysl er Cor-
porati on recommends a Mopar or equi val ent oi l
fi l ter be used.
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se (Fi g. 73)to
remove i t from the cyl i nder bl ock oi l fi l ter boss.
(4) When fi l ter separates from cyl i nder bl ock oi l
fi l ter boss, ti p gasket end upward to mi ni mi ze oi l
spi l l . Remove fi l ter from vehi cl e.
NOTE: Make sure filter gasket was removed with fil-
ter.
(5) Wi th a wi pi ng cl oth, cl ean the gasket seal i ng
surface of oi l and gri me.
INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l .
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 74)hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
OIL PAN
DESCRIPTION
The engi ne oi l pan i s made of l ami nated steel and
has a si ngl e pl ane seal i ng surface. The sandwi ch
styl e oi l pan gasket has an i ntegrated wi ndage tray
and steel carri er (Fi g. 75). The seal i ng area of the
gasket i s mol ded wi th rubber and i s desi gned to be
reused as l ong as the gasket i s not cut, torn or
ri pped.
REMOVAL
(1) Remove the engi ne (Refer to 9 - ENGI NE -
REMOVAL).
(2) Posi ti on the engi ne i n a sui tabl e engi ne stand.
NOTE: Do not pry on oil pan or oil pan gasket. Gas-
ket is integral to engine windage tray and does not
come out with oil pan (Fig. 76).
(3) Remove the oi l pan mounti ng bol ts and oi l pan.
(4) Unbol t oi l pump pi ckup tube and remove tube.
(5) Remove the oi l pan gasket/wi ndage tray
assembl yfrom engi ne.
CLEANING
(1) Cl ean oi l pan i n sol vent and wi pe dry wi th a
cl ean cl oth.
(2) Cl ean the oi l pan gasket surface. DO NOT use
a gri nder wheel or other abrasi ve tool to cl ean seal -
i ng surface.
(3) Cl ean oi l screen and tube thoroughl y i n cl ean
sol vent.
INSPECTION
(1) I nspect oi l drai n pl ug and pl ug hol e for
stri pped or damaged threads. Repai r as necessary.
Fig. 73 Oil Filter - 3.7L Engine
1 - ENGINE OIL FILTER
Fig. 74 Oil Filter Sealing SurfaceTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
KJ ENGINE - 3. 7L 9 - 63
(2) I nspect the oi l pan mounti ng fl ange for bends
or di storti on. Strai ghten fl ange, i f necessary.
INSTALLATION
(1) Cl ean the oi l pan gasket mati ng surface of the
bedpl ate and oi l pan.
(2) I nspect i ntegrated oi l pan gasket, and repl ace
as necessary.
(3) Posi ti on the i ntegrated oi l pan gasket/wi ndage
tray assembl y.
(4) I nstal l the oi l pi ckup tube
(5) I nstal l the mounti ng bol t and nuts. Ti ghten
(6) Posi ti on the oi l pan and i nstal l the mounti ng
bol ts. Ti ghten the mounti ng bol ts to 15 Nm (11 ft.
l bs.) i n the sequence shown (Fi g. 77).
(7) Remove engi ne from engi ne stand.
(8) I nstal l engi ne (Refer to 9 - ENGI NE - I NSTAL-
LATI ON).
Fig. 75 OIL PAN AND GASKET
1 - OIL PAN
2 - WINDAGE TRAY AND INTEGRATED OIL PAN GASKET
Fig. 76 OIL PAN AND GASKET
1 - OIL PAN
2 - WINDAGE TRAY AND INTEGRATED OIL PAN GASKET
Fig. 77 OIL PAN MOUNTING BOLT SEQUENCE
9 - 64 ENGINE - 3. 7L KJ
OIL PAN (Continued)
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3wi re, sol i d-state engi ne oi l pressure sensor
(sendi ng uni t) i s l ocated i n an engi ne oi l pressure
gal l ery.
OPERATION
The oi l pressure sensor uses three ci rcui ts. They
are:
A 5vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM)
A sensor ground through the PCMs sensor
return
A si gnal to the PCM rel ati ng to engi ne oi l pres-
sure
The oi l pressure sensor has a 3wi re el ectri cal
functi on very much l i ke the Mani fol d Absol ute Pres-
sure (MAP) sensor. Meani ng di fferent pressures
rel ate to di fferent output vol tages.
A 5vol t suppl y i s sent to the sensor from the PCM
to power up the sensor. The sensor returns a vol tage
si gnal back to the PCM rel ati ng to engi ne oi l pres-
sure. Thi s si gnal i s then transferred (bussed) to the
i nstrument panel on ei ther a CCD or PCI bus ci rcui t
(dependi ng on vehi cl e l i ne) to operate the oi l pressure
gauge and the check gauges l amp. Ground for the
sensor i s provi ded by the PCM through a l ow-noi se
sensor return.
REMOVAL
(3) Remove front spl ash shi el d.
(4) Di sconnect oi l pressure sender wi re (Fi g. 78).
(5) Remove the pressure sender (Fi g. 78).
INSTALLATION
(1) I nstal l oi l pressure sender.
(2) Connect oi l pressure sender wi re.
(3) I nstal l front spl ash shi el d.
OIL PUMP
REMOVAL
(1) Remove the oi l pan and pi ck-up tube (Refer to
9 - ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
(2) Remove the ti mi ng chai n cover (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - REMOVAL).
(3) Remove the ti mi ng chai ns and tensi oners
(Refer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG
BELT/CHAI N AND SPROCKETS - REMOVAL).
(4) Remove the four bol ts, pri mary ti mi ng chai n
tensi oner and the oi l pump.
DISASSEMBLY
(1) Remove oi l pump cover screws and l i ft off cover
pl ate.
(2) Remove pump i nner and outer rotors.
NOTE: Once the oil pressure relief valve, cup plug,
and pin are removed, the pump assembly must be
replaced.
(3) I f i t i s necessary to remove the pressure rel i ef
val ve, dri ve the rol l pi n from pump housi ng and
remove cup pl ug, spri ng and val ve.
Fig. 78 Oil Pressure Sending Unit
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
KJ ENGINE - 3. 7L 9 - 65
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
these components are disassembled and or
removed from the pump the entire oil pump assem-
bly must be replaced.
(1) Cl ean al l parts thoroughl y. Mati ng surface of
the oi l pump housi ng shoul d be smooth. I f the pump
cover i s scratched or grooved the oi l pump assembl y
shoul d be repl aced.
(2) Lay a strai ght edge across the pump cover sur-
face (Fi g. 79). I f a 0.025 mm (0.001 i n.) feel er gauge
can be i nserted between the cover and the strai ght
edge the oi l pump assembl y shoul d be repl aced.
(3) Measure the thi ckness of the outer rotor (Fi g.
80). I f the outer rotor thi ckness measures at 12.005
mm (0.4727 i n.) or l ess the oi l pump assembl y must
be repl aced.
(4) Measure the di ameter of the outer rotor. I f the
outer rotor di ameter measures at 85.925 mm (3.382
i n.) or l ess the oi l pump assembl y must be repl aced.
(5) Measure the thi ckness of the i nner rotor (Fi g.
81). I f the i nner rotor thi ckness measures at 12.005
mm (0.472 i n.) or l ess then the oi l pump assembl y
must be repl aced.
(6) Sl i de outer rotor i nto the body of the oi l pump.
Press the outer rotor to one si de of the oi l pump body
and measure cl earance between the outer rotor and
the body (Fi g. 82). I f the measurement i s 0.235mm
(0.009 i n.) or more the oi l pump assembl y must be
repl aced.
(7) I nstal l the i nner rotor i n the i nto the oi l pump
body. Measure the cl earance between the i nner and
outer rotors (Fi g. 83). I f the cl earance between the
rotors i s .150 mm (0.006 i n.) or more the oi l pump
assembl y must be repl aced.
(8) Pl ace a strai ght edge across the body of the oi l
pump (between the bol t hol es), i f a feel er gauge of
.095 mm (0.0038 i n.) or greater can be i nserted
between the strai ghtedge and the rotors, the pump
must be repl aced (Fi g. 84).
NOTE: The 3.7 Oil pump is released as an assem-
bly. There are no DaimlerChrysler part numbers for
Sub-Assembly components. In the event the oil
pump is not functioning or out of specification it
must be replaced as an assembly.
Fig. 79 Checking Oil Pump Cover Flatness
1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
Fig. 80 Measuring Outer Rotor Thickness
Fig. 81 Measuring Inner Rotor Thickness
9 - 66 ENGINE - 3. 7L KJ
OIL PUMP (Continued)
ASSEMBLY
(1) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear.
(2) I nstal l i nner and outer rotors
(3) I nstal l oi l pump cover pl ate and i nstal l cover
bol ts and ti ghten them to 12 Nm (105 i n. l bs.).
(4) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
(5) I f oi l pressure i s l ow and pump i s wi thi n spec-
i fi cati ons, i nspect for worn engi ne beari ngs or other
causes for oi l pressure l oss.
INSTALLATION
(1) Posi ti on the oi l pump onto the crankshaft and
i nstal l two oi l pump retai ni ng bol ts.
(2) Posi ti on the pri mary ti mi ng chai n tensi oner
and i nstal l the two retai ni ng bol ts.
(3) Ti ghten the oi l pump and pri mary ti mi ng chai n
tensi oner retai ni ng bol ts to 28 Nm (250 i n. l bs.) i n
the sequence shown (Fi g. 85).
(4) I nstal l the secondary ti mi ng chai n tensi oners
and ti mi ng chai ns (Refer to 9 - ENGI NE/VALVE
TI MI NG/TI MI NG BELT/CHAI N AND SPROCKETS -
I NSTALLATI ON).
(5) I nstal l the ti mi ng chai n cover (Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
COVER(S) - I NSTALLATI ON).
(6) I nstal l the pi ck-up tube and oi l pan (Refer to 9
- ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
Fig. 82 Measuring Outer Rotor Clearance in
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 83 Measuring Clearance Between Rotors
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 84 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
KJ ENGINE - 3. 7L 9 - 67
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d (Fi g. 86) i s made of a compos-
i te materi al and features 300 mm (11.811 i n.) l ong
runners whi ch maxi mi zes l ow end torque. The i ntake
mani fol d uses si ngl e pl ane seal i ng whi ch consi st of
si x i ndi vi dual press i n pl ace port gaskets to prevent
l eaks. The throttl e body attaches di rectl y to the
i ntake mani fol d. Ei ght studs and two bol ts are used
to fasten the i ntake to the head.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
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) Start the engi ne.
(2) Spray a smal l stream of water (Spray Bottl e) at
the suspected l eak area.
(3) I f engi ne RPMS change, the area of the sus-
pected l eak has been found.
(4) Repai r as requi red.
REMOVAL
(2) Remove resonator assembl y and ai r i nl et hose.
(3) Di sconnect throttl e and speed control cabl es.
(4) Di sconnect el ectri cal connectors for the fol l ow-
i ng components: Refer to FUEL SYSTEM for compo-
nent l ocati ons.
Mani fol d Absol ute Pressure (MAP) Sensor
I ntake Ai r Temperature (I AT) Sensor
Throttl e Posi ti on (TPS) Sensor
Cool ant Temperature (CTS) Sensor
(5) Di sconnect vapor purge hose, brake booster
hose, speed control servo hose, posi ti ve crankcase
venti l ati on (PCV) hose.
(6) Di sconnect generator el ectri cal connecti ons.
(7) Di sconnect ai r condi ti oni ng compressor el ectri -
cal connecti ons.
(8) Di sconnect l eft and ri ght radi o suppressor
straps.
(9) Di sconnect and remove i gni ti on coi l towers.
(10) Remove top oi l di psti ck tube retai ni ng bol t
and ground strap.
Fig. 85 Oil Pump and Primary Timing Chain
Tensioner Tightening Sequence
Fig. 86 INTAKE MANIFOLD
1 - THROTTLE BODY
2 - INTAKE MANIFOLD
3 - INTAKE PORT GASKETS
9 - 68 ENGINE - 3. 7L KJ
(11) Bl eed fuel system. Refer to FUEL SYSTEM.
(12) Remove fuel rai l .
(13) Remove throttl e body assembl y and mounti ng
bracket.
(14) Drai n cool i ng system bel ow cool ant tempera-
ture l evel . Refer to COOLI NG SYSTEM.
(15) Remove the heater hoses from the engi ne
front cover and the heater core.
(16) Uncl i p and remove heater hoses and tubes
from i ntake mani fol d.
(17) Remove cool ant temperature sensor. Refer to
FUEL SYSTEM.
(18) Remove i ntake mani fol d retai ni ng fasteners i n
reverse order of ti ghteni ng sequence.
(19) Remove i ntake mani fol d.
INSTALLATION
(1) I nstal l i ntake mani fol d gaskets.
(2) I nstal l i ntake mani fol d.
(3) I nstal l i ntake mani fol d retai ni ng bol ts and
ti ghten i n sequence shown i n to 12 Nm (105 i n. l bs.).
(4) I nstal l l eft and ri ght radi o suppressor straps.
(5) I nstal l throttl e body assembl y.
(6) I nstal l throttl e cabl e bracket.
(7) Connect throttl e cabl e and speed control cabl e
to throttl e body.
(8) I nstal l fuel rai l .
(9) I nstal l i gni ti on coi l towers.
(10) Posi ti on and i nstal l heater hoses and tubes
onto i ntake mani fol d.
(11) I nstal l the heater hoses to the heater core and
engi ne front cover.
(12) Connect el ectri cal connectors for the fol l owi ng
components:
Mani fol d Absol ute Pressure (MAP) Sensor
I ntake Ai r Temperature (I AT) Sensor
Throttl e Posi ti on (TPS) Sensor
Cool ant Temperature (CTS) Sensor
I gni ti on coi l towers
Fuel i njectors
(13) I nstal l top oi l di psti ck tube retai ni ng bol t and
ground strap.
(14) Connect generator el ectri cal connecti ons.
(15) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Posi ti ve crankcase
venti l ati on (PCV) hose.
(16) Fi l l cool i ng system.
(17) I nstal l resonator assembl y and ai r i nl et hose.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol ds (Fi g. 87) are l og styl e wi th
a patented fl ow enhanci ng desi gn to maxi mi ze perfor-
mance. The exhaust mani fol ds are made of hi gh si l i -
con mol ybdenum cast i ron. A perforated core graphi te
exhaust mani fol d gasket i s used to i mprove seal i ng
to the cyl i nder head. The exhaust mani fol ds are cov-
ered by a three l ayer l ami nated heat shi el d for ther-
mal protecti on and noi se reducti on. The heat shi el ds
(Fi g. 88) are fastened wi th a torque prevai l i ng nut
that i s backed off sl i ghtl y to al l ow for the thermal
expansi on of the exhaust mani fol d.
REMOVAL
RIGHT EXHAUST MANIFOLD
(3) Remove the bol ts and nuts attachi ng the
exhaust pi pe to the engi ne exhaust mani fol d.
(5) Remove the exhaust heat shi el d (Fi g. 89).
(6) Remove bol ts, nuts and washers attachi ng
mani fol d to cyl i nder head.
(7) Remove mani fol d and gasket from the cyl i nder
head.
Fig. 87 EXHAUST MANIFOLDS
1 - LEFT SIDE EXHAUST MANIFOLD
2 - RIGHT SIDE EXHAUST MANIFOLD
KJ ENGINE - 3. 7L 9 - 69
INTAKE MANIFOLD (Continued)
LEFT EXHAUST MANIFOLD
(3) Remove the bol ts and nuts attachi ng the
exhaust pi pe to the engi ne exhaust mani fol d.
(5) Remove the exhaust heat shi el ds (Fi g. 90).
(6) Remove bol ts, nuts and washers attachi ng
mani fol d to cyl i nder head.
(7) Remove mani fol d and gasket from the cyl i nder
head.
INSTALLATION
RIGHT EXHAUST MANIFOLD
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
Fig. 88 EXHAUST MANIFOLD HEAT SHIELDS
1 - RIGHT SIDE EXHAUST MANIFOLD HEAT SHIELD
2 - RIGHT SIDE EXHAUST MANIFOLD FLANGE
3 - LEFT SIDE EXHAUST MANIFOLD HEAT SHIELD
2 - LEFT SIDE EXHAUST MANIFOLD FLANGE
Fig. 89 EXHAUST MANIFOLD RIGHT
1 - Heat Shield
2 - Nuts
3 - Manifold Flange
Fig. 90 EXHAUST MANIFOLD LEFT
1 - Heat Shield
2 - Nuts
3 - Manifold Flange
9 - 70 ENGINE - 3. 7L KJ
EXHAUST MANIFOLD (Continued)
(1) Posi ti on the engi ne exhaust mani fol d and gas-
ket on the two studs l ocated on the cyl i nder head.
I nstal l coni cal washers and nuts on these studs.
(2) I nstal l remai ni ng coni cal washers. Starti ng at
the center arm and worki ng outward, ti ghten the
bol ts and nuts to 25 Nm (18 ft. l bs.) torque.
(3) I nstal l the exhaust heat shi el ds.
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(5) Assembl e exhaust pi pe to mani fol d and secure
wi th bol ts, nuts and retai ners. Ti ghten the bol ts and
nuts to 34 Nm (25 ft. l bs.) torque.
LEFT EXHAUST MANIFOLD
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
(1) Posi ti on the engi ne exhaust mani fol d and gas-
ket on the two studs l ocated on the cyl i nder head.
I nstal l coni cal washers and nuts on these studs.
(2) I nstal l remai ni ng coni cal washers. Starti ng at
the center arm and worki ng outward, ti ghten the
bol ts and nuts to 25 Nm (18 ft. l bs.) torque.
(3) I nstal l the exhaust heat shi el ds.
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(5) Assembl e exhaust pi pe to mani fol d and secure
wi th bol ts, nuts and retai ners. Ti ghten the bol ts and
VALVE TIMING
DESCRIPTION
The ti mi ng dri ve system has been desi gned to pro-
vi de qui et performance and rel i abi l i ty to support a
non-free wheeling engi ne. Speci fi cal l y the i ntake
val ves are non-free wheel i ng and can be easi l y dam-
aged wi th forceful engi ne rotati on i f camshaft-to-
crankshaft ti mi ng i s i ncorrect. The ti mi ng dri ve
system consi sts of a pri mary chai n, two secondary
ti mi ng chai n dri ves and a counterbal ance shaft dri ve.
OPERATION
The pri mary ti mi ng chai n i s a si ngl e i nverted tooth
chai n type. The pri mary chai n dri ves the l arge 40
tooth i dl er sprocket di rectl y from a 20 tooth crank-
shaft sprocket. Pri mary chai n moti on i s control l ed by
a pi voti ng l eaf spri ng tensi oner arm and a fi xed
gui de. The arm and the gui de both use nyl on pl asti c
wear faces for l ow fri cti on and l ong wear. The pri -
mary chai n recei ves oi l spl ash l ubri cati on from the
secondary chai n dri ve and desi gned oi l pump l eak-
age. The i dl er sprocket assembl y connects the pri -
mary chai n dri ve, secondary chai n dri ves, and the
counterbal ance shaft. The i dl er sprocket assembl y
consi sts of two i ntegral 26 tooth sprockets a 40 tooth
sprocket and a hel i cal gear that i s press-fi t to the
assembl y. The spl i ne joi nt for the 40 tooth sprocket i s
a non servi ceabl e press fi t anti rattl e type. A spi ral
ri ng i s i nstal l ed on the outboard si de of the fi fty
tooth sprocket to prevent spl i ne di sengagement. The
i dl er sprocket assembl y spi ns on a stati onary i dl er
shaft. The i dl er shaft i s a l i ght press-fi t i nto the cyl -
i nder bl ock. A l arge washer on the i dl er shaft bol t
and the rear fl ange of the i dl er shaft are used to con-
trol sprocket thrust movement. Pressuri zed oi l i s
routed through the center of the i dl er shaft to pro-
vi de l ubri cati on for the two bushi ngs used i n the
i dl er sprocket assembl y.
There are two secondary dri ve chai ns, both are
rol l er type, one to dri ve the camshaft i n each SOHC
cyl i nder head. There are no shaft speed changes i n
the secondary chai n dri ve system. Each secondary
chai n dri ves a 26 tooth cam sprocket di rectl y from
the 26 tooth sprocket on the i dl er sprocket assembl y.
A fi xed chai n gui de and a hydraul i c oi l damped ten-
si oner are used to mai ntai n tensi on i n each second-
ary chai n system. The hydraul i c tensi oners for the
secondary chai n systems are fed pressuri zed oi l from
oi l reservoi r pockets i n the bl ock. Each tensi oner
i ncorprates a control ed l eak path through a devi ce
known as a vent di sc l ocated i n the nose of the pi ston
to manage chai n l oads. Each tensi oner al so has a
mechani cal ratchet system that l i mi ts chai n sl ack i f
the tensi oner pi ston bl eeds down after engi ne shut
down. The tensi oner arms and gui des al so uti l i ze
nyl on wear faces for l ow fri cti on and l ong wear. The
secondary ti mi ng chai ns recei ve l ubri cati on from a
smal l ori fi ce i n the tensi oners. Thi s ori fi ce i s pro-
tected from cl oggi ng by a fi ne mesh screen whi ch i s
l ocated on the back of the hydraul i c tensi oners.
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed.
(1) Remove the ti mi ng chai n cover. Refer to Ti mi ng
Chai n Cover i n thi s secti on for procedure.
KJ ENGINE - 3. 7L 9 - 71
EXHAUST MANIFOLD (Continued)
(2) To determi ne i f the secondary ti mi ng chai ns
are worn, rotate the engi ne cl ockwi se unti l maxi mum
tensi oner pi ston extensi on i s obtai ned. Measure the
di stance between the secondary ti mi ng chai n ten-
si oner housi ng and the step l edge on the pi ston. The
measurement at poi nt (A) must be l ess than 15mm
(.5906 i nches).
(3) I f the measurement exceeds the speci fi cati on
the secondary ti mi ng chai ns are worn and requi re
repl acement. Refer to Ti mi ng Chai n and Sprockets i n
thi s secti on for procedure.
SERVICE PROCEDURES
TIMING VERIFICATION
CAUTION: The 3.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
NOTE: Components referred to as left hand or right
hand are as viewed from the drivers position inside
the vehicle.
NOTE: The blue link plates on the chains and the
dots on the camshaft drive sprockets may not line
up during the timing verification procedure. The
blue link plates are lined up with the sprocket dots
only when re-timing the complete timing drive.
Once the timing drive is rotated blue link-to-dot
alignment is no longer valid.
Engi ne base ti mi ng can be veri fi ed by the fol l owi ng
procedure:
(1) Remove the cyl i nder head covers. Refer to the
procedure i n thi s secti on.
(2) Usi ng a mi rror, l ocate the TDC arrow on the
front cover (Fi g. 91). Rotate the crankshaft unti l the
mark on the crankshaft damper i s al i gned wi th the
TDC arrow on the front cover. The engi ne i s now at
TDC.
(3) Note the l ocati on of the V6 mark stamped i nto
the camshaft dri ve gears. I f the V6 mark on each
camshaft dri ve gear i s at the twel ve ocl ock posi ti on,
the engi ne i s at TDC on the exhaust stroke. I f the V6
mark on each gear i s at the si x ocl ock posi ti on, the
engi ne i s at TDC on the compressi on stroke. (Fi g. 95)
(4) I f both of the camshaft dri ve gears are off i n
the same or opposi te di recti ons, the pri mary chai n or
both secondary chai ns are at faul t. Refer to Ti mi ng
Chai n and Sprockets procedure i n thi s secti on.
(5) I f onl y one of the camshaft dri ve gears i s off
and the other i s correct, the probl em i s confi ned to
one secondary chai n. Refer to Si ngl e camshaft ti m-
i ng, i n thi s procedure.
(6) I f both camshaft dri ve gear V6 marks are at
the twel ve ocl ock or the si x o cl ock posi ti on the
engi ne base ti mi ng i s correct. Rei nstal l the cyl i nder
head covers.
COUNTER BALANCE SHAFT TIMING
(1) Ensure that the engi ne i s at TDC wi th both
camshaft sprocket marks are i n the 12 ocl ock posi -
ti on. (Fi g. 94)
(2) Look down the l eft cyl i nder gear chai n cavi ty.
The ti mi ng dot on the counter bal ance shaft dri ve
gear shoul d be i n the 6 ocl ock posi ti on (Fi g. 92).
TIMING - SINGLE CAMSHAFT
NOTE: to adjust the timing on one camshaft, pre-
form the following procedure.
(1) Usi ng Chai n Tensi oner Wedge, Speci al Tool
8379, stabi l i ze the secondary chai n dri ve. For refer-
ence purposes, mark the chai n-to-sprocket posi ti on.
(Fi g. 93)
(2) Remove the camshaft dri ve gear retai ni ng bol t.
(3) Careful l y remove the camshaft dri ve gear from
the camshaft.
(4) Re-i ndex the camshaft dri ve gear i n the chai n
unti l the V6 mark i s at the same posi ti on as the V6
mark on the opposi te camshaft dri ve gear.
Fig. 91 Engine Top Dead Center (TDC) Indicator
Mark
9 - 72 ENGINE - 3. 7L KJ
VALVE TIMING (Continued)
rotate the camshaft unti l the al i gnment dowel on the
camshaft i s al i gned wi th the sl ot i n the camshaft
dri ve gear.
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(6) Posi ti on the camshaft dri ve gear onto the cam-
shaft, remove oi l from bol t then i nstal l the retai ni ng
bol t. Usi ng Speci al Tool s, Spanner Wrench 6958 wi th
Adapter Pi ns 8346 and a sui tabl e torque wrench,
Ti ghten retai ni ng bol t to 122Nm (90 ft. Lbs.).
(8) Rotate the crankshaft two ful l revol uti ons, then
reveri fy that the camshaft dri ve gear V6 marks are
i n fact al i gned.
(9) I nstal l the cyl i nder head covers. Refer to Cyl i n-
der Head Cover i n thi s secti on.
Fig. 92 COUNTERBALANCE SHAFT ALIGNMENT
MARKS
1 - COUNTERBALANCE SHAFT
2 - TIMING MARKS
3 - IDLER SPROCKET
Fig. 93 SECURING TIMING CHAIN TENSIONER
USING TIMING CHAIN WEDGE
1 - CYLINDER HEAD
2 -SPECIAL TOOL 8379
2 - TIMING CHAIN
Fig. 94 CAMSHAFT DRIVE GEAR REMOVAL/INST
1 - SPECIAL TOOL 8279 TIMING CHAIN WEDGE
3 - RETAINING BOLT
4 - CYLINDER HEAD
KJ ENGINE - 3. 7L 9 - 73
BALANCE SHAFT
REMOVAL
(1) Remove the pri mary and secondary ti mi ng
chai ns. Refer to TI MI NG CHAI N and SPROCKET.
NOTE: The balance shaft and gear are serviced as
an assembly. Do not attempt to remove the gear
from the balance shaft.Remove the retaining bolt
from the counterbalance shaft thrust plate (Fig. 96).
(2) Usi ng Speci al Tool 8641 Counterbal ance shaft
remover/i nstal l er tool , remove the counterbal ance
shaft from the engi ne (Fi g. 97).
INSTALLATION
NOTE: The balance shaft and gear are serviced as
an assembly. Do not attempt to remove the gear
from the balance shaft.
(1) Coat counterbal ance shaft beari ng journal s
wi th cl ean engi ne oi l .
NOTE: The balance shaft is heavy, and care should
be used when installing shaft, so bearings are not
damaged.
(2) Usi ng Speci al Tool 8641 Counterbal ance shaft
remover/i nstal l er tool , careful l y i nstal l counterbal -
ance shaft i nto engi ne.
(3) I nstal l Counterbal ance shaft thrust pl ate
retai ni ng bol t fi nger ti ght.Do not ti ghten bol t at thi s
ti me.
(4) Posi ti on the ri ght si de of the thrust pl ate wi th
the ri ght chai n gui de bol t, i nstal l bol t fi nger ti ght.
(5) Torque the thrust pl ate retai ni ng bol t to 28
Nm (250 i n. l bs.).
(6) Remove the chai n gui de bol t so that gui de can
be i nstal l ed.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(3) Remove el ectri c cool i ng fan and fan shroud
assembl y.
(4) Remove fan and fan dri ve assembl y (Refer to 7
- COOLI NG/ENGI NE/FAN DRI VE VI SCOUS
CLUTCH - REMOVAL).
(5) Di sconnect both heater hoses at ti mi ng cover.
(6) Di sconnect l ower radi ator hose at engi ne.
9 - 74 ENGINE - 3. 7L KJ
(7) Remove accessory dri ve bel t tensi oner assembl y
(Fi g. 98).
(8) Remove crankshaft damper (Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
REMOVAL).
(9) Remove the generator (Refer to 8 - ELECTRI -
CAL/CHARGI NG/GENERATOR - REMOVAL).
(10) Remove A/C compressor (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C COM-
PRESSOR - REMOVAL).
CAUTION: The 3.7L engine uses an anerobic sealer
instead of a gasket to seal the front cover to the
engine block, from the factory. For service, Mopar
Engine RTV sealant must be substituted.
NOTE: It is not necessary to remove the water
pump for timing cover removal.
(11) Remove the bol ts hol di ng the ti mi ng cover to
engi ne bl ock. (Fi g. 99).
(12) Remove the ti mi ng cover.
Fig. 96 COUNTERBALANCE SHAFT RETAINING
PLATE
1 - IDLER SHAFT
2 - COUNTERBALANCE SHAFT THRUST PLATE
3 - COUNTERBALANCE SHAFT DRIVE GEAR
4 - RETAINING BOLT
Fig. 97 COUNTERBALANCE SHAFT REMOVAL/
INSTALLATION TOOL
1 - COUNTERBALANCE SHAFT REMOVAL AND INSTALLATION
TOOL
2 - COUNTERBALANCE SHAFT THRUST PLATE
Fig. 98 Accessory Drive Belt Tensioner
1 - TENSIONER ASSEMBLY
2 - FASTENER TENSIONER TO FRONT COVER
KJ ENGINE - 3. 7L 9 - 75
TIMING BELT / CHAIN COVER(S) (Continued)
INSTALLATION
CAUTION: Do not use oil based liquids to clean tim-
ing cover or block surfaces. Use only rubbing alco-
hol, along with plastic or wooden scrapers. Use no
wire brushes or abrasive wheels or metal scrapers,
or damage to surfaces could result.
(1) Cl ean ti mi ng chai n cover and bl ock surface
usi ng rubbi ng al cohol .
CAUTION: The 3.7L uses a special anerobic sealer
instead of a gasket to seal the timing cover to the
engine block, from the factory. For service repairs,
Mopar Engine RTV must be used as a substitute.
(2) I nspect the water passage o-ri ngs for any dam-
age, and repl ace as necessary.
(3) Appl y Mopar Engi ne RTV seal er to front cover
(Fi g. 100).
(4) I nstal l cover. Ti ghten fasteners i n sequence as
shown i n (Fi g. 101) to 54 Nm (40 ft. l bs.).
(5) I nstal l crankshaft damper (Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
I NSTALLATI ON).
(6) I nstal l the A/C compressor (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C COM-
PRESSOR - I NSTALLATI ON).
(7) I nstal l the generator (Refer to 8 - ELECTRI -
CAL/CHARGI NG/GENERATOR - I NSTALLATI ON).
(8) I nstal l accessory dri ve bel t tensi oner assembl y
(Refer to 7 - COOLI NG/ACCESSORY DRI VE/BELT
TENSI ONERS - I NSTALLATI ON).
(9) I nstal l radi ator upper and l ower hoses.
(10) I nstal l both heater hoses.
(11) I nstal l el ectri c fan shroud and vi scous fan
dri ve assembl y (Refer to 7 - COOLI NG/ENGI NE/FAN
DRI VE VI SCOUS CLUTCH - I NSTALLATI ON).
Fig. 99 Timing Chain Cover Fasteners - Typical
Fig. 100 TIMING COVER SEALANT
2 - WATER PASSAGE ORING
3 - MOPAR ENGINE RTV SEALER
Fig. 101 Timing Chain Cover Fasteners - Typical
9 - 76 ENGINE - 3. 7L KJ
TIMING BELT / CHAIN COVER(S) (Continued)
IDLER SHAFT
REMOVAL
(1) Remove the pri mary and secondary ti mi ng
chai ns and sprockets. Refer to procedure i n thi s sec-
ti on.
NOTE: To remove the idler shaft, it is necessary to
tap threads into the shaft, to install the removal
tool.
(2) Usi ng a 12 mm X 1.75 tap, cut threads i n the
i dl er shaft center bore.
(3) Cover the radi ator core wi th a sui tabl e cover.
CAUTION: Use care when removing the idler shaft,
Do not strike the radiator cooling fins with the slide
hammer.
(4) Usi ng Speci al Tool 8517 Sl i de Hammer, remove
the i dl er shaft.
INSTALLATION
(1) Thoroughl y cl ean the i dl er shaft bore.
(2) Posi ti on the i dl er shaft i n the bore.
NOTE: The two lubrication holes in the idler shaft
do not require any special alignment.
NOTE: Before using the retaining bolt to install the
idler shaft, coat the threads and the pilot on the
idler shaft, with clean engine oil.
(3) Usi ng the pri mary i dl er sprocket retai ni ng bol t
and washer, careful l y draw the i dl er shaft i nto the
bore unti l ful l y seated.
(4) Coat the i dl er shaft wi th cl ean engi ne oi l .
(5) I nstal l the ti mi ng chai ns and sprockets. Refer
to procedure i n thi s secti on.
TIMING BELT/CHAIN AND
SPROCKET(S
REMOVAL
(2) Drai n cool i ng system. Refer to COOLI NG SYS-
TEM for procedures.
(3) Remove ri ght and l eft cyl i nder head covers.
Refer to CYLI NDER HEAD COVER.
(4) Remove radi ator fan shroud. Refer to COOL-
I NG SYSTEM for procedure.
(5) Rotate engi ne unti l ti mi ng mark on crankshaft
damper al i gns wi th TDC mark on ti mi ng chai n cover
(Fi g. 103) (#1 cyl i nder exhaust stroke) and the cam-
shaft sprocket V6 marks are at the 12 ocl ock posi -
ti on (Fi g. 102).
(6) Remove power steeri ng pump. Refer to STEER-
I NG for procedure.
(7) Remove access pl ug from l eft and ri ght cyl i nder
heads for access to chai n gui de fasteners (Fi g. 104).
(8) Remove the oi l fi l l housi ng to gai n access to the
ri ght si de tensi oner arm fastener.
(9) Remove crankshaft damper and ti mi ng chai n
cover. Refer to procedures.
(10) Col l apse and pi n pri mary chai n tensi oner.
CAUTION: Plate behind left secondary chain ten-
sioner could fall into oil pan. Therefore, cover pan
opening.
(11) Remove secondary chai n tensi oners.
(12) Remove camshaft posi ti on and crankshaft
posi ti on sensors (Fi g. 105) and (Fi g. 106).
KJ ENGINE - 3. 7L 9 - 77
Fig. 103 Engine Top Dead Center
Fig. 104 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
9 - 78 ENGINE - 3. 7L KJ
TIMING BELT/CHAIN AND SPROCKET(S (Continued)
CAUTION: Care should be taken not to damage
camshaft target wheel. Do not hold target wheel
while loosening or tightening camshaft sprocket.
Do not place the target wheel near a magnetic
source of any kind. A damaged or magnetized tar-
get wheel could cause a vehicle no start condition.
CAUTION: Do not forcefully rotate the camshafts or
crankshaft independently of each other. Damaging
intake valve to piston contact will occur. Ensure
negative battery cable is disconnected to guard
against accidental starter engagement.
(13) Remove l eft and ri ght camshaft sprocket bol ts.
(14) Whi l e hol di ng the l eft camshaft steel tube
wi th Speci al Tool 8428 Camshaft Wrench, remove the
l eft camshaft sprocket. Sl owl y rotate the camshaft
approxi matel y 5 degrees cl ockwi se to a neutral posi -
ti on.
(15) Whi l e hol di ng the ri ght camshaft steel tube
wi th Speci al Tool 8428 Camshaft Wrench, remove the
ri ght camshaft sprocket.
(16) Remove i dl er sprocket assembl y bol t.
(17) Sl i de the i dl er sprocket assembl y and crank
sprocket forward si mul taneousl y to remove the pri -
mary and secondary chai ns.
(18) Remove both pi voti ng tensi oner arms and
chai n gui des.
(19) Remove chai n tensi oner.
INSPECTION
I nspect the fol l owi ng components:
Sprockets for excessi ve tooth wear. Some tooth
marki ngs are normal and not a cause for sprocket
repl acement.
I dl er sprocket assembl y bushi ng and shaft for
excessi ve wear.
I dl er sprocket assembl y spl i ne joi nt. The joi nt
shoul d be ti ght wi th no backl ash or axi al movement.
Chai n gui des and tensi oner arms. Repl ace these
parts i f groovi ng i n pl asti c face i s more than 1 mm
(0.039 i n.) deep. I f pl asti c face i s severel y grooved or
mel ted, the tensi oner l ube jet may be cl ogged. The
tensi oner shoul d be repl aced.
Secondary chai n tensi oner pi ston and ratcheti ng
devi ce. I nspect for evi dence of heavy contact between
tensi oner pi ston and tensi oner arm. I f thi s condi ti on
exi st the tensi oner tensi oner arm and chai n shoul d
be repl aced.
Pri mary chai n tensi oner pl asti c faces. Repl ace as
requi red.
Fig. 105 CAMSHAFT POSITION SENSOR
1 - CYLINDER HEAD
2 - CAMSAHFT POSITION SENSOR
2 - SCREW
Fig. 106 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
2 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
KJ ENGINE - 3. 7L 9 - 79
INSTALLATION
(1) Usi ng a vi se, l i ghtl y compress the secondary
chai n tensi oner pi ston unti l the pi ston step i s fl ush
wi th the tensi oner body. Usi ng a pi n or sui tabl e tool ,
rel ease ratchet pawl by pul l i ng pawl back agai nst
spri ng force through access hol e on si de of tensi oner.
Whi l e conti nui ng to hol d pawl back, Push ratchet
devi ce to approxi matel y 2 mm from the tensi oner
body. I nstal l Speci al Tool 8514 l ock pi n i nto hol e on
front of tensi oner (Fi g. 107). Sl owl y open vi se to
transfer pi ston spri ng force to l ock pi n.
(2) Posi ti on pri mary chai n tensi oner over oi l pump
and i nsert bol ts i nto l ower two hol es on tensi oner
bracket. Ti ghten bol ts to 28 Nm (250 i n. l bs.).
(3) I nstal l ri ght si de chai n tensi oner arm. Appl y
Mopar Lock N, Seal to torx bol t, ti ghten bol t to 28
Nm (250 i n. l bs.).
CAUTION: The silver bolts retain the guides to the
cylinder heads and the black bolts retain the guides
to the engine block.
(4) I nstal l the l eft si de chai n gui de. Ti ghten the
(5) I nstal l l eft si de chai n tensi oner arm. Appl y
Mopar Lock N, Seal to torx bol t, ti ghten bol t to 28
Nm (250 i n. l bs.).
(6) I nstal l the ri ght si de chai n gui de. Ti ghten the
(7) I nstal l both secondary chai ns onto the i dl er
sprocket. Al i gn two pl ated l i nks on the secondary
chai ns to be vi si bl e through the two l ower openi ngs
on the i dl er sprocket (4 ocl ock and 8 ocl ock). Once
the secondary ti mi ng chai ns are i nstal l ed, posi ti on
speci al tool 8429 to hol d chai ns i n pl ace for i nstal l a-
ti on.
(8) Al i gn pri mary chai n doubl e pl ated l i nks wi th
the ti mi ng mark at 12 ocl ock on the i dl er sprocket.
Al i gn the pri mary chai n si ngl e pl ated l i nk wi th the
ti mi ng mark at 6 ocl ock on the crankshaft sprocket.
(9) Lubri cate i dl er shaft and bushi ngs wi th cl ean
engi ne oi l .
NOTE: The idler sprocket must be timed to the
counterbalance shaft drive gear before the idler
sprocket is fully seated.
(10) I nstal l al l chai ns, crankshaft sprocket, and
i dl er sprocket as an assembl y (Fi g. 108). After gui d-
i ng both secondary chai ns through the bl ock and cyl -
i nder head openi ngs, affi x chai ns wi th a el asti c strap
or the equi val ent, Thi s wi l l mai ntai n tensi on on
chai ns to ai d i n i nstal l ati on. Al i gn the ti mi ng mark
on the i dl er sprocket to the ti mi ng mark on the coun-
terbal ance shaft dri ve gear, then seat i dl er sprocket
ful l y (Fi g. 109). Before i nstal l i ng i dl er sprocket bol t,
l ubri cate washer wi th oi l , and ti ghten i dl er sprocket
assembl y retai ni ng bol t to 34 Nm (25 ft. l bs.).
Fig. 107 Resetting Secondary Chain Tensioners
1 - VISE
2 - INSERT LOCK PIN
3 - RATCHET PAWL
4 - RATCHET
5 - PISTON
Fig. 108 Installing Idler Gear, Primary and
Secondary Timing Chains
2 - PRIMARY CHAIN IDLER SPROCKET
3 - CRANKSHAFT SPROCKET
9 - 80 ENGINE - 3. 7L KJ
NOTE: It will be necessary to slightly rotate cam-
shafts for sprocket installation.
(11) Al i gn l eft camshaft sprocket L dot to pl ated
l i nk on chai n.
(12) Al i gn ri ght camshaft sprocket R dot to
pl ated l i nk on chai n.
CAUTION: Remove excess oil from the camshaft
sprocket bolt. Failure to do so can result in over-
torque of bolt resulting in bolt failure.
(13) Remove Speci al Tool 8429, then attach both
sprockets to camshafts. Remove excess oi l from bol ts,
then I nstal l sprocket bol ts, but do not ti ghten at thi s
ti me.
(14) Veri fy that al l pl ated l i nks are al i gned wi th
the marks on al l sprockets and the V6 marks on
camshaft sprockets are at the 12 ocl ock posi ti on.
CAUTION: Ensure the plate between the left sec-
ondary chain tensioner and block is correctly
installed.
(15) I nstal l both secondary chai n tensi oners.
Ti ghten bol ts to 28 Nm (250 i n. l bs.).
NOTE: Left and right secondary chain tensioners
are not common.
(16) Remove al l l ocki ng pi ns (3) from tensi oners.
CAUTION: After pulling locking pins out of each
tensioner, DO NOT manually extend the tensioner(s)
ratchet. Doing so will over tension the chains,
resulting in noise and/or high timing chain loads.
(17) Usi ng Speci al Tool 6958, Spanner wi th Adap-
tor Pi ns 8346, ti ghten l eft (Fi g. 110) and ri ght (Fi g.
111). camshaft sprocket bol ts to 122 Nm (90 ft. l bs.).
(18) Rotate engi ne two ful l revol uti ons. Veri fy ti m-
i ng marks are at the fol l ow l ocati ons:
pri mary chai n i dl er sprocket dot i s at 12 ocl ock
pri mary chai n crankshaft sprocket dot i s at 6
ocl ock
secondary chai n camshaft sprockets V6 marks
are at 12 ocl ock
counterbal ancer shaft dri ve gear dot i s al i gned
to the i dl er sprocket gear dot
(19) Lubri cate al l three chai ns wi th engi ne oi l .
Fig. 109 COUNTERBALANCE SHAFT ALIGNMENT
MARKS
1 - COUNTERBALANCE SHAFT
2 - TIMING MARKS
3 - IDLER SPROCKET
Fig. 110 Tightening Left Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
2 - CAMSHAFT SPROCKET
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
KJ ENGINE - 3. 7L 9 - 81
(20) After i nstal l i ng al l chai ns, i t i s recommended
that the i dl er gear end pl ay be checked (Fi g. 112).
The end pl ay must be wi thi n 0.100.25 mm (0.004
0.010 i n.). I f not wi thi n speci fi cati on, the i dl er gear
must be repl aced.
(21) I nstal l ti mi ng chai n cover and crankshaft
damper. Refer to procedures.
(22) I nstal l cyl i nder head covers. Refer to proce-
dures.
NOTE: Before installing threaded plug in right cylin-
der head, the plug must be coated with sealant to
prevent leaks.
(23) Coat the l arge threaded access pl ug wi th
Mopar Thread Sealant with Teflon, then i nstal l
i nto the ri ght cyl i nder head and ti ghten to 81 Nm
(60 ft. l bs.).
(24) I nstal l the oi l fi l l housi ng.
(25) I nstal l access pl ug i n l eft cyl i nder head.
(26) I nstal l power steeri ng pump.
(27) Fi l l cool i ng system.
Fig. 111 Tightening Right Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKET
Fig. 112 Measuring Idler Gear End Play
1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
9 - 82 ENGINE - 3. 7L KJ
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER . . . . . 2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CROSS-OVER PIPE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HEAT SHIELDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MUFFLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EXHAUST SYSTEM
DESCRIPTION
The basi c exhaust system consi sts of an engi ne
exhaust mani fol d, exhaust down pi pe, exhaust pi pe,
exhaust heat shi el d(s), muffl er and exhaust tai l pi pe
The exhaust system uses a si ngl e muffl er.
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. I f the sys-
tem contacts any body panel , i t wi l l transfer objec-
ti onabl e noi ses ori gi nati ng from the engi ne to the
body.
When i nspecti ng an exhaust system, cri ti cal l y
i nspect for cracked or l oose joi nts, stri pped screw or
bol t threads, corrosi on damage and worn, cracked or
broken hangers. Repl ace al l components that are
badl y corroded or damaged. DO NOT attempt to
repai r.
When repl acement i s requi red, use ori gi nal equi p-
ment parts (or equi val ent). Thi s wi l l assure proper
al i gnment and provi de acceptabl e exhaust noi se l ev-
el s.
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
KJ EXHAUST SYSTEM 11 - 1
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints. 1. Tighten clamps/bolts to specified
torque at leaking joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.
7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
CAUTION:
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stai nl ess steel catal yti c converter body i s
desi gned to l ast the l i fe of the vehi cl e. Excessi ve heat
can resul t i n bul gi ng or other di storti on, but exces-
si ve heat wi l l not be the faul t of the converter. I f
unburned fuel enters the converter, overheati ng may
occur. I f a converter i s heat-damaged, correct the
cause of the damage at the same ti me the converter
i s repl aced. Al so, i nspect al l other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emi ssi on vehi cl es i ncorporate two mi ni
catal yti c converters l ocated after the exhaust mani -
fol ds and before the i nl i ne catal yti c converter.
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(2) Saturate the bol ts and nuts wi th heat val ve
l ubri cant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the bol ts from the crossover pi pe to the
catal yti c converter connecti on.
(4) Di sconnect oxygen sensor wi ri ng.
(5) Loosen the nuts from the cl amp that hol d the
catal yti c converter to the exhaust pi pe fl ange connec-
ti on.
11 - 2 EXHAUST SYSTEM KJ
EXHAUST SYSTEM (Continued)
NOTE: Do not remove nut from T-Bolt. Only remove
nut far enough, so that the T end can be removed
from the clamp.
(6) Remove the T bol t end of the fastener, from the
cl amp.
(7) Spread the cl amp, and remove the catal yti c
converter from the vehi cl e.
(8) Di scard the cl amp (Fi g. 1).
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
INSPECTION
Look at the stai nl ess steel body of the converter,
i nspect for bul gi ng or other di storti on that coul d be a
resul t of overheati ng. I f the converter has a heat
shi el d attached make sure i t i s not bent or l oose.
I f you suspect i nternal damage to the catal yst, tap-
pi ng the bottom of the catal yst wi th a rubber mal l et
may i ndi cate a damaged core.
INSTALLATION
(1) Posi ti on the catal yti c converter onto the
exhaust pi pe fl ange connecti on. Ti ghten the nuts to
28 Nm (250 i n. l bs.) torque.
(2) I nstal l the muffl er onto the catal yti c converter
unti l the al i gnment tab i s i nserted i nto the al i gn-
ment sl ot.
(3) I nstal l the exhaust cl amp at the muffl er and
catal yti c converter connecti on. Ti ghten the cl amp
(4) Connect oxygen sensor wi ri ng.
(6) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
CROSS-OVER PIPE
REMOVAL
(2) Saturate the bol ts and nuts wi th l ubri cant.
Al l ow 5 mi nutes for penetrati on.
(3) Remove the retai ni ng fasteners hol di ng cross-
over pi pe to exhaust pi pe.
(4) Remove the fasteners from the crossover pi pe
to the catal yti c converter connecti on.
(5) Remove the crossove pi pe from the hanger
i nsul ator (Fi g. 2).
INSTALLATION
Fig. 1 Catalyst Removal
1 - V-Clamp
2 - Catalytic Converter
3 - Flange
4 - Crossover Pipe
5 - T-Bolt
CATALYTIC CONVERTER (Continued)
(1) I nstal l the crossove pi pe i nto the hanger i nsu-
l ator.
(2) I nstal l and torque the fasteners i n the cross-
over pi pe to the l eft and ri ght catal yti c converter con-
necti on.
(3) I nstal l and torque the retai ni ng fasteners hol d-
i ng the crossover pi pe to exhaust pi pe.
(4) Lower vehi cl e..
(5) Start engi ne and check for l eaks.
HEAT SHIELDS
DESCRIPTION
Heat shi el ds are needed to protect both the vehi cl e
and the envi ronment from the hi gh temperatures
devel oped by the catal yti c converter. The catal yti c
converter rel eases addi ti onal heat i nto the exhaust
system. Under severe operati ng condi ti ons, the tem-
perature i ncreases i n the area of the converter. Such
condi ti ons can exi st when the engi ne mi sfi res or oth-
erwi se does not operate at peak effi ci ency (Fi g. 3).
MUFFLER
DESCRIPTION
The 3.7L engi ne uses a gal vani zed steel muffl er
(Fi g. 4) to control exhaust noi se l evel s and exhaust
back pressure.
Fig. 2 Crossover Pipe
1 - Crossover-toCatalytic Converter flange
2 - Crossover Pipe
3 - Crossover Pipe to Tail Pipe Flange
4 - Hanger Bracket
Fig. 3 Front and Rear Floor Pan Heat Shields
Typical
1 - REAR FLOOR PAN HEAT SHIELD
2 - HEAT SHIELD RETAINING NUTS
3 - FRONT FLOOR PAN HEAT SHIELD
Fig. 4 Muffler - Typical
1 - MUFFLER
CROSS-OVER PIPE (Continued)
REMOVAL
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the exhaust tai l pi pe wel ded to the muf-
fl er. Servi ce repl acement muffl ers and exhaust
tai l pi pes are ei ther cl amped together or wel ded
together.
THE FLAME NEAR THE FUEL LINE.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
(2) Di sconnect front tai l pi pe hanger from the i nsu-
l ator (Fi g. 5).
(3) Remove the mounti ng nuts from the muffl er to
catal yti c converter fl ange (Fi g. 5).
(4) Remove the tai l pi pe from the rear tai l pi pe
hanger (Fi g. 5).
(5) Remove the muffl er and tai l pi pe assembl y from
the vehi cl e.
INSTALLATION
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the exhaust tai l pi pe wel ded to the muf-
fl er. Servi ce repl acement muffl ers and exhaust
tai l pi pes are ei ther cl amped together or wel ded
together.
THE FLAME NEAR THE FUEL LINE.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
(1) Posi ti on muffl er and tai l pi pe assembl y i nto
vehi cl e.
(2) I nstal l cl amp retai ni ng tai l pi pe to the rear
tai l pi pe hanger (Fi g. 5). DO NOT ti ghten cl amp at
thi s ti me.
(3) I nstal l mounti ng nuts onto the muffl er to cata-
l yti c converter fl ange studs (Fi g. 5). DO NOT ti ghten
nuts at thi s ti me.
(4) Make sure the exhaust system i s i n proper
al i gnment. There shoul d be at l east 25mm (1 i nch)
cl earance between the exhaust components and any
surroundi ng components.
(5) Ti ghten muffl er to catal yti c converter fl ange
mounti ng nuts to 28.5 Nm (21 ft. l bs.).
(6) Ti ghten tai l pi pe cl amp to 48 Nm (35 ft. l bs.).
MUFFLER (Continued)
Fig. 5 Muffler/Tailpipe Removal and Installation
1 - EXHAUST PIPE FLANGE JOINT
2 - REAR TAILPIPE HANGER
3 - FRONT TAILPIPE HANGER
4 - MUFFLER
5 - FLANGE JOINT
6 - CATALYTIC CONVERTER
7 - NUT
MUFFLER (Continued)
FRAMES & BUMPERS
TABLE OF CONTENTS
page page
FRONT FASCIA
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REAR FASCIA
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REAR FASCIA SUPPORT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 3
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . 6
FRONT SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE CRADLE CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSFER CASE SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT TOW HOOK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REAR TOW HOOK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRAILER HITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FUEL TANK SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT FASCIA
REMOVAL
(1) Remove the gri l l e. (Refer to 23 - BODY/EXTE-
RI OR/GRI LLE - REMOVAL)
(3) Remove the front wheel openi ng fl are mol di ngs.
(Refer to 23 - BODY/EXTERI OR/FRONT WHEEL
OPENI NG FLARE MOLDI NGS - REMOVAL)
(4) Remove the four screws through the l ower ai r
dam (Fi g. 1).
(5) Di sconnect the el ectri cal connectors:
Fasci a to gri l l e openi ng rei nforcement. (Fi g. 1)
Si de repeater l i ghts, both si des, i f equi pped.
(Fi g. 2)
(6) Remove the si x push pi ns from the gri l l sup-
port.
(7) Remove the ri vets attachi ng the ai r dam to the
(8) Rel ease the support tabs beneath the head-
l amps.
(9) Rel ease the i nner support cl i ps from wi thi n the
fasci a between the l i ghts (Fi g. 2).
(10) Remove the fasci a.
Fig. 1 FRONT FASCIA
2 - PUSH PINS
3 - FRONT FASCIA ASSEMBLY
4 - LOWER SCREWS
5 - PLASTIC RIVETS (2)
6 - INNER SUPPORT CLIPS
7 - SUPPORT TABS
KJ FRAMES & BUMPERS 13 - 1
INSTALLATION
(1) I nstal l the fasci a.
(2) Connect the el ectri cal connectors.
Si de repeater l i ghts, both si des, i f equi pped.
Fasci a to gri l l e openi ng rei nforcement.
(3) I nstal l the si x push pi n fasteners i nto the gri l l
support.
(4) I nstal l the four screws through the l ower ai r
damn.
(5) I nstal l new ri vets attachi ng the ai r dam to the
(6) I nstal l the front wheel openi ng fl are mol di ngs.
(Refer to 23 - BODY/EXTERI OR/WHEEL OPENI NG
FLARE MOLDI NG - I NSTALLATI ON)
(7) I nstal l the gri l l e. (Refer to 23 - BODY/EXTERI -
OR/GRI LLE - I NSTALLATI ON)
REAR FASCIA
REMOVAL
(1) Remove the wheel fl ares (rear). (Refer to 23 -
BODY/EXTERI OR/REAR WHEEL OPENI NG
FLARE MOLDI NGS - REMOVAL)
(2) Remove the rear l amp uni ts. (Refer to 8 -
REAR LAMP UNI T - REMOVAL)
(3) Remove the four si de bol ts. (Fi g. 3)
(4) Remove the four bottom ri vets.
(5) Remove the 3 bol ts al ong the upper edge.
(6) Separate the si de pl asti c retai ners and remove
the fasci a from the vehi cl e.
INSTALLATION
NOTE: Fascia must be pushed completely forward
to allow the plastic retainers full engagement in
their respective slots.
(1) I nstal l the fasci a and i nsert the pl asti c retai n-
ers.
(2) I nstal l the three upper bol ts.
(3) I nstal l the four si de bol ts.
(4) I nstal l four bottom ri vets.
(5) I nstal l the rear l amp uni ts. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/REAR
LAMP UNI T - I NSTALLATI ON)
(6) I nstal l the rear hal f wheel openi ng fl ares.
(Refer to 23 - BODY/EXTERI OR/WHEEL OPENI NG
Fig. 2 FASCIA INNER SUPPORT
1 - INNER SUPPORT CLIP
2 - SIDE REPEATER CONNECTOR (IF EQUIPPED)
3 - FASCIA ASSEMBLY
4 - FOG LAMP
Fig. 3 REAR FASCIA
1 - REAR FASCIA ASSEMBLY
2 - PLASTIC RETAINERS
3 - FASCIA SUPPORT BRACKET
4 - SIDE BOLTS
5 - RIVETS
6 - UPPER BOLTS
13 - 2 FRAMES & BUMPERS KJ
FRONT FASCIA (Continued)
REAR FASCIA SUPPORT
REMOVAL
(1) Remove the rear fasci a assembl y. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/REAR FASCI A -
REMOVAL)
(2) Remove the si x ri vets and remove the fasci a
support (Fi g. 4).
INSTALLATION
(1) I nstal l the fasci a support onto the vehi cl e and
i nstal l si x new ri vets.
(2) I nstal l the rear fasci a assembl y. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/REAR FASCI A -
I NSTALLATI ON)
FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS
Frame di mensi ons are l i sted i n metri c scal e. Al l
di mensi ons are from center to center of Pri nci pal
Locati ng Poi nt (PLP), or from center to center of PLP
and fastener l ocati on.
VEHICLE PREPARATION
Posi ti on the vehi cl e on a l evel work surface. Usi ng
screw or bottl e jacks, adjust the vehi cl e PLP hei ghts
to the speci fi ed di mensi on above a l evel work surface.
Verti cal di mensi ons can be taken from the work sur-
face to the l ocati ons i ndi cated were appl i cabl e.
NOTE: All measurements are in MM.
DIMENSION ILLUSTRATIONS
DESCRIPTION FIGURE
TOP VIEW ( 5 )
SIDE VIEW ( 6 )
Fig. 4 REAR FASCIA SUPPORT
1 - RIVETS
2 - SUPPORT
Fig. 5 TOP VIEW
FRAME (Continued)
F
i
g
.
6
S
I
D
E
V
I
E
W
FRAME (Continued)
SPECIFICATIONS - TORQUE
ENGINE CRADLE CROSSMEMBER INNER RAIL BOLTS 47 35
ENGINE CRADLE CROSSMEMBER MOUNTING BOLTS 122 90
ENGINE MOUNT THROUGH BOLTS/NUTS 88 65
FRONT SKID PLATE BOLTS 61 45
FRONT TOW HOOK NUTS/BOLT 61 45
FUEL TANK SKID PLATE 88 65
REAR CROSSMEMBER BOLTS 47 35
REAR TOW HOOK BOLTS 88 65
TRAILER HITCH BOLTS 88 65
TRANSFER CASE SKID PLATE BOLTS 34 25
TRANSMISSION MOUNT THROUGH BOLT/NUT 88 65
FRONT SKID PLATE
REMOVAL
(2) Remove the ski d pl ate bol ts and remove the
ski d pl ate. (Fi g. 7)
INSTALLATION
(1) I nstal l the ski d pl ate.
(2) I nstal l the bol ts and ti ghten to 61 Nm (45 ft.
l bs.).
ENGINE CRADLE
CROSSMEMBER
REMOVAL
(1) I nstal l a sui tabl e engi ne support tool .
(3) Remove the l ower control arms. (Refer to 2 -
REMOVAL)
(4) Remove the sway bar. (Refer to 2 - SUSPEN-
SI ON/FRONT/STABI LI ZER BAR - REMOVAL)
(5) Remove the front axl e, i f equi pped. (Refer to 3 -
DI FFERENTI AL & DRI VELI NE/FRONT AXLE -
REMOVAL)
(6) Remove the power steeri ng rack. (Refer to 19 -
STEERI NG/GEAR - REMOVAL)
(7) Loosen the engi ne mount through bol ts.
(8) Support the engi ne cradl e wi th a sui tabl e l i ft-
i ng devi ce.
(9) Usi ng a grease penci l or equi val ent, mark the
l ocati on of the engi ne support cradl e.
(10) Remove the engi ne cradl e bol ts and remove
the engi ne cradl e.
INSTALLATION
(2) Usi ng a sui tabl e l i fti ng devi ce rai se the engi ne
cradl e i nto the vehi cl e whi l e l i ni ng up the engi ne
mount through bol ts.
Fig. 7 SKID PLATE
1 - SKID PLATE
2 - BOLTS (4)
FRAME (Continued)
(3) Al i gn the engi ne cradl e to the marks made dur-
i ng removal and i nstal l the mounti ng and i nner rai l
bol ts.
(4) Ti ghten the mounti ng bol ts to 122 Nm (90 ft.
l bs.).
(5) Ti ghten the i nner rai l bol ts to 47 Nm (35 ft.
l bs.).
(6) Ti ghten the engi ne mount through bol ts to 88
Nm (65 ft. l bs.).
(7) I nstal l the power steeri ng rack. (Refer to 19 -
STEERI NG/GEAR - I NSTALLATI ON)
(8) I nstal l the front axl e, i f equi pped. (Refer to 3 -
DI FFERENTI AL & DRI VELI NE/FRONT AXLE -
I NSTALLATI ON)
(9) I nstal l the stabi l i zer bar. (Refer to 2 - SUS-
PENSI ON/FRONT/STABI LI ZER BAR - I NSTALLA-
TI ON)
(10) I nstal l the l ower control arms. (Refer to 2 -
I NSTALLATI ON)
(11) Lower the vehi cl e and remove the engi ne sup-
port tool .
TRANSFER CASE SKID PLATE
REMOVAL
(1) Remove the bol ts and remove the ski d pl ate.
(Fi g. 8)
INSTALLATION
(1) I nstal l the ski d pl ate.
l bs.).
REAR CROSSMEMBER
REMOVAL
(2) Support the transmi ssi on wi th a sui tabl e l i fti ng
devi ce.
(3) Remove the transmi ssi on mount through bol t.
(4) Remove the crossmember bol ts and remove the
crossmember. (Fi g. 9)
INSTALLATION
(1) I nstal l the crossmember and i nstal l the bol ts.
(2) Ti ghten the bol ts to 47 Nm (35 ft. l bs.)
(3) I nstal l transmi ssi on mount through bol t and
ti ghten to 88 Nm (65 ft. l bs.).
Fig. 8 SKID PLATE
1 - SKID PLATE
2 - BOLTS
Fig. 9 CROSS MEMBER
1 - CROSSMEMBER
2 - BOLTS
ENGINE CRADLE CROSSMEMBER (Continued)
FRONT TOW HOOK
REMOVAL
NOTE: Front fascia must be removed to replace the
stud plate. (Refer to 13 - FRAME & BUMPERS/
BUMPERS/FRONT FASCIA - REMOVAL)
(1) Remove the nuts and bol t and remove the tow
eye/hook. (Fi g. 10)
INSTALLATION
(1) I nstal l the stud pl ate i f previ ousl y removed.
(2) I nstal l the tow eye/hook.
(3) I nstal l the nuts and bol t and ti ghten to 61 Nm
(45 ft. l bs.).
(4) I nstal l the front fasci a i f the stud pl ate was
repl aced. (Refer to 13 - FRAME & BUMPERS/
BUMPERS/FRONT FASCI A - I NSTALLATI ON)
REAR TOW HOOK
REMOVAL
(1) Remove the bol ts and remove the tow hook/eye.
(Fi g. 11)
INSTALLATION
(1) I nstal l the tow hook/eye.
l bs.).
Fig. 10 TOW HOOKS/EYE
1 - STUD PLATE
2 - U-NUT
3 - BOLTS
4 - NUTS
5 - TOW HOOK
6 - TOW EYE
Fig. 11 TOW HOOK/EYE
1 - U-NUT
2 - TOW EYE
3 - BOLTS
4 - TOW HOOK
TRAILER HITCH
REMOVAL
(1) Remove the tow hooks, i f equi pped. (Refer to 13
- FRAME & BUMPERS/FRAME/REAR TOW HOOK
- REMOVAL)
(2) Di sconnect trai l er el ectri cal connector.
(3) Support the hi tch wi th a sui tabl e l i fti ng devi ce.
(4) Remove the bol ts and remove the trai l er hi tch.
(Fi g. 12)
INSTALLATION
(1) Support the hi tch wi th a sui tabl e l i fti ng devi ce
and i nstal l the hi tch.
l bs.)
FUEL TANK SKID PLATE
REMOVAL
(2) Support the ski d pl ate wi th a sui tabl e l i fti ng
devi ce.
(3) Remove the trai l er hi tch, i f equi pped. (Refer to
13 - FRAME & BUMPERS/FRAME/TRAI LER
HI TCH - REMOVAL)
(4) Remove the tow hooks, i f not previ ousl y
removed. (Refer to 13 - FRAME & BUMPERS/
FRAME/REAR TOW HOOK - REMOVAL)
(5) Remove the bol ts and remove the fuel tank
ski d pl ate.
INSTALLATION
(1) I nstal l the ski d pl ate and support wi th a sui t-
abl e l i fti ng devi ce.
(2) I nstal l the trai l er hi tch, i f equi pped. (Refer to
13 - FRAME & BUMPERS/FRAME/TRAI LER
HI TCH - I NSTALLATI ON)
(3) I nstal l the tow hooks, i f equi pped. (Refer to 13
- FRAME & BUMPERS/FRAME/REAR TOW HOOK
- I NSTALLATI ON)
l bs.).
Fig. 12 TRAILER HITCH
1 - BOLTS
2 - TRAILER LIGHTS ELECTRICAL CONNECTOR
3 - TRAILER HITCH
FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 29
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - FUEL
PRESSURE LEAK DOWN TEST . . . . . . . . . . . 3
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . 5
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 6
FLOW MANAGEMENT VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL FILTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - FUEL LEVEL
SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
QUICK CONNECT FITTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL PRESSURE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
FUEL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - FUEL PUMP
CAPACITY TEST . . . . . . . . . . . . . . . . . . . . . . 15
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . 15
AMPERAGE TEST . . . . . . . . . . . . . . . . . . . . . 16
FUEL PUMP MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL RAIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
FUEL TANK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
FUEL TANK CHECK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
INLET FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
KJ FUEL SYSTEM 14 - 1
FUEL DELIVERY
DESCRIPTION
The fuel del i very system consi sts of:
the 2secti on fuel pump modul e contai ni ng the
el ectri c fuel pump, fuel pressure regul ator, fuel gauge
sendi ng uni t (fuel l evel sensor) and a fuel fi l ter
l ocated i nsi de the l ower secti on of pump modul e
fuel tubes/l i nes/hoses
A separatel y mounted mai n fuel fi l ter
qui ck-connect fi tti ngs
fuel i njector rai l
fuel tank
fuel tank fi l l er/vent tube assembl y
fuel tank fi l l er tube cap
accel erator pedal
throttl e cabl e
Certai n fuel del i very components can be found i n
(Fi g. 1).
Fig. 1 FUEL DELIVERY COMPONENTS
1 - FUEL TANK 10 - EVAP CANISTER
2 - FUEL TANK STRAPS 11 - FLOW MANAGEMENT VALVE
3 - FUEL PUMP MODULE LOCK RING 12 - FRESH AIR TUBE
4 - CHECK (CONTROL) VALVE 13 - HOSE SLEEVE
5 - FUEL PUMP MODULE FLANGE 14 - FUEL FILTER
6 - FUEL FILL HOSE 15 - LEAK DETECTION PUMP
7 - FRESH AIR FILTER 16 - HEAT SHIELD
8 - FUEL FILL CAP/BEZEL 17 - SKID PLATE
9 - FUEL FILL TUBE
14 - 2 FUEL DELIVERY KJ
OPERATION
Fuel i s pi cked up i n the fuel tank by the fuel pump
modul e. Thi s modul e i s l ocated on the bottom of the
fuel tank.
A fuel return system i s provi ded wi thi n the fuel
pump modul e usi ng check val ves. A separate fuel
return l i ne from the engi ne to the tank i s not used.
The fuel pressure regul ator and the mai n fuel fi l ter
are not combi ned. They are separate i tems.
The fuel tank assembl y consi sts of: the fuel tank,
fuel pump modul e assembl y, fuel pump modul e l ock
ri ng/gasket, ORVR components. Refer to 25, Emi s-
si on Control System for ORVR i nformati on.
A fuel fi l l er/vent tube assembl y usi ng a pressure/
vacuum, 1/4 turn fuel fi l l er cap i s used. The fuel
fi l l er tube contai ns a fl ap door l ocated bel ow the fuel
fi l l cap. A one-way check val ve i s i nstal l ed i nto the
tanks fuel fi l l fi tti ng.
Al so to be consi dered part of the fuel system i s the
evaporati on control system and ORVR system. Thi s
i s desi gned to reduce the emi ssi on of fuel vapors i nto
the atmosphere. The descri pti on and functi on of the
Evaporati ve Control System i s found i n 25, Emi ssi on
Control Systems.
Both fuel fi l ters (mounted to front of fuel tank, and
i nsi de the bottom fuel pump modul e) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. The bottom secti on of the fuel
pump modul e (wi th i ncl uded fi l ter) shoul d onl y be
repl aced i f a di agnosti c procedure i ndi cates to do so.
Al so, the fuel fi l ter mounted to the front of the fuel
tank shoul d onl y be repl aced i f a di agnosti c proce-
dure i ndi cates to do so.
DIAGNOSIS AND TESTING - FUEL PRESSURE
LEAK DOWN TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Pressure Test and Fuel Pump Capaci ty Test.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
Abnormal l y l ong peri ods of cranki ng to restart a
hot engi ne that has been shut down for a short
peri od of ti me may be caused by:
Fuel pressure bl eedi ng past a fuel i njector(s).
Fuel pressure bl eedi ng past the check val ve i n
the fuel pump modul e.
(1) Di sconnect the fuel i nl et l i ne at fuel rai l . Refer
to Qui ck Connect Fi tti ngs for procedures. On some
engi nes, ai r cl eaner housi ng removal may be neces-
sary before fuel l i ne di sconnecti on.
(2) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16 fuel
l i nes and tool number 6631 i s used for 3/8 fuel l i nes.
(3) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose between di sconnected fuel l i ne
and fuel rai l (Fi g. 2).
(4) Connect the 0-414 kPa (0-60 psi ) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropri ate Adaptor Tool . The DRB III Scan
Tool along with the PEP module, the 500 psi
pressure transducer, and the transducer-to-test
port adapter may also be used in place of the
fuel pressure gauge.
The fittings on both tools must be in good
condition and free from any small leaks before
performing the proceeding test.
(5) Start engi ne and bri ng to normal operati ng
temperature.
(6) Observe test gauge. Normal operati ng pressure
shoul d be 339 kPa +/34 kPa (49.2 psi +/5 psi ).
(7) Shut engi ne off.
Fig. 2 CONNECTING ADAPTER TOOLTYPICAL
1 - VEHICLE FUEL LINE
2 - TEST PORT T
3 - SPECIAL TOOL 6923, 6631, 6541 OR 6539
4 - FUEL PRESSURE TEST GAUGE
5 - FUEL LINE CONNECTION AT RAIL
6 - FUEL RAIL
KJ FUEL DELIVERY 14 - 3
FUEL DELIVERY (Continued)
(8) Pressure shoul d not fal l bel ow 30 psi for five
minutes.
(9) I f pressure fal l s bel ow 30 psi , i t must be deter-
mi ned i f a fuel i njector, the check val ve wi thi n the
fuel pump modul e, or a fuel tube/l i ne i s l eaki ng.
(10) Agai n, start engi ne and bri ng to normal oper-
ati ng temperature.
(11) Shut engi ne off.
(12) Testing for fuel injector or fuel rail leak-
age: Cl amp off the rubber hose porti on of Adaptor
Tool between the fuel rai l and the test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a fuel i njector or the fuel rai l i s l eaki ng.
(13) Testing for fuel pump check valve, filter,
regulator check valve or fuel tube/line leakage:
Cl amp off the rubber hose porti on of Adaptor Tool
between the vehi cl e fuel l i ne and test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a l eak may be found at a fuel tube/l i ne. I f no
l eaks are found at fuel tubes or l i nes, one of the
check val ves i n ei ther the el ectri c fuel pump, fuel fi l -
ter or fuel pressure regul ator may be l eaki ng.
Note: A qui ck l oss of pressure usual l y i ndi cates a
defecti ve check val ve i n the pressure regul ator. A
sl ow l oss of pressure usual l y i ndi cates a defecti ve
check val ve i n the bottom of the fuel pump modul e.
The check val ves are not servi ced separatel y. Al so,
the el ectri c fuel pump i s not servi ced separatel y.
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fi l l cap.
(2) Remove fuel pump rel ay from Power Di stri bu-
ti on Center (PDC). For l ocati on of rel ay, refer to l abel
on undersi de of PDC cover.
(3) Start and run engi ne unti l i t stal l s.
(4) Attempt restarti ng engi ne unti l i t wi l l no
l onger run.
(5) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unpl ug connector from any fuel i njector.
(7) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(8) Connect other end of jumper wi re to posi ti ve
si de of battery.
(9) Connect one end of a second jumper wi re to
remai ni ng i njector termi nal .
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentari l y touch other end of jumper wi re
to negati ve termi nal of battery for no more than a
few seconds.
(11) Pl ace a rag or towel bel ow fuel l i ne qui ck-con-
nect fi tti ng at fuel rai l .
(12) Di sconnect qui ck-connect fi tti ng at fuel rai l .
Refer to Qui ck-Connect Fi tti ngs.
(13) Return fuel pump rel ay to PDC.
(14) One or more Di agnosti c Troubl e Codes (DTCs)
may have been stored i n PCM memory due to fuel
pump rel ay removal . The DRB scan tool must be
used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
339 kPa +/- 34 kPa (49.2 psi +/- 2 psi ).
TORQUE
Accelerator Pedal Bracket Mounting Nuts 12 - 105
Crankshaft Position Sensor - 2.4L 28 21 -
Camshaft Position Sensor - 2.4L 12 - 106
Engine Coolant Temperature Sensor 11 - 96
EVAP Canister-to-Body Bolts 48 35 -
EVAP Canister-to-Canis. Bracket Bolt/Nut 11 - 100
Fuel Filler Hose Clamp at Tank 3 - 30
Fuel Filler Housing-to-Body Screws 2 - 17
Fuel Filter Mounting Nut at Tank 5.5 - 49
Fuel Pump Module Access Plate Nuts 3 - 26
Fuel Rail Mounting Bolts - 3.7L 11 - 100
Fuel Tank Heat Sheild Nuts 5.5 - 49
Fuel Tank Mounting Strap Bolts 61 45 -
Fuel Tank Skid Plate and Trailer Hitch 88 65 -
IAC Motor Mounting Screws 7 - 60
Leak Detection Pump Mounting Bracket-to-Fuel
Tank Nuts
5.5 - 49
Leak Detection Pump-to-Bracket Nuts 1.2 - 11
Map Sensor Mounting Screws 3 - 25
PCM-to-Mounting Bracket Mounting Screws 4 - 35
Power Steering Pressure Switch 14-22 - 124-195
TPS Mounting Screws 7 - 60
Throttle Body Mounting Bolts 11 - 100
Oxygen Sensors 30 22 -
SPECIAL TOOLS
FUEL SYSTEM
FLOW MANAGEMENT VALVE
DESCRIPTION
The fl ow management val ve i s a part of the ORVR
system. Thi s pl asti c val ve i s pl aced i nl i ne between
the fuel tank vent fi tti ng and the EVAP cani ster. I t i s
l ocated on top of the fuel tank (Fi g. 1).
OPERATION
The fl ow management val ve (Fi g. 1) i s one of the com-
ponents used i n the ORVR system. The val ve meters
the fl ow of fuel vapors to the EVAP cani ster duri ng
vehi cl e run and refuel i ng. Pressure from the tank dur-
i ng refuel i ng opens the mai n port val ve and al l ows
vapors to enter the EVAP cani ster. Duri ng vehi cl e run,
the vapors are metered through an ori fi ce to the EVAP
cani ster. I t i s al so used as a l i qui d separator to keep l i q-
ui d fuel out of the EVAP cani ster.
REMOVAL
The fl ow management val ve i s l ocated on top of the
fuel tank (Fi g. 1).
(1) Four cargo hol down cl amps are l ocated i nsi de
the vehi cl e on the fl oor of the rear cargo area.
Remove the 2 rearward mounted cl amps by dri l l i ng
out the cl amp ri vets.
(2) Fol d carpeti ng forward to gai n access to fuel
pump modul e access pl ate (Fi g. 3).
Fig. 3 ACCESS PLATE
1 - FLOORPAN AT REAR
2 - FUEL PUMP MODULE ACCESS PLATE
3 - NUTS (4)
4 - OPENING TO PUMP MODULE
ADAPTERS, FUEL PRESSURE TEST6539 AND/OR
6631
TEST KIT, FUEL PRESSURE5069
TEST KIT, FUEL
(3) Remove 4 fuel pump modul e access pl ate nuts
(Fi g. 3).
(4) Whi l e appl yi ng heat from a heat gun, careful l y
pry up fuel pump modul e access pl ate. Take care not
to bend pl ate.
(5) Di sconnect fl ow management val ve hose cl amp
and hose (Fi g. 4) at pump modul e fi tti ng. Al so di scon-
nect smal l reci rcul ati on l i ne at top hal f of manage-
ment val ve.
(7) Di sconnect opposi te end of fl ow management
val ve hose at EVAP cani ster (Fi g. 1).
(8) Remove val ve and 2 hoses as an assembl y.
INSTALLATION
(2) Attach 2 l arge hoses and 1 smal l l i ne to fl ow
management val ve. Posi ti on thi s assembl y to top of
fuel tank.
(3) Connect val ve hose at EVAP cani ster.
(5) Attach val ve hose and cl amp to top of fuel
pump modul e.
(6) Appl y si l i cone seal ant to bottom of fuel pump
modul e metal access pl ate.
(7) I nstal l fuel pump modul e metal access pl ate
and 4 nuts. Ti ghten nuts to 3 Nm (26 i n. l bs.)
torque.
(8) Posi ti on carpet and i nstal l 2 new cargo cl amp
ri vets.
FUEL FILTER
DESCRIPTION
The fuel pressure regul ator and fuel fi l ter are not
combi ned on thi s vehi cl e. The mai n fuel fi l ter i s
attached to the front of the fuel tank (Fi g. 1) and i s a
servi ceabl e/repl aceabl e i tem. Al so refer to I nl et Fi l ter
and Fuel Pressure Regul ator.
REMOVAL
The mai n fuel fi l ter i s attached to the front of fuel
tank (Fi g. 1). Three fuel l i nes are used at fi l ter.
Fuel tank removal will not be necessary for
fuel filter removal. Access is from rear cargo
area.
WARNING: THE FUEL SYSTEM MAY BE UNDER A
CONSTANT PRESSURE (EVEN WITH THE ENGINE
OFF). BEFORE SERVICING MOST FUEL SYSTEM
COMPONENTS, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED. REFER TO THE FUEL SYS-
TEM PRESSURE RELEASE PROCEDURE.
(1) Rel ease fuel system pressure.
vehi cl e on fl oor of rear cargo area. Two of these four
cl amps must be removed. Remove 2 rearward
mounted cl amps by dri l l i ng out cl amp ri vets.
(Fi g. 5).
pry up metal fuel pump modul e access pl ate. Take
care not to bend pl ate.
(6) Cl ean top of fuel pump modul e area around
fuel l i ne connecti on poi nts.
(7) Di sconnect 2 fuel l i nes at fuel pump modul e
(Fi g. 6) by pressi ng on tabs at si de of fi tti ng.
(9) Pl ace drai n pan under fuel fi l ter.
(10) A thi rd fuel l i ne i s attached to bottom of fi l ter
(Fi g. 7). The di sconnecti on poi nt for thi s 3rd l i ne i s
approxi matel y 1 foot towards front of vehi cl e. Cl ean
fuel l i ne connecti on poi nt before di sconnecti on. Di s-
connect by pressi ng on tabs at si de of fi tti ng.
(11) Di sconnect 3rd fuel l i ne from body retenti on
cl i p. Pl ace a smal l screwdri ver i nto si de of cl i p and
twi st for removal .
Fig. 4 TOP OF FUEL PUMP MODULE
1 - LOCK RING
2 - ALIGNMENT NOTCH
3 - FUEL FILTER FITTINGS (2)
4 - ORVR SYSTEM HOSE AND CLAMP
5 - FLOW MANAGEMENT VALVE
7 - LEAK DETECTION PUMP
8 - FUEL TANK CHECK (CONTROL) VALVE
9 - FUEL PUMP MODULE (UPPER SECTION)
FLOW MANAGEMENT VALVE (Continued)
(12) Remove fi l ter ground strap at fuel tank
mounti ng strap.
(13) Remove 1 fi l ter mounti ng nut (Fi g. 7) and
remove fi l ter.
INSTALLATION
(2) Posi ti on fuel l i nes on fi l ter towards top of fuel
tank.
(3) Posi ti on fi l ter to mounti ng stud on front of fuel
tank.
(4) I nstal l fi l ter mounti ng nut and ti ghten. Refer
to torque speci fi cati ons.
(5) A thi rd fuel l i ne i s attached to bottom of fi l ter.
The connecti on poi nt for thi s 3rd l i ne i s approxi -
matel y 1 foot towards front of vehi cl e. Connect by
snappi ng together.
(6) Connect 3rd fuel l i ne to body retenti on cl i p
(snaps i n).
(7) Attach fi l ter ground strap to tank mounti ng
strap.
(9) Attach (snap on) 2 fi l ter fuel l i nes at fuel pump
modul e fi tti ngs.
(10) Start engi ne and check fuel l i ne fi tti ngs for
l eaks.
(11) Appl y si l i cone seal ant to fuel pump modul e
metal access pl ate.
and 4 nuts. Ti ghten 4 nuts. Refer to torque speci fi ca-
ti ons.
ri vets i n each cargo hol down cl amp.
Fig. 5 ACCESS PLATE
3 - NUTS (4)
Fig. 6 FUEL LINES AT PUMP MODULE
1 - FUEL PUMP MODULE LOCKRING
2 - FUEL LINES TO FUEL FILTER (2)
3 - QUICK-CONNECT FITTINGS (2)
4 - ROLLOVER VALVE
Fig. 7 FUEL FILTER LOCATION
1 - FUEL FILTER
2 - 3RD FUEL LINE TO ENGINE
3 - FILTER MOUNTING NUT
FUEL FILTER (Continued)
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel pump modul e. The
sendi ng uni t consi sts of a fl oat, an arm, and a vari -
abl e resi stor track (card).
OPERATION
The fuel pump modul e has 4 di fferent ci rcui ts
(wi res). Two of these ci rcui ts are used for the fuel
gauge sendi ng uni t for fuel gauge operati on, and for
certai n OBD I I emi ssi on requi rements. The other 2
wi res are used for el ectri c fuel pump operati on.
For Fuel Gauge Operation: A constant current
source of approxi matel y 32 mi l l i amps i s suppl i ed to
the resi stor track on the fuel gauge sendi ng uni t.
Thi s i s fed di rectl y from the Powertrai n Control Mod-
ul e (PCM). NOTE: For diagnostic purposes, this
12V power source can only be verified with the
circuit opened (fuel pump module electrical
connector unplugged). With the connectors
plugged, output voltages will vary from about
0.6 volts at FULL, to about 8.6 volts at EMPTY
(about 8.6 volts at EMPTY for J eep models, and
about 7.0 volts at EMPTY for Dodge Truck mod-
els). The resi stor track i s used to vary the vol tage
(resi stance) dependi ng on fuel tank fl oat l evel . As
fuel l evel i ncreases, the fl oat and arm move up,
whi ch decreases vol tage. As fuel l evel decreases, the
fl oat and arm move down, whi ch i ncreases vol tage.
The vari ed vol tage si gnal i s returned back to the
PCM through the sensor return ci rcui t.
Both of the el ectri cal ci rcui ts between the fuel
gauge sendi ng uni t and the PCM are hard-wi red (not
mul ti -pl exed). After the vol tage si gnal i s sent from
the resi stor track, and back to the PCM, the PCM
wi l l i nterpret the resi stance (vol tage) data and send
a message across the mul ti -pl ex bus ci rcui ts to the
i nstrument panel cl uster. Here i t i s transl ated i nto
the appropri ate fuel gauge l evel readi ng. Refer to
I nstrument Panel for addi ti onal i nformati on.
For OBD II Emission Monitor Requirements:
The PCM wi l l moni tor the vol tage output sent from
the resi stor track on the sendi ng uni t to i ndi cate fuel
l evel . The purpose of thi s feature i s to prevent the
OBD I I system from recordi ng/setti ng fal se mi sfi re
and fuel system moni tor di agnosti c troubl e codes.
The feature i s acti vated i f the fuel l evel i n the tank
i s l ess than approxi matel y 15 percent of i ts rated
capaci ty. I f equi pped wi th a Leak Detecti on Pump
(EVAP system moni tor), thi s feature wi l l al so be acti -
vated i f the fuel l evel i n the tank i s more than
approxi matel y 85 percent of i ts rated capaci ty.
DIAGNOSIS AND TESTING - FUEL LEVEL
SENDING UNIT
The fuel l evel sendi ng uni t contai ns a vari abl e
resi stor (track). As the fl oat moves up or down, el ec-
tri cal resi stance wi l l change. Refer to I nstrument
Panel and Gauges for Fuel Gauge testi ng. To test the
gauge sendi ng uni t onl y, i t must be removed from
vehi cl e. The uni t i s a separate part of the l ower fuel
pump modul e secti on. Refer to Fuel Pump Modul e
Removal /I nstal l ati on for procedures (remove onl y the
upper secti on of the fuel pump modul e). Measure the
resi stance across the sendi ng uni t termi nal s. Wi th
fl oat i n up posi ti on, resi stance shoul d be 20 ohms (+/-
5%). Wi th fl oat i n down posi ti on, resi stance shoul d be
270 ohms (+/- 5%).
REMOVAL
The fuel l evel sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of the l ower sec-
ti on of the fuel pump modul e. The l ower secti on of
the fuel pump modul e i s l ocated wi thi n the fuel tank.
(1) Remove l ower secti on of fuel pump modul e
from fuel tank. Refer to Fuel Pump Modul e Removal /
I nstal l ati on.
(2) To remove sendi ng uni t from pump modul e, l i ft
on pl asti c l ocki ng tab (Fi g. 8) whi l e sl i di ng sendi ng
uni t upwards.
(3) Di sconnect 4wi re el ectri cal connector (Fi g. 9)
from bottom of upper secti on of fuel pump modul e.
Separate necessary sendi ng uni t wi ri ng.
Fig. 8 FUEL LEVEL SENDING UNIT
1 - LIFT TAB HERE FOR REMOVAL
2 - FUEL LEVEL SENDING UNIT
3 - LOWER SECTION OF PUMP MODULE
INSTALLATION
(1) Connect necessary wi ri ng i nto el ectri cal con-
nectors. Connect 4wi re connector to upper secti on of
pump modul e.
(2) Posi ti on sendi ng uni t to pump modul e. Sl i de
and snap i nto pl ace.
(3) I nstal l l ower secti on of fuel pump modul e.
Refer to Fuel Pump Modul e Removal /I nstal l ati on.
FUEL LINES
DESCRIPTION
Al so refer to Qui ck-Connect Fi tti ngs.
WARNING: THE FUEL SYSTEM MAY BE UNDER A
CONSTANT PRESSURE (EVEN WITH THE ENGINE
OFF). BEFORE SERVICING ANY FUEL SYSTEM
HOSES, FITTINGS, LINES, OR MOST COMPO-
NENTS, FUEL SYSTEM PRESSURE MUST BE
RELEASED. REFER TO THE FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
The l i nes/tubes/hoses used on fuel i njected vehi cl es
are of a speci al constructi on. Thi s i s due to the
hi gher fuel pressures and the possi bi l i ty of contami -
nated fuel i n thi s system. I f i t i s necessary to repl ace
these l i nes/tubes/hoses, onl y those marked EFM/EFI
may be used.
If equipped: The hose cl amps used to secure rub-
ber hoses on fuel i njected vehi cl es are of a speci al
rol l ed edge constructi on. Thi s constructi on i s used to
prevent the edge of the cl amp from cutti ng i nto the
hose. Onl y these rol l ed edge type cl amps may be
used i n thi s system. Al l other types of cl amps may
cut i nto the hoses and cause hi gh-pressure fuel l eaks.
Use new ori gi nal equi pment type hose cl amps.
QUICK CONNECT FITTING
DESCRIPTION
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Some are equi pped wi th
safety l atch cl i ps. Some may requi re the use of a spe-
ci al tool for di sconnecti on and removal . Refer to
Qui ck-Connect Fi tti ngs Removal /I nstal l ati on for more
i nformati on.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
Al so refer to Fuel Tubes/Li nes/Hoses and Cl amps.
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Safety l atch cl i ps are
used on certai n components/l i nes. Certai n fi tti ngs
may requi re use of a speci al tool for di sconnecti on.
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
Fig. 9 FUEL PRESSURE REGULATOR/SENDING
UNIT ELECTRICAL CONNECTOR
1 - UPPER SECTION OF PUMP MODULE
2 - QUICK-CONNECT FITTINGS
3 - FUEL PRESSURE REGULATOR
4 - 4-WIRE ELECTRICAL CONNECTOR
FUEL LEVEL SENDING UNIT / SENSOR (Continued)
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure rel ease procedure. Refer
to Fuel Pressure Rel ease Procedure.
(3) Cl ean fi tti ng of any forei gn materi al before di s-
assembl y.
(4) 2Button Type Fitting: Thi s type of fi tti ng i s
equi pped wi th a push-button l ocated on each si de of
qui ck-connect fi tti ng (Fi g. 10). Press on both buttons
si mul taneousl y for removal .
(5) Single-Tab Type Fitting: Thi s type of fi tti ng
i s equi pped wi th a si ngl e pul l tab (Fi g. 11). The tab i s
removabl e. After tab i s removed, qui ck-connect fi tti ng
can be separated from fuel system component.
(a) Press rel ease tab on si de of fi tti ng to rel ease
pul l tab (Fi g. 12). If release tab is not pressed
prior to releasing pull tab, pull tab will be
damaged.
(b) Whi l e pressi ng rel ease tab on si de of fi tti ng,
use screwdri ver to pry up pul l tab (Fi g. 12).
(c) Rai se pul l tab unti l i t separates from qui ck-
connect fi tti ng (Fi g. 13).
(6) Two-Tab Type Fitting: Thi s type of fi tti ng i s
equi pped wi th tabs l ocated on both si des of fi tti ng
(Fi g. 14). The tabs are suppl i ed for di sconnecti ng
qui ck-connect fi tti ng from component bei ng servi ced.
(a) To di sconnect qui ck-connect fi tti ng, squeeze
pl asti c retai ner tabs (Fi g. 14) agai nst si des of
qui ck-connect fi tti ng wi th your fi ngers. Tool use i s
not requi red for removal and may damage pl asti c
retai ner.
(b) Pul l fi tti ng from fuel system component
bei ng servi ced.
(c) The pl asti c retai ner wi l l remai n on compo-
nent bei ng servi ced after fi tti ng i s di sconnected.
The o-ri ngs and spacer wi l l remai n i n qui ck-con-
nect fi tti ng connector body.
Fig. 10 2-BUTTON TYPE FITTING
1 - QUICK-CONNECT FITTING
2 - PUSH-BUTTONS (2)
Fig. 11 SINGLE-TAB TYPE FITTING
1 - PULL TAB
3 - PRESS HERE TO REMOVE PULL TAB
4 - INSERTED TUBE END
Fig. 12 DISCONNECTING SINGLE-TAB TYPE
FITTING
1 - PULL TAB
2 - SCREWDRIVER
QUICK CONNECT FITTING (Continued)
(7) Plastic Retainer Ring Type Fitting: Thi s
type of fi tti ng can be i denti fi ed by the use of a ful l -
round pl asti c retai ner ri ng (Fi g. 15) usual l y bl ack i n
col or.
(a) To rel ease fuel system component from qui ck-
connect fi tti ng, fi rml y push fi tti ng towards compo-
nent bei ng servi ced whi l e fi rml y pushi ng pl asti c
retai ner ri ng i nto fi tti ng (Fi g. 15). Wi th pl asti c ri ng
depressed, pul l fi tti ng from component. The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.
Fig. 13 REMOVING PULL TAB
1 - FUEL TUBE OR FUEL SYSTEM COMPONENT
2 - PULL TAB
4 - FUEL TUBE STOP
Fig. 14 TYPICAL 2TAB TYPE FITTING
1 - TAB(S)
Fig. 15 PLASTIC RETAINER RING TYPE FITTING
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
Fig. 16 LATCH CLIP-TYPE 1
1 - TETHER STRAP
2 - FUEL LINE
3 - SCREWDRIVER
4 - LATCH CLIP
5 - FUEL RAIL
(b) After di sconnecti on, pl asti c retai ner ri ng wi l l
remai n wi th qui ck-connect fi tti ng connector body.
(c) I nspect fi tti ng connector body, pl asti c retai ner
ri ng and fuel system component for damage.
Repl ace as necessary.
(8) Latch Clips: Dependi ng on vehi cl e model and
engi ne, 2 di fferent types of safety l atch cl i ps are used
(Fi g. 16) or (Fi g. 17). Type-1 i s tethered to fuel l i ne
and type-2 i s not. A speci al tool wi l l be necessary to
di sconnect fuel l i ne after l atch cl i p i s removed. The
l atch cl i p may be used on certai n fuel l i ne/fuel rai l
connecti on, or to joi n fuel l i nes together.
(a) Type 1: Pry up on l atch cl i p wi th a screw-
dri ver (Fi g. 16).
(b) Type 2: Separate and unl atch 2 smal l arms
on end of cl i p (Fi g. 17) and swi ng away from fuel
l i ne.
(c) Sl i de l atch cl i p toward fuel rai l whi l e l i fti ng
wi th screwdri ver.
(d) I nsert speci al fuel l i ne removal tool (Snap-On
number FI H 9055-1 or equi val ent) i nto fuel l i ne
(Fi g. 18). Use tool to rel ease l ocki ng fi ngers i n end
of l i ne.
(e) Wi th speci al tool sti l l i nserted, pul l fuel l i ne
from fuel rai l .
(f) After di sconnecti on, l ocki ng fi ngers wi l l
remai n wi thi n qui ck-connect fi tti ng at end of fuel
l i ne.
(9) Di sconnect qui ck-connect fi tti ng from fuel sys-
tem component bei ng servi ced.
CONNECTING
(1) I nspect qui ck-connect fi tti ng body and fuel sys-
tem component for damage. Repl ace as necessary.
(2) Pri or to connecti ng qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean parts wi th a l i nt-free cl oth.
Lubri cate wi th cl ean engi ne oi l .
(3) I nsert qui ck-connect fi tti ng i nto fuel tube or
fuel system component unti l bui l t-on stop on fuel
tube or component rests agai nst back of fi tti ng.
(4) Conti nue pushi ng unti l a cl i ck i s fel t.
(5) Si ngl e-tab type fi tti ng: Push new tab down
unti l i t l ocks i nto pl ace i n qui ck-connect fi tti ng.
(6) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(7) Latch Cl i p Equi pped: I nstal l l atch cl i p (snaps
i nto posi ti on). If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
FUEL PRESSURE REGULATOR
DESCRIPTION
The fuel pressure regul ator i s l ocated on the bot-
tom of the upper secti on of the fuel pump modul e.
The fuel fi l ter is not combined i nto the pressure
regul ator on thi s model .
Fig. 17 LATCH CLIP-TYPE 2
1 - LATCH CLIP
Fig. 18 FUEL LINE DISCONNECTION USING
SPECIAL TOOL
1 - SPECIAL FUEL LINE TOOL
2 - FUEL LINE
3 - FUEL RAIL
OPERATION
The fuel pressure regul ator i s a mechani cal devi ce
that i s not control l ed by engi ne vacuum or the Pow-
ertrai n Control Modul e (PCM).
The regul ator i s cal i brated to mai ntai n fuel system
operati ng pressure of approxi matel y 339 kPa +/- 34
kPa (49.2 psi +/- 5 psi ) at the fuel i njectors. I t con-
tai ns a di aphragm, cal i brated spri ngs and a fuel
return val ve.
The mai n fuel fi l ter is not combined wi thi n the
fuel pressure regul ator as i n other Jeep model s.
Three di fferent fuel fi l ters are used: 1. a servi ceabl e,
separate, external l y mounted, mai n fuel fi l ter; 2. a
non-servi ceabl e pri mary fi l ter l ocated on the bottom
of the el ectri c fuel pump; 3. a non-servi ceabl e second-
ary fi l ter attached to the si de of the fuel pump mod-
ul e.
Fuel Flow: Fuel mi grates i nto the fuel pump mod-
ul e reservoi r through a one-way check val ve l ocated
on the bottom of the modul e. Thi s check val ve pre-
vents the reservoi r from runni ng empty such as
when goi ng up or down hi l l s wi th a l ow amount of
fuel i n the tank. A pri mary fuel fi l ter (sock) i s l ocated
at the bottom of the el ectri c fuel pump. Fuel i s drawn
i n through thi s fi l ter, and up to the el ectri c fuel
pump. Hi gh pressure fuel (unregul ated) i s suppl i ed
from the el ectri c fuel pump through a hi gh-pressure
l i ne to one of 3 fi tti ngs on the mai n fuel fi l ter. I f fuel
pressure at the pressure regul ator exceeds approxi -
matel y 49 psi , an i nternal di aphragm wi thi n the reg-
ul ator cl oses, and excess fuel i s routed through a
second fi tti ng on the mai n fuel fi l ter, and back i nto
the fuel tank (the fuel pressure regul ator i s i nstal l ed
i nto the return si de of the system). Pressure regu-
l ated fuel i s then del i vered from the thi rd fi tti ng on
the fuel fi l ter, up to and through the fuel rai l , and on
to the fuel i njectors.
A secondary fuel fi l ter i s attached to the si de of the
fuel pump modul e. Hi gh-pressure from the el ectri c
fuel pump causes a si phoni ng acti on across a passage
connected to thi s fi l ter, and fuel i s drawn i nto the
fuel pump modul e reservoi r. Thi s i s used to hel p keep
the modul e reservoi r ful l of fuel .
The fuel pressure regul ator al so acts as a check
val ve to mai ntai n some fuel pressure when the
engi ne i s not operati ng. Thi s wi l l hel p to start the
engi ne. A second check val ve i s l ocated at the outl et
of the fuel pump modul e housi ng. Refer to Fuel
Pump - Description and Operation for more
information. Also refer to the Fuel Pressure
Leak Down Test, and the Fuel Pump Pressure
Tests.
A separate fuel return l i ne from the engi ne i s not
used wi th thi s system.
REMOVAL
The fuel pressure regul ator i s l ocated i n the fuel
tank. I t i s attached to the bottom of the upper sec-
ti on of the fuel pump modul e wi th a qui ck-connect
fi tti ng (Fi g. 19). The fuel pump modul e i s suppl i ed i n
2 secti ons (upper and l ower). To repl ace the pressure
regul ator, the bottom secti on of the fuel pump mod-
ul e must be repl aced.
(1) Remove upper and l ower secti ons of fuel pump
modul e from fuel tank. Refer to Fuel Pump Modul e
(2) Repl ace l ower secti on of fuel pump modul e
(i ncl udes fuel pressure regul ator).
INSTALLATION
The fuel pressure regul ator i s l ocated i n the fuel
tank. I t i s attached to the bottom of the upper sec-
ti on of the fuel pump modul e wi th a qui ck-connect
fi tti ng. The fuel pump modul e i s suppl i ed i n 2 sec-
ti ons (upper and l ower). To repl ace the pressure reg-
ul ator, the bottom secti on of the fuel pump modul e
must be repl aced.
(1) Repl ace l ower secti on of fuel pump modul e
(i ncl udes fuel pressure regul ator).
(2) I nstal l upper and l ower secti ons of fuel pump
modul e to fuel tank. Refer to Fuel Pump Modul e
I nstal l ati on.
FUEL PRESSURE REGULATOR (Continued)
FUEL PUMP
DESCRIPTION
The el ectri c fuel pump i s l ocated i nsi de of the fuel
pump modul e. A 12 vol t, permanent magnet, el ectri c
motor powers the fuel pump. The el ectri c fuel pump
i s not a separate, servi ceabl e component.
OPERATION
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay.
Fuel i s drawn i n through a fi l ter at the bottom of
the modul e and pushed through the el ectri c motor
gearset to the pump outl et.
Check Valve Operation: The bottom secti on of
the fuel pump modul e contai ns a one-way check
val ve to prevent fuel fl ow back i nto the tank and to
mai ntai n fuel suppl y l i ne pressure (engi ne warm)
when pump i s not operati onal . I t i s al so used to keep
the fuel suppl y l i ne ful l of gasol i ne when pump i s not
operati onal . After the vehi cl e has cool ed down, fuel
pressure may drop to 0 psi (col d fl ui d contracts), but
l i qui d gasol i ne wi l l remai n i n fuel suppl y l i ne
between the check val ve and fuel i njectors. Fuel
pressure that has dropped to 0 psi on a cooled
down vehicle (engine off) is a normal condition.
Refer to the Fuel Pressure Leak Down Test for more
i nformati on.
The el ectri c fuel pump i s not a separate, servi ce-
abl e component.
CAPACITY TEST
Before performing this test, verify fuel pump
pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.
(1) Rel ease fuel system pressure. Refer to Fuel
Pressure Rel ease Procedure.
(2) Di sconnect fuel suppl y l i ne at fuel rai l . Refer to
Qui ck-Connect Fi tti ngs. Some engi nes may requi re
ai r cl eaner housi ng removal before l i ne di sconnecti on.
(3) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16 fuel
l i nes and tool number 6631 i s used for 3/8 fuel l i nes.
(4) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose i nto di sconnected fuel suppl y l i ne.
I nsert other end of Adaptor Tool Hose i nto a gradu-
ated contai ner.
(5) Remove fuel fi l l cap.
(6) To acti vate fuel pump and pressuri ze system,
obtai n DRB scan tool and actuate ASD Fuel System
Test.
(7) A good fuel pump wi l l del i ver at l east 1/10 l i ter
of fuel i n 7 seconds. Do not operate fuel pump for
l onger than 7 seconds wi th fuel l i ne di sconnected as
fuel pump modul e reservoi r may run empty.
(a) I f capaci ty i s l ower than speci fi cati on, but
fuel pump can be heard operati ng through fuel fi l l
cap openi ng, check for a ki nked/damaged fuel sup-
pl y l i ne somewhere between fuel rai l and fuel
pump modul e.
(b) I f l i ne i s not ki nked/damaged, and fuel pres-
sure i s OK, but capaci ty i s l ow, repl ace fuel fi l ter.
Refer to Fuel Fi l ter Removal /I nstal l ati on for addi -
ti onal i nformati on.
(c) I f both fuel pressure and capaci ty are l ow,
repl ace bottom secti on of fuel pump modul e. Refer
to Fuel Pump Modul e Removal /I nstal l ati on.
PRESSURE TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Capaci ty Test, Fuel Pressure Leak Down Test and
Fuel Pump Amperage Test found el sewhere i n thi s
group.
Check Valve Operation: The bottom secti on of
the fuel pump modul e contai ns a one-way check
val ve to prevent fuel fl ow back i nto the tank and to
mai ntai n fuel suppl y l i ne pressure (engi ne warm)
when pump i s not operati onal . I t i s al so used to keep
the fuel suppl y l i ne ful l of gasol i ne when pump i s not
operati onal . After the vehi cl e has cool ed down, fuel
pressure may drop to 0 psi (col d fl ui d contracts), but
l i qui d gasol i ne wi l l remai n i n fuel suppl y l i ne
between the check val ve and fuel i njectors. Fuel
pressure that has dropped to 0 psi on a cooled
down vehicle (engine off) is a normal condition.
When the el ectri c fuel pump i s acti vated, fuel pres-
sure shoul d immediately (12 seconds) ri se to spec-
i fi cati on.
The fuel system i s equi pped wi th a separate fuel
pump modul e mounted, fuel pressure regul ator. The
fuel fi l ter i s remotel y mounted. The fuel pressure
regul ator i s not control l ed by engi ne vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Remove protecti ve cap at fuel rai l test port.
Connect the 0414 kPa (0-60 psi ) fuel pressure gauge
(from gauge set 5069) to test port pressure fi tti ng on
fuel rai l (Fi g. 20). The DRB III Scan Tool along
with the PEP module, the 500 psi pressure
transducer, and the transducer-to-test port
adapter may also be used in place of the fuel
pressure gauge.
(2) Start and warm engi ne and note pressure
gauge readi ng. Fuel pressure shoul d be 339 kPa 34
kPa (49.2 psi 5 psi ) at i dl e.
(3) I f engi ne runs, but pressure i s bel ow 44.2 psi ,
check for a ki nked fuel suppl y l i ne somewhere
between fuel rai l and fuel pump modul e. I f l i ne i s not
ki nked, but speci fi cati ons for ei ther the Fuel Pump
Capaci ty, Fuel Pump Amperage or Fuel Pressure
Leak Down Tests were not met, repl ace l ower secti on
of fuel pump modul e. Refer to Fuel Pump Modul e
(4) I f operati ng pressure i s above 54.2 psi , el ectri c
fuel pump i s OK, but fuel pressure regul ator i s defec-
ti ve. Repl ace l ower secti on of fuel pump modul e.
(5) I nstal l protecti ve cap to fuel rai l test port.
AMPERAGE TEST
Thi s amperage (current draw) test i s to be done i n
conjuncti on wi th the Fuel Pump Pressure Test, Fuel
Pump Capaci ty Test and Fuel Pressure Leak Down
Test. Before performi ng the amperage test, be sure
the temperature of the fuel tank i s above 50 F (10
C).
The DRB Scan Tool al ong wi th the DRB Low Cur-
rent Shunt (LCS) adapter (Fi g. 21) and i ts test l eads
wi l l be used to check fuel pump amperage speci fi ca-
ti ons.
(1) Be sure fuel tank contai ns fuel before starti ng
test. I f tank i s empty or near empty, amperage read-
i ngs wi l l be i ncorrect.
(2) Obtai n LCS adapter.
(3) Pl ug cabl e from LCS adapter i nto DRB scan
tool at SET 1 receptacl e.
(4) Pl ug DRB i nto vehi cl e 16way connector (data
l i nk connector).
(5) Connect (-) and (+) test cabl e l eads i nto LCS
adapter receptacl es. Use 10 amp (10A +) receptacl e
and common (-) receptacl es.
(6) Gai n access to MAI N MENU on DRB screen.
(7) Press DVOM button on DRB.
(8) Usi ng l eft/ri ght arrow keys, hi ghl i ght CHAN-
NEL 1 functi on on DRB screen.
(9) Press ENTER three ti mes.
(10) Usi ng up/down arrow keys, hi ghl i ght RANGE
on DRB screen (screen wi l l defaul t to 2 amp scal e).
(11) Press ENTER to change 2 amp scal e to 10
amp scal e. This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Di stri buti on Center
(PDC).
(13) Remove fuel pump rel ay from PDC. Refer to
Fig. 20 FUEL PRESSURE TEST GAUGE (TYPICAL
GAUGE INSTALLATION AT TEST PORT)
1 - SERVICE (TEST) PORT
2 - FUEL PRESSURE TEST GAUGE
3 - FUEL RAIL
Fig. 21 LOW CURRENT SHUNT
1 - LOW CURRENT SHUNT ADAPTER
2 - PLUG TO DRB
3 - TEST LEAD RECEPTACLES
FUEL PUMP (Continued)
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND
FUEL SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: To prevent possible damage to the vehi-
cle electrical system and LCS adapter, the test
leads must be connected into relay cavities exactly
as shown in following steps.
Dependi ng upon vehi cl e model , year or engi ne con-
fi gurati on, three di fferent types of rel ays may be
used: Type-1, type-2 and type3.
(14) I f equi pped wi th type1 relay (Fi g. 22),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 22).
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 23).
cavi ti es number 3 and 5. For l ocati on of these cavi -
ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 24).
Fig. 22 FUEL PUMP RELAY - TYPE 1
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
TERMINAL LEGEND
1 COIL BATTERY
2 COIL GROUND
3 COMMON FEED
4 NORMALLY CLOSED
5 NORMALLY OPEN
(17) When LCS adapter test l eads are attached
i nto rel ay cavi ti es, fuel pump will be activated.
Determi ne fuel pump amperage on DRB screen.
Amperage shoul d be bel ow 10.0 amps. I f amperage i s
bel ow 10.0 amps, and speci fi cati ons for the Fuel
Pump Pressure, Fuel Pump Capaci ty and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ul e i s OK.
(18) I f amperage i s more than 10.0 amps, repl ace
fuel pump modul e assembl y. The el ectri c fuel pump
i s not servi ced separatel y.
(19) Di sconnect test l eads from rel ay cavi ti es
i mmedi atel y after testi ng.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump modul e assembl y i s l ocated i n the
fuel tank (Fi g. 1). The assembl y i s di vi ded i nto 2sec-
ti ons, upper and l ower. The l ower secti on i s l ocked to
the bottom of the fuel tank. The compl ete assembl y
contai ns the fol l owi ng components:
A fuel pressure regul ator
A separate fuel pi ck-up, or i nl et fi l ter
An el ectri c fuel pump
A l ockri ng to retai n upper secti on of pump mod-
ul e to tank
A rol l over val ve
A vent fi tti ng for ORVR system
A soft gasket between tank fl ange and modul e
A fuel gauge sendi ng uni t (fuel l evel sensor)
Two fuel l i ne connecti ons (suppl y and return)
The fuel gauge sendi ng uni t may be servi ced sepa-
ratel y. I f the el ectri cal fuel pump, pri mary i nl et fi l ter
or fuel pressure regul ator requi re servi ce, the l ower
secti on of the fuel pump modul e must be repl aced.
OPERATION
Refer to Fuel Pump, I nl et Fi l ter, Fuel Pressure
Regul ator and Fuel Gauge Sendi ng Uni t.
REMOVAL
The fuel pump modul e i s di vi ded i nto 2 secti ons,
upper and l ower. To servi ce the check (control ) val ve,
repl ace onl y the upper secti on. To servi ce the fuel
gauge sendi ng uni t, remove the upper secti on. To ser-
vi ce the el ectri c fuel pump, fuel pressure regul ator or
pri mary i nl et fi l ter, remove both secti ons and repl ace
l ower secti on.
fuel pump module removal. Access is from rear
cargo area.
(Fi g. 25).
to bend pl ate.
(5) Thoroughl y cl ean area around top of pump
modul e to prevent contami nants from enteri ng fuel
tank or fuel l i nes.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING THE FUEL PUMP MODULE,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
(6) Rel ease fuel system pressure. Refer to Fuel
System Pressure Rel ease procedure.
(7) Di sconnect 2 fuel l i nes at fuel pump modul e
(Fi g. 26) by pressi ng on 2 buttons at si des of fi tti ng.
(8) Di sconnect el ectri cal connector (Fi g. 26) at top
of fuel pump modul e by sl i di ng red col ored tab fi rst
to unl ock, and push grey col ored tab down for
removal .
(9) Di sconnect ORVR hose cl amp and hose (Fi g.
26) at pump modul e fi tti ng.
(10) Remove modul e l ockri ng (Fi g. 26) usi ng a
brass dri ft and hammer (counter-cl ockwi se).
(11) Careful l y l i ft upper secti on of pump modul e
(Fi g. 26) from fuel tank exposi ng connecti ons (lift
upper section from tank very slowly until rub-
ber gasket can be retained. If not, gasket will
fall into fuel tank.)
(a) Di sconnect el ectri cal connector (Fi g. 27) at
bottom of upper pump modul e secti on.
(b) Di sconnect fuel pressure regul ator (Fi g. 27)
at bottom of upper pump modul e secti on. Press on
2 l ocki ng tabs.
(c) Di sconnect fuel return l i ne (Fi g. 27) at bot-
tom of upper pump modul e secti on. Press on 2
l ocki ng tabs.
(d) Remove upper secti on of pump modul e (Fi g.
28) from fuel tank.
(12) Usi ng an approved gas hol di ng tank, drai n
fuel tank through pump modul e openi ng. If check
(control) valve, or, only upper section of pump
module is being serviced, tank draining is not
necessary. If any other fuel pump module com-
ponent is being serviced, the tank must be com-
pletely drained to the bottom.
(13) To remove l ower secti on of pump modul e from
fuel tank:
(a) Usi ng fi nger pressure, push on pl asti c
rel ease tab (Fi g. 29) whi l e sl i di ng l ock tab upward.
(b) The si des of pump modul e are equi pped wi th
tensi on spri ngs (Fi g. 29). These spri ngs hol d mod-
ul e to bottom of fuel tank i nto 2 formed gui des
(Fi g. 30). Rel ease modul e assembl y from these 2
gui des by sl i di ng toward ri ght si de of fuel tank.
(c) Li ft assembl y from fuel tank.
INSTALLATION
CAUTION: Whenever fuel pump module is serviced,
pump module gasket must be replaced.
(1) Posi ti on l ower secti on of fuel pump modul e
assembl y i nto fuel tank.
(2) The bottom of fuel tank has 2 formed gui des.
Lock modul e assembl y i nto these 2 gui des by sl i di ng
toward l eft si de of fuel tank.
(3) Push down on pl asti c tab to l ock modul e to fuel
tank gui des.
(4) Connect fuel suppl y l i ne to bottom of upper
pump modul e secti on.
(5) Connect fuel pressure regul ator to bottom of
upper pump modul e secti on.
(6) Connect el ectri cal connector to bottom of upper
pump modul e secti on.
(7) Posi ti on pump modul e i nto fuel tank. Notch on
modul e must be faci ng rear of tank.
(8) Posi ti on l ock ri ng to modul e. Tap l ockri ng
usi ng a brass dri ft and hammer (cl ockwi se) unti l
rotated up to bui l t-on stops.
(9) Attach (snap on) 2 fuel fi l ter fuel l i nes to top of
fuel pump modul e.
(10) Connect hoses/l i nes to ORVR components.
(11) Fi l l fuel tank wi th fuel .
(12) Start engi ne and check for fuel l eaks.
torque.
ri vets i nto each cargo hol down cl amp.
Fig. 25 ACCESS PLATE
3 - NUTS (4)
1 - LOCK RING
2 - ALIGNMENT NOTCH
FUEL PUMP MODULE (Continued)
Fig. 28 UPPER SECTION - FUEL PUMP MODULE
1 - UPPER SECTION - FUEL PUMP MODULE
Fig. 29 LOWER SECTION - FUEL PUMP MODULE
1 - LOWER SECTION - FUEL PUMP MODULE
2 - RELEASE LOCK AND TAB
3 - TENSION SPRINGS
Fig. 30 FUEL PUMP MODULE GUIDES (IN FUEL
TANK)
1 - FUEL TANK (INSIDE/LOWER)
2 - FUEL PUMP MODULE GUIDES
FUEL PUMP MODULE (Continued)
FUEL RAIL
DESCRIPTION
2. 4L
The fuel i njector rai l i s used to mount the fuel
i njectors to the engi ne (Fi g. 31). On the 2.4L 4-cyl i n-
der engi ne, a fuel damper i s l ocated near the front
of the fuel rai l (Fi g. 31).
3. 7L
The fuel i njector rai l i s mounted to the i ntake
mani fol d (Fi g. 32). I t i s used to mount the fuel i njec-
tors to the engi ne. The rai l i s equi pped wi th a test
port (Fi g. 33) to check/test fuel system pressure.
A fuel rai l mounted, fuel damper i s not used wi th
thi s engi ne.
OPERATION
2. 4L
The fuel i njector rai l suppl i es the necessary fuel to
each i ndi vi dual fuel i njector.
The fuel damper i s used onl y to hel p control fuel
pressure pul sati ons. These pul sati ons are the resul t
Fig. 31 FUEL RAIL-2.4L
1 - FUEL RAIL
2 - MOUNTING BOLTS
3 - TEST PORT
5 - INJ. #1
6 - DAMPER
7 - INJ #2
8 - INJ #3
9 - INJ #4
10- INJECTOR RETAINING CLIP
Fig. 32 FUEL RAIL - 3.7L
3 - FUEL RAIL
4 - INJ. #1
5 - INJ. #3
6 - INJ. #5
7 - INJ. #2
8 - INJ. #4
9 - INJ. #6
10 - CONNECTOR TUBE
Fig. 33 FUEL RAIL TEST PORT - 3.7L
1 - FUEL RAIL
2 - TEST PORT
of the fi ri ng of the fuel i njectors. I t i s not used as a
fuel pressure regul ator. The fuel pressure regul ator i s
not mounted to the fuel rai l on any engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Refer to Fuel Pressure Regul ator for addi ti onal i nfor-
mati on.
The fuel rai l i s not repai rabl e.
A qui ck-connect fi tti ng wi th a safety l atch i s used
to attach the fuel l i ne to the fuel rai l .
3. 7L
Hi gh pressure fuel from the fuel pump i s routed to
the fuel rai l . The fuel rai l then suppl i es the neces-
sary fuel to each i ndi vi dual fuel i njector.
A qui ck-connect fi tti ng wi th a safety l atch i s used
to attach the fuel l i ne to the fuel rai l .
The fuel rai l i s not repai rabl e.
REMOVAL
2. 4L
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
The fuel rai l can be removed wi thout removi ng the
i ntake mani fol d i f the fol l owi ng procedures are fol -
l owed.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure.
(3) Remove negati ve battery cabl e at battery.
(4) Remove ai r duct at throttl e body.
(5) Di sconnect fuel l i ne l atch cl i p and fuel l i ne at
fuel rai l . A speci al tool wi l l be necessary for fuel l i ne
di sconnecti on. Refer to Qui ck-Connect Fi tti ngs.
(6) Remove necessary vacuum l i nes at throttl e
body.
(7) Drai n engi ne cool ant and remove thermostat
and thermostat housi ng.
(8) Remove PCV hose and val ve at val ve cover.
(9) Remove 3 upper i ntake mani fol d mounti ng
bol ts (Fi g. 35), but onl y l oosen 2 l ower bol ts about 2
turns.
(10) Di sconnect 2 mai n engi ne harness connectors
at rear of i ntake mani fol d (Fi g. 34).
(11) Di sconnect 2 i njecti on wi ri ng harness cl i ps at
harness mounti ng bracket (Fi g. 35).
(12) Di sconnect el ectri cal connectors at al l 4 fuel
i njectors. To remove connector refer to (Fi g. 37). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(13) Remove 2 i njecti on rai l mounti ng bol ts (Fi g.
31).
Fig. 34 MAP SENSOR LOCATION-2.4L
1 - REAR OF INTAKE MANIFOLD
2 - MAP SENSOR
3 - ALIGNMENT PIN
4 - MOUNTING BOLT (TORX)
6 - MAIN ENGINE HARNESS CONNECTORS
Fig. 35 FUEL RAIL MOUNTING-2.4L
1 - FUEL RAIL
2 - INJECTION HARNESS CLIPS
3 - LOWER MOUNTING HOLES
4 - UPPER MOUNTING HOLES
5 - INTAKE MANIFOLD
FUEL RAIL (Continued)
(14) Gentl y rock and pul l fuel rai l unti l fuel i njec-
tors just start to cl ear machi ned hol es i n i ntake man-
i fol d.
(15) Remove fuel rai l (wi th i njectors attached)
from i ntake mani fol d.
(16) I f fuel i njectors are to be removed, refer to
Fuel I njector Removal /I nstal l ati on.
3. 7L
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connector tube (Fig. 36). Due to design of
tube, it does not use any clamps. Never attempt to
install a clamping device of any kind to tube. When
removing fuel rail assembly for any reason, be care-
ful not to bend or kink tube.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure.
(3) Remove negati ve battery cabl e at battery.
(4) Remove ai r duct at throttl e body ai r box.
(5) Remove ai r box at throttl e body.
(6) Di sconnect fuel l i ne l atch cl i p and fuel l i ne at
fuel rai l . A speci al tool wi l l be necessary for fuel l i ne
di sconnecti on. Refer to Qui ck-Connect Fi tti ngs.
(7) Remove necessary vacuum l i nes at throttl e
body.
(8) Di sconnect el ectri cal connectors at al l 6 fuel
i njectors. To remove connector refer to (Fi g. 37). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(9) Di sconnect el ectri cal connectors at throttl e
body sensors.
(10) Remove 6 i gni ti on coi l s. Refer to I gni ti on Coi l
(11) Remove 4 fuel rai l mounti ng bol ts (Fi g. 36).
(12) Gentl y rock and pul l left si de of fuel rai l unti l
fuel i njectors just start to cl ear machi ned hol es i n
cyl i nder head. Gentl y rock and pul l right si de of rai l
unti l i njectors just start to cl ear cyl i nder head hol es.
Repeat thi s procedure (l eft/ri ght) unti l al l i njectors
have cl eared cyl i nder head hol es.
(13) Remove fuel rai l (wi th i njectors attached)
from engi ne.
Fig. 36 FUEL RAIL REMOVE/INSTALL - 3.7L
3 - FUEL RAIL
4 - INJ. #1
5 - INJ. #3
6 - INJ. #5
7 - INJ. #2
8 - INJ. #4
9 - INJ. #6
10 - CONNECTOR TUBE
Fig. 37 REMOVE/INSTALL INJECTOR CONNECTOR
(14) I f fuel i njectors are to be removed, refer to
Fuel I njector Removal /I nstal l ati on.
INSTALLATION
2. 4L Engine
(1) I f fuel i njectors are to be i nstal l ed, refer to Fuel
I njector Removal /I nstal l ati on.
(2) Cl ean out fuel i njector machi ned bores i n
i ntake mani fol d.
(3) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
(4) Posi ti on fuel rai l /fuel i njector assembl y to
machi ned i njector openi ngs i n i ntake mani fol d.
(5) Gui de each i njector i nto cyl i nder head. Be care-
ful not to tear i njector o-ri ngs.
(6) Push fuel rai l down unti l fuel i njectors have
bottomed on shoul ders.
(7) I nstal l 2 fuel rai l mounti ng bol ts and ti ghten.
(8) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 37). Push con-
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(9) Snap 2 i njecti on wi ri ng harness cl i ps (Fi g. 35)
i nto brackets.
(10) Connect 2 mai n engi ne harness connectors at
rear of i ntake mani fol d (Fi g. 34).
(11) Ti ghten 5 i ntake mani fol d mounti ng bol ts.
Refer to Engi ne Torque Speci fi cati ons.
(12) I nstal l PCV val ve and hose.
(13) I nstal l thermostat and radi ator hose. Fi l l wi th
cool ant. Refer to Cool i ng.
(14) Connect necessary vacuum l i nes to throttl e
body.
(15) Connect fuel l i ne l atch cl i p and fuel l i ne to
fuel rai l . Refer to Qui ck-Connect Fi tti ngs.
(16) I nstal l ai r duct to throttl e body.
(17) Connect battery cabl e to battery.
3. 7L Engine
(1) I f fuel i njectors are to be i nstal l ed, refer to Fuel
I njector Removal /I nstal l ati on.
(2) Cl ean out fuel i njector machi ned bores i n
i ntake mani fol d.
(3) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
(4) Posi ti on fuel rai l /fuel i njector assembl y to
machi ned i njector openi ngs i n cyl i nder head.
(5) Gui de each i njector i nto cyl i nder head. Be care-
ful not to tear i njector o-ri ngs.
(6) Push right si de of fuel rai l down unti l fuel
i njectors have bottomed on cyl i nder head shoul der.
Push left fuel rai l down unti l i njectors have bot-
tomed on cyl i nder head shoul der.
(7) I nstal l 4 fuel rai l mounti ng bol ts and ti ghten.
(8) I nstal l 6 i gni ti on coi l s. Refer to I gni ti on Coi l
(9) Connect el ectri cal connectors to throttl e body.
(10) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 37). Push con-
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(11) Connect necessary vacuum l i nes to throttl e
body.
(12) Connect fuel l i ne l atch cl i p and fuel l i ne to
fuel rai l . Refer to Qui ck-Connect Fi tti ngs.
(13) I nstal l ai r box to throttl e body.
(14) I nstal l ai r duct to ai r box.
(15) Connect battery cabl e to battery.
FUEL TANK
DESCRIPTION
The fuel tank i s constructed of a pl asti c materi al .
I ts mai n functi ons are for fuel storage and for pl ace-
ment of the fuel pump modul e, and certai n ORVR
components.
OPERATION
Al l model s pass a ful l 360 degree rol l over test
wi thout fuel l eakage. To accompl i sh thi s, fuel and
vapor fl ow control s are requi red for al l fuel tank con-
necti ons.
A check (control ) val ve i s mounted i nto the top sec-
ti on of the 2pi ece fuel pump modul e. Refer to Fuel
Tank Check Val ve for addi ti onal i nformati on.
An evaporati on control system i s connected to the
fuel tank to reduce emi ssi ons of fuel vapors i nto the
atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal cani ster where they are temporari l y hel d.
When the engi ne i s runni ng, the vapors are drawn
i nto the i ntake mani fol d. Certai n model s are al so
equi pped wi th a sel f-di agnosi ng system usi ng a Leak
Detecti on Pump (LDP) and/or an ORVR system.
Refer to Emi ssi on Control System for addi ti onal
i nformati on.
REMOVAL
Fuel Tank Draining
WARNING: THE FUEL SYSTEM MAY BE UNDER
CONSTANT FUEL PRESSURE EVEN WITH THE
ENGINE OFF. THIS PRESSURE MUST BE
RELEASED BEFORE SERVICING FUEL TANK.
Two di fferent procedures may be used to drai n fuel
tank: removi ng fuel pump modul e access pl ate, or
usi ng DRB scan tool . Due to a one-way check val ve
i nstal l ed i nto the fuel fi l l openi ng fi tti ng at the tank
(Fi g. 38), the tank cannot be drai ned conventi onal l y
at the fi l l cap.
The qui ckest drai ni ng procedure i nvol ves removi ng
fuel pump modul e access pl ate.
As an al ternati ve procedure, the el ectri c fuel pump
may be acti vated al l owi ng tank to be drai ned at fuel
rai l connecti on. Refer to DRB scan tool for fuel pump
acti vati on procedures. Before di sconnecti ng fuel l i ne
at fuel rai l , rel ease fuel pressure. Refer to the Fuel
System Pressure Rel ease Procedure for procedures.
Attach end of speci al test hose tool number 6541,
6539, 6631 or 6923 at fuel rai l di sconnecti on (tool
number wi l l depend on model and/or engi ne appl i ca-
ti on). Posi ti on opposi te end of thi s hose tool to an
approved gasol i ne drai ni ng stati on. Acti vate fuel
pump and drai n tank unti l empty.
I f el ectri c fuel pump i s not operati ng, fuel pump
modul e access pl ate must be removed for fuel drai n-
i ng. Refer to fol l owi ng procedures.
fuel tank draining. Access for draining is from
rear cargo area.
(1) Open al l wi ndows i n vehi cl e to al l ow for ai r
venti l ati on.
(Fi g. 39).
to bend pl ate.
(6) Thoroughl y cl ean area around top of pump
modul e to prevent contami nants from enteri ng fuel
tank or fuel l i nes.
(7) Rel ease fuel system pressure.
(8) Di sconnect 2 fuel l i nes (Fi g. 40) at fuel pump
modul e by pressi ng on tabs at si de of fi tti ng.
(9) Di sconnect el ectri cal connector (Fi g. 40). Sl i de
red tab fi rst to unl ock, and push grey tab down for
removal .
(10) Di sconnect ORVR hose (Fi g. 40) at pump mod-
ul e fi tti ng.
Fig. 38 FUEL FILL CHECK VALVE
1 - ONE-WAY CHECK VALVE
2 - FUEL FILL FITTING
3 - SIDE OF FUEL TANK
Fig. 39 ACCESS PLATE
3 - NUTS (4)
FUEL TANK (Continued)
(11) Remove modul e l ockri ng (Fi g. 40) usi ng a
brass dri ft and hammer (counter-cl ockwi se).
(12) Careful l y l i ft upper secti on of pump modul e
from fuel tank a few i nches (lift upper section
from tank very slowly until rubber gasket can
be retained. If not, gasket will fall into fuel
tank).
(13) Usi ng an approved gas hol di ng tank, drai n
fuel tank through fuel pump modul e openi ng.
Tank Removal
(1) After drai ni ng tank, temporari l y pl ace upper
secti on of fuel pump modul e back i nto fuel tank.
(3) I f equi pped, remove fuel tank ski d pl ate and
tow hooks. Certai n equi pment packages wi l l al so
requi re removal of the trai l er hi tch. Refer to Tow
Hooks, Trai l er Hi tch or Ski d Pl ate i n 23, Body for
removal /i nstal l ati on procedures.
(4) Di sconnect fuel fi l ter ground strap.
(5) Di sconnect fuel fi l ter outl et l i ne from body
retenti on cl i p l ocated on frame near front/center of
tank (Fi g. 41). Pl ace a smal l screwdri ver i nto si de of
cl i p and twi st for removal . Al so di sconnect Leak
Detecti on Pump (LDP) l i ne (Fi g. 41) from thi s cl i p.
(6) Remove both 3/4 hoses at si des of Leak Detec-
ti on Pump (LDP) (Fi g. 41).
(7) Di sconnect 3/4 fl ow management val ve hose
(Fi g. 41) at EVAP cani ster.
(8) Remove fuel fi l l hose cl amp (Fi g. 42) at fuel
tank, and di sconnect hose from fuel tank.
(9) A thi rd fuel l i ne i s attached to bottom of fuel
fi l ter. The di sconnecti on poi nt (qui ck-connect fi tti ng)
for thi s 3rd l i ne i s approxi matel y 1 foot from front of
tank towards front of vehi cl e (Fi g. 41). Cl ean connec-
ti on poi nt before di sconnecti on. Di sconnect by press-
i ng on tabs at si de of qui ck-connect fi tti ng. Al so
di sconnect LDP vent l i ne near thi s same poi nt.
(10) Di sconnect 2 vacuum/vent hoses from pl asti c
retenti on cl i p at l eft/front of fuel tank l i ne (Fi g. 41).
(11) Support tank wi th a hydraul i c jack.
(12) Remove 4 fuel tank strap bol ts (Fi g. 41) (2 at
front of tank; 2 at rear of tank), and remove both
tank support straps (Fi g. 41).
(13) Careful l y l ower tank a few i nches and di scon-
nect el ectri cal connector at top of LDP (Fi g. 43). To
di sconnect el ectri cal connector: Push upward on red
col ored tab to unl ock. Push on bl ack col ored tab
whi l e removi ng connector.
1 - LOCK RING
2 - ALIGNMENT NOTCH
Fig. 41 FRONT OF FUEL TANK
1 - TANK MOUNTING BOLTS (4)
2 - TANK MOUNTING STRAPS (2)
3 - LEAK DETECTION PUMP (LDP)
4 - BODY RETENTION CLIP (CENTER)
5 - LDP HOSES
6 - HOSE TO FUEL MANAGEMENT VALVE
7 - BODY RETENTION CLIP (LEFT/FRONT)
8 - QUICK-CONECT FITTING
9 - LDP LINE
(14) Conti nue l oweri ng tank whi l e gui di ng remai n-
i ng hoses and l i nes.
(15) I f fuel tank i s to be repl aced, remove LDP,
fuel fi l ter and fuel pump modul e from tank. Refer to
Leak Detecti on Pump, Fuel Fi l ter and Fuel Pump
Modul e Removal /I nstal l ati on procedures.
INSTALLATION
(1) I f fuel tank i s to be repl aced, i nstal l LDP, fuel
fi l ter and fuel pump modul e to tank. Refer to Leak
Detecti on Pump, Fuel Fi l ter and Fuel Pump Modul e
Removal /I nstal l ati on procedures.
(2) Posi ti on fuel tank to hydraul i c jack.
(3) Rai se tank whi l e careful l y gui di ng vent tubes/
hoses through frame rai l and crossmember. Before
tank reaches body, connect el ectri cal connector to
Leak Detecti on Pump (LDP).
(4) Conti nue rai si ng tank unti l posi ti oned to body.
(5) Attach two fuel tank mounti ng straps and 4
mounti ng bol ts. Ti ghten bol ts to 61 Nm (45 ft. l bs.)
torque.
(6) Connect 2 hoses to body retenti on cl i p at l eft/
front of tank.
(7) Connect fuel fi l ter fuel l i ne to mai n fuel l i ne
(snaps together). After connecti ng, snap thi s l i ne i nto
body retenti on cl i p. Al so connect LDP vacuum hose
near thi s poi nt.
(8) I nstal l fuel fi l l hose and hose cl amp to fuel
tank fi tti ng. Rotate hose unti l whi te pai nted i ndex
mark on hose (Fi g. 42) i s l ocated between al i gnment
notches on fuel tank fi tti ng. Ti ghten cl amp to 3.4
Nm (30 i n. l bs.) torque.
(9) Connect fresh ai r and reci rcul ati on l i nes to fuel
fi l l tube.
(10) Connect 3/4 l i nes to Leak Detecti on Pump
(LDP).
(11) Connect 3/4 fl ow management val ve hose to
EVAP cani ster.
(12) Snap remai ni ng l i nes i nto body retenti on cl i p
at front/center of fuel tank.
(13) I f equi pped, i nstal l fuel tank ski d pl ate,
trai l er hi tch and tow hooks. Refer to Tow Hooks,
Trai l er Hi tch or Ski d Pl ate i n 23, Body for removal /
i nstal l ati on procedures.
(15) Attach (snap on) 2 fuel fi l ter fuel l i nes to top
of fuel pump modul e.
(16) I nstal l el ectri cal connector to top of fuel pump
modul e.
(18) Fi l l fuel tank wi th fuel .
(19) Start engi ne and check for fuel l eaks near top
of modul e.
Fig. 42 FUEL FILL HOSE AT TANK
1 - FUEL FILL HOSE AT TANK
2 - HOSE CLAMP
3 - WHITE PAINTED INDEX MARK
4 - ALIGNMENT NOTCHES
5 - LEFT SIDE OF FUEL TANK
6 - FUEL FILL FITTING
Fig. 43 LDP ELECTRICAL CONNECTOR
3 - FUEL FILTER
torque.
ri vets i nto each cargo hol down cl amp.
FUEL TANK CHECK VALVE
DESCRIPTION
The fuel tank i s equi pped wi th a check val ve. The
val ve (al so referred to as a control val ve) i s l ocated i n
the top secti on of the fuel pump modul e assembl y
(Fi g. 1).
OPERATION
The fuel tank check val ve (al so referred to as
ei ther a control val ve, one-way check val ve or fl oat
val ve) wi l l prevent fuel fl ow through the fuel tank
vent i n the event of an acci dental vehi cl e rol l over. I t
i s al so used as a part of the ORVR system. The
EVAP cani ster and ORVR system draw fuel vapors
from the fuel tank through thi s val ve. Refer to ORVR
i n Emi ssi ons for addi ti onal i nformati on.
The val ve may be servi ced by repl aci ng the upper
secti on of the fuel pump modul e assembl y.
REMOVAL
The fuel tank check (control ) val ve i s attached i nto
the top secti on of the fuel pump modul e (Fi g. 44). I f
repl acement i s necessary, the top secti on of the fuel
pump modul e must be repl aced. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
INSTALLATION
The fuel tank check (control ) val ve i s attached to
the top secti on of the fuel pump modul e. I f repl ace-
ment i s necessary, the top secti on of the fuel pump
modul e must be repl aced. Refer to Fuel Pump Mod-
ul e Removal /I nstal l ati on.
INLET FILTER
REMOVAL
The fuel pump i nl et fi l ter i s l ocated on the bottom/
si de of the l ower fuel pump modul e secti on (Fi g. 45).
The fuel pump modul e assembl y i s l ocated i n the fuel
tank.
(1) Remove l ower secti on of fuel pump modul e.
(2) Remove fi l ter by pryi ng from pump modul e
wi th 2 smal l screwdri vers. Fi l ter i s snapped to mod-
ul e wi th 2 rel ease tabs (Fi g. 45).
(3) Cl ean fi l ter entrance i nto pump modul e open-
i ng.
INSTALLATION
(1) Snap new fi l ter to bottom of fuel pump modul e.
(2) I nstal l l ower secti on of fuel pump modul e.
Fig. 44 UPPER SECTION - FUEL PUMP MODULE
1 - UPPER SECTION - FUEL PUMP MODULE
Fig. 45 INLET FILTER
1 - INLET FILTER
2 - RELEASE TABS (2)
3 - BOTTOM OF FUEL PUMP MODULE
FUEL INJ ECTION
TABLE OF CONTENTS
page page
FUEL INJECTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
ACCELERATOR PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
CRANKSHAFT POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
FUEL INJECTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION
OPERATION - FUEL INJECTOR . . . . . . . . . . 33
OPERATION - PCM OUTPUT . . . . . . . . . . . . 33
DIAGNOSIS AND TESTING - FUEL INJECTOR . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
FUEL PUMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
IDLE AIR CONTROL MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
MAP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OXYGEN SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
THROTTLE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
THROTTLE CONTROL CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
THROTTLE POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
FUEL INJ ECTION
DESCRIPTION
The Powertrai n Control Modul e (PCM) operates
the fuel i njecti on system. Refer to Powertrai n Control
Modul e i n El ectroni c Control Modul es for i nforma-
ti on.
ACCELERATOR PEDAL
REMOVAL
The accel erator pedal i s servi ced as a compl ete
assembl y i ncl udi ng the bracket.
The accel erator pedal i s connected to the upper
part of the accel erator pedal arm by a pl asti c
retai ner (cl i p) (Fi g. 1). Thi s pl asti c retai ner snaps
i nto the top of the accel erator pedal arm.
(1) From i nsi de the vehi cl e, hol d up accel erator
pedal . Remove pl asti c cabl e retai ner (cl i p) and throt-
tl e cabl e core wi re from upper end of accel erator
pedal arm (Fi g. 1). Pl asti c cabl e retai ner (cl i p) snaps
i nto pedal arm.
(2) Remove 2 accel erator pedal mounti ng bracket
nuts. Remove accel erator pedal assembl y.
KJ FUEL INJECTION 14 - 29
INSTALLATION
(1) Pl ace accel erator pedal assembl y over 2 studs
(Fi g. 1) protrudi ng from fl oor pan.
(2) I nstal l 2 mounti ng nuts. Refer to torque speci -
fi cati ons.
(3) Sl i de throttl e cabl e i nto openi ng sl ot i n top of
pedal arm.
(4) Push pl asti c cabl e retai ner (cl i p) i nto accel era-
tor pedal arm openi ng unti l i t snaps i nto pl ace.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
2. 4L
The Crankshaft Posi ti on (CKP) sensor i s mounted
i nto the ri ght front si de of the cyl i nder bl ock (Fi g. 2).
I t i s posi ti oned and bol ted i nto a machi ned hol e.
3. 7L
i nto the ri ght rear si de of the cyl i nder bl ock (Fi g. 3).
Fig. 1 ACCELERATOR PEDAL/BRACKET ASSEMBLY
1 - METAL THROTTLE CABLE CLIP
2 - THROTTLE CABLE
3 - PLASTIC CABLE RETAINER
4 - PEDAL/BRACKET ASSEMBLY
5 - PEDAL MOUNTING NUTS (2)
6 - PEDAL MOUNTING STUDS (2)
Fig. 2 CKP SENSOR LOCATION-2.4L
1 - RIGHT FRONT ENGINE MOUNT
2 - CKP SENSOR
3 - MOUNTING BOLT
Fig. 3 CKP - 3.7L
1 - MOUNTING BOLT
2 - CKP SENSOR
3 - O-RING
14 - 30 FUEL INJECTION KJ
ACCELERATOR PEDAL (Continued)
OPERATION
2. 4L
Engi ne speed and crankshaft posi ti on are provi ded
through the CKP (Crankshaft Posi ti on) sensor. The
sensor generates pul ses that are the i nput sent to the
Powertrai n Control Modul e (PCM). The PCM i nter-
prets the sensor i nput to determi ne the crankshaft
posi ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
A tonewheel (targetwheel ) i s a part of the engi ne
crankshaft (Fi g. 4). Thi s tonewheel has sets of
notches at i ts outer edge.
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM.
3. 7L
Engi ne speed and crankshaft posi ti on are provi ded
through the CKP (Crankshaft Posi ti on) sensor. The
sensor generates pul ses that are the i nput sent to the
Powertrai n Control Modul e (PCM). The PCM i nter-
prets the sensor i nput to determi ne the crankshaft
posi ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
A tonewheel (targetwheel ) i s bol ted to the engi ne
crankshaft (Fi g. 5). Thi s tonewheel has sets of
notches at i ts outer edge (Fi g. 5).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM.
REMOVAL
2. 4L
i nto the ri ght front si de of the cyl i nder bl ock (Fi g. 6).
(1) Di sconnect sensor el ectri cal connector.
(2) Remove sensor bol t.
(3) Careful l y pry sensor from cyl i nder bl ock i n a
rocki ng acti on.
(4) Check condi ti on of sensor o-ri ng (Fi g. 7).
3. 7L
i nto the ri ght rear si de of the cyl i nder bl ock (Fi g. 8).
(2) Di sconnect sensor el ectri cal connector.
(3) Remove sensor mounti ng bol t (Fi g. 8).
(4) Careful l y remove sensor from cyl i nder bl ock i n
a rocki ng and twi sti ng acti on.
Fig. 4 CKP OPERATION-2.4L
1 - NOTCHES
2 - CRANKSHAFT
Fig. 5 CKP OPERATION-3.7L
1 - TONEWHEEL
2 - NOTCHES
3 - CRANKSHAFT POSITION SENSOR
4 - CRANKSHAFT
CRANKSHAFT POSITION SENSOR (Continued)
INSTALLATION
2. 4L
(1) Cl ean out machi ned hol e i n engi ne bl ock.
o-ri ng.
(3) I nstal l sensor i nto engi ne bl ock wi th a sl i ght
rocki ng acti on. Do not twi st sensor i nto posi ti on as
damage to o-ri ng may resul t.
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) I nstal l mounti ng bol t and ti ghten to 28 Nm
3. 7L
(1) Cl ean out machi ned hol e i n engi ne bl ock.
o-ri ng.
(3) I nstal l sensor i nto engi ne bl ock wi th a sl i ght
rocki ng and twi sti ng acti on.
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
mounting tang may result.
(4) I nstal l mounti ng bol t and ti ghten to 28 Nm
Fig. 6 CKP SENSOR LOCATION-2.4L
1 - RIGHT FRONT ENGINE MOUNT
2 - CKP SENSOR
3 - MOUNTING BOLT
Fig. 7 CKP AND O-RING-2.4L
1 - CKP SENSOR
2 - O-RING
Fig. 8 CKP - 3.7L
1 - MOUNTING BOLT
2 - CKP SENSOR
3 - O-RING
CRANKSHAFT POSITION SENSOR (Continued)
FUEL INJ ECTOR
DESCRIPTION
An i ndi vi dual fuel i njector (Fi g. 9) i s used for each
i ndi vi dual cyl i nder.
OPERATION
OPERATION - FUEL INJECTOR
The top (fuel entry) end of the i njector (Fi g. 9) i s
attached i nto an openi ng on the fuel rai l .
The fuel i njectors are el ectri cal sol enoi ds. The
i njector contai ns a pi ntl e that cl oses off an ori fi ce at
the nozzl e end. When el ectri c current i s suppl i ed to
the i njector, the armature and needl e move a short
di stance agai nst a spri ng, al l owi ng fuel to fl ow out
the ori fi ce. Because the fuel i s under hi gh pressure, a
fi ne spray i s devel oped i n the shape of a penci l
stream. The sprayi ng acti on atomi zes the fuel , add-
i ng i t to the ai r enteri ng the combusti on chamber.
The nozzl e (outl et) ends of the i njectors are posi -
ti oned i nto openi ngs i n the i ntake mani fol d just
above the i ntake val ve ports of the cyl i nder head.
The engi ne wi ri ng harness connector for each fuel
i njector i s equi pped wi th an attached numeri cal tag
(I NJ 1, I NJ 2 etc.). Thi s i s used to i denti fy each fuel
i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the Powertrai n Control Modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage i s suppl i ed to the i njectors through
the ASD rel ay.
The PCM determi nes i njector pul se wi dth based on
vari ous i nputs.
OPERATION - PCM OUTPUT
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the Powertrai n Control Modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage (12 vol ts +) i s suppl i ed to the i njec-
tors through the ASD rel ay. The ASD rel ay wi l l shut-
down the 12 vol t power source to the fuel i njectors i f
the PCM senses the i gni ti on i s on, but the engi ne i s
not runni ng. Thi s occurs after the engi ne has not
been runni ng for approxi matel y 1.8 seconds.
The PCM determi nes i njector on-ti me (pul se wi dth)
based on vari ous i nputs.
DIAGNOSIS AND TESTING - FUEL INJECTOR
To perform a compl ete test of the fuel i njectors and
thei r ci rcui try, use the DRB scan tool and refer to the
appropri ate Powertrai n Di agnosti cs Procedures man-
ual . To test the i njector onl y, refer to the fol l owi ng:
Di sconnect the fuel i njector wi re harness connector
from the i njector. The i njector i s equi pped wi th 2
el ectri cal termi nal s (pi ns). Pl ace an ohmmeter across
the termi nal s. Resi stance readi ng shoul d be approxi -
matel y 12 ohms 1.2 ohms at 20C (68F).
Fig. 9 FUEL INJECTOR TYPICAL
REMOVAL
(1) Remove fuel rai l . Refer to Fuel I njector Rai l
Removal .
(2) Di sconnect cl i p(s) that retai n fuel i njector(s) to
fuel rai l (Fi g. 10).
INSTALLATION
(1) I nstal l fuel i njector(s) i nto fuel rai l assembl y
and i nstal l retai ni ng cl i p(s).
(2) I f same i njector(s) i s bei ng rei nstal l ed, i nstal l
new o-ri ng(s).
(3) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(4) I nstal l fuel rai l . Refer to Fuel Rai l I nstal l ati on.
(5) Start engi ne and check for fuel l eaks.
FUEL PUMP RELAY
DESCRIPTION
The 5pi n, 12vol t, fuel pump rel ay i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
l abel on the PDC cover for rel ay l ocati on.
OPERATION
The Powertrai n Control Modul e (PCM) energi zes
the el ectri c fuel pump through the fuel pump rel ay.
The fuel pump rel ay i s energi zed by fi rst appl yi ng
battery vol tage to i t when the i gni ti on key i s turned
ON, and then appl yi ng a ground si gnal to the rel ay
from the PCM.
Whenever the i gni ti on key i s turned ON, the el ec-
tri c fuel pump wi l l operate. But, the PCM wi l l shut-
down the ground ci rcui t to the fuel pump rel ay i n
approxi matel y 13 seconds unl ess the engi ne i s oper-
ati ng or the starter motor i s engaged.
RELAY
For procedures, refer to ASD Rel ay Di agnosi s and
Testi ng i n the I gni ti on secti on.
REMOVAL
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 11). Refer to l abel on PDC
cover for rel ay l ocati on.
INSTALLATION
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC). Refer to l abel on PDC cover for
rel ay l ocati on.
Fig. 10 INJECTOR RETAINING CLIP
1 - PLIERS
2 - INJECTOR CLIP
3 - FUEL INJECTOR
4 - FUEL RAIL - TYPICAL
1 - BATTERY
2 - PDC
3 - PDC COVER
FUEL INJ ECTOR (Continued)
IDLE AIR CONTROL MOTOR
DESCRIPTION
The I AC stepper motor i s mounted to the throttl e
body, and regul ates the amount of ai r bypassi ng the
control of the throttl e pl ate. As engi ne l oads and
ambi ent temperatures change, engi ne rpm changes.
A pi ntl e on the I AC stepper motor protrudes i nto a
passage i n the throttl e body, control l i ng ai r fl ow
through the passage. The I AC i s control l ed by the
Powertrai n Control Modul e (PCM) to mai ntai n the
target engi ne i dl e speed.
OPERATION
At i dl e, engi ne speed can be i ncreased by retract-
i ng the I AC motor pi ntl e and al l owi ng more ai r to
pass through the port, or i t can be decreased by
restri cti ng the passage wi th the pi ntl e and di mi ni sh-
i ng the amount of ai r bypassi ng the throttl e pl ate.
The I AC i s cal l ed a stepper motor because i t i s
moved (rotated) i n steps, or i ncrements. Openi ng the
I AC opens an ai r passage around the throttl e bl ade
whi ch i ncreases RPM.
The PCM uses the I AC motor to control i dl e speed
(al ong wi th ti mi ng) and to reach a desi red MAP dur-
i ng decel (keep engi ne from stal l i ng).
The I AC motor has 4 wi res wi th 4 ci rcui ts. Two of
the wi res are for 12 vol ts and ground to suppl y el ec-
tri cal current to the motor wi ndi ngs to operate the
stepper motor i n one di recti on. The other 2 wi res are
al so for 12 vol ts and ground to suppl y el ectri cal cur-
rent to operate the stepper motor i n the opposi te
di recti on.
To make the I AC go i n the opposi te di recti on, the
PCM just reverses pol ari ty on both wi ndi ngs. I f onl y
1 wi re i s open, the I AC can onl y be moved 1 step
(i ncrement) i n ei ther di recti on. To keep the I AC
motor i n posi ti on when no movement i s needed, the
PCM wi l l energi ze both wi ndi ngs at the same ti me.
Thi s l ocks the I AC motor i n pl ace.
I n the I AC motor system, the PCM wi l l count
every step that the motor i s moved. Thi s al l ows the
PCM to determi ne the motor pi ntl e posi ti on. I f the
memory i s cl eared, the PCM no l onger knows the
posi ti on of the pi ntl e. So at the fi rst key ON, the
PCM dri ves the I AC motor cl osed, regardl ess of
where i t was before. Thi s zeros the counter. From
thi s poi nt the PCM wi l l back out the I AC motor and
keep track of i ts posi ti on agai n.
When engi ne rpm i s above i dl e speed, the I AC i s
used for the fol l owi ng:
Off-i dl e dashpot (throttl e bl ade wi l l cl ose qui ckl y
but i dl e speed wi l l not stop qui ckl y)
Decel erati on ai r fl ow control
A/C compressor l oad control (al so opens the pas-
sage sl i ghtl y before the compressor i s engaged so
that the engi ne rpm does not di p down when the
compressor engages)
Power steeri ng l oad control
The PCM can control pol ari ty of the ci rcui t to con-
trol di recti on of the stepper motor.
IAC Stepper Motor Program: The PCM i s al so
equi pped wi th a memory program that records the
number of steps the I AC stepper motor most recentl y
advanced to duri ng a certai n set of parameters. For
exampl e: The PCM was attempti ng to mai ntai n a
1000 rpm target duri ng a col d start-up cycl e. The l ast
recorded number of steps for that may have been
125. That val ue woul d be recorded i n the memory
cel l so that the next ti me the PCM recogni zes the
i denti cal condi ti ons, the PCM recal l s that 125 steps
were requi red to mai ntai n the target. Thi s program
al l ows for greater customer sati sfacti on due to
greater control of engi ne i dl e.
Another functi on of the memory program, whi ch
occurs when the power steeri ng swi tch (i f equi pped),
or the A/C request ci rcui t, requi res that the I AC step-
per motor control engi ne rpm, i s the recordi ng of the
l ast targeted steps i nto the memory cel l . The PCM
can anti ci pate A/C compressor l oads. Thi s i s accom-
pl i shed by del ayi ng compressor operati on for approx-
i matel y 0.5 seconds unti l the PCM moves the I AC
stepper motor to the recorded steps that were l oaded
i nto the memory cel l . Usi ng thi s program hel ps el i m-
i nate i dl e-qual i ty changes as l oads change. Fi nal l y,
the PCM i ncorporates a No-Load engi ne speed l i m-
i ter of approxi matel y 1800 - 2000 rpm, when i t rec-
ogni zes that the TPS i s i ndi cati ng an i dl e si gnal and
I AC motor cannot mai ntai n engi ne i dl e.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the I AC motor through the PCM.
REMOVAL
2. 4L
The I dl e Ai r Control (I AC) motor i s l ocated on the
rear si de of the throttl e body (Fi g. 12).
(1) Di sconnect el ectri cal connector from I AC motor.
(2) Remove two mounti ng bol ts (screws).
(3) Remove I AC motor from throttl e body.
3. 7L
si de of the throttl e body (Fi g. 13).
(1) Di sconnect el ectri cal connector from I AC motor.
(2) Remove two mounti ng bol ts (screws).
(3) Remove I AC motor from throttl e body.
INSTALLATION
2. 4L
rear si de of the throttl e body.
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 Nm (60 i n. l bs.) torque.
(3) I nstal l el ectri cal connector.
3. 7L
si de of the throttl e body (Fi g. 13).
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 Nm (60 i n. l bs.) torque.
INTAKE AIR TEMPERATURE
SENSOR
DESCRIPTION
The 2wi re I ntake Mani fol d Ai r Temperature (I AT)
sensor i s i nstal l ed i n the i ntake mani fol d wi th the
sensor el ement extendi ng i nto the ai r stream.
The I AT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as i ntake mani -
fol d temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
The I AT sensor provi des an i nput vol tage to the
Powertrai n Control Modul e (PCM) i ndi cati ng the
densi ty of the ai r enteri ng the i ntake mani fol d based
upon i ntake mani fol d temperature. At key-on, a
5vol t power ci rcui t i s suppl i ed to the sensor from
the PCM. The sensor i s grounded at the PCM
through a l ow-noi se, sensor-return ci rcui t.
The PCM uses thi s i nput to cal cul ate the fol l owi ng:
Adjustment of spark ti mi ng (to hel p prevent
spark knock wi th hi gh i ntake mani fol d ai r-charge
temperatures)
Fig. 12 TPS/IAC MOTOR - 2.4L
1 - THROTTLE POSITION SENSOR (TPS)
2 - MOUNTING SCREWS
3 - IDLE AIR CONTROL MOTOR (IAC)
4 - MOUNTING SCREWS
2 - MOUNTING SCREWS
4 - MOUNTING SCREWS
IDLE AIR CONTROL MOTOR (Continued)
The resi stance val ues of the I AT sensor i s the same
as for the Engi ne Cool ant Temperature (ECT) sensor.
REMOVAL
2. 4L
The i ntake mani fol d ai r temperature (I AT) sensor
i s i nstal l ed i nto the i ntake mani fol d pl enum at the
rear end of the i ntake mani fol d (Fi g. 14).
(1) Di sconnect el ectri cal connector from I AT sen-
sor.
(2) Cl ean di rt from i ntake mani fol d at sensor base.
(3) Gentl y l i ft on smal l pl asti c rel ease tab (Fi g. 14)
or (Fi g. 15) and rotate sensor about 1/4 turn counter-
cl ockwi se for removal .
3. 7L
i s i nstal l ed i nto the l eft si de of i ntake mani fol d pl e-
num (Fi g. 16).
(1) Di sconnect el ectri cal connector from I AT sen-
sor.
(2) Cl ean di rt from i ntake mani fol d at sensor base.
(3) Gentl y l i ft on smal l pl asti c rel ease tab (Fi g. 16)
or (Fi g. 15) and rotate sensor about 1/4 turn counter-
cl ockwi se for removal .
Fig. 14 IAT SENSOR LOCATION-2.4L
1 - RELEASE TAB
2 - IAT SENSOR
3 - PRESS HERE FOR REMOVAL
5 - REAR END OF INTAKE MANIFOLD
Fig. 15 IAT SENSOR TAB / O-RING
1 - IAT SENSOR
2 - SENSOR O-RING
3 - RELEASE TAB
Fig. 16 IAT SENSOR LOCATION- 3.7L
1 - IAT SENSOR
2 - RELEASE TAB
INTAKE AIR TEMPERATURE SENSOR (Continued)
INSTALLATION
2. 4L
i s i nstal l ed i nto the i ntake mani fol d pl enum at the
rear end of the i ntake mani fol d.
(2) Cl ean sensor mounti ng hol e i n i ntake mani fol d.
(3) Posi ti on sensor i nto i ntake mani fol d and rotate
cl ockwi se unti l past rel ease tab.
3. 7L
i s i nstal l ed i nto the l eft si de of i ntake mani fol d pl e-
num (Fi g. 16).
(2) Cl ean sensor mounti ng hol e i n i ntake mani fol d.
(3) Posi ti on sensor i nto i ntake mani fol d and rotate
cl ockwi se unti l past rel ease tab (Fi g. 16).
MAP SENSOR
DESCRIPTION
2. 4L
The Mani fol d Absol ute Pressure (MAP) sensor i s
mounted i nto the rear of the i ntake mani fol d wi th 1
screw.
3. 7L
mounted i nto the front of the i ntake mani fol d wi th 2
screws.
OPERATION
The MAP sensor i s used as an i nput to the Power-
trai n Control Modul e (PCM). I t contai ns a si l i con
based sensi ng uni t to provi de data on the mani fol d
vacuum that draws the ai r/fuel mi xture i nto the com-
busti on chamber. The PCM requi res thi s i nformati on
to determi ne i njector pul se wi dth and spark advance.
When mani fol d absol ute pressure (MAP) equal s
Barometri c pressure, the pul se wi dth wi l l be at max-
i mum.
A 5 vol t reference i s suppl i ed from the PCM and
returns a vol tage si gnal to the PCM that refl ects
mani fol d pressure. The zero pressure readi ng i s 0.5V
and ful l scal e i s 4.5V. For a pressure swi ng of 015
psi , the vol tage changes 4.0V. To operate the sensor,
i t i s suppl i ed a regul ated 4.8 to 5.1 vol ts. Ground i s
provi ded through the l ow-noi se, sensor return ci rcui t
at the PCM.
The MAP sensor i nput i s the number one contri b-
utor to fuel i njector pul se wi dth. The most i mportant
functi on of the MAP sensor i s to determi ne baromet-
ri c pressure. The PCM needs to know i f the vehi cl e i s
at sea l evel or at a hi gher al ti tude, because the ai r
densi ty changes wi th al ti tude. I t wi l l al so hel p to cor-
rect for varyi ng barometri c pressure. Barometri c
pressure and al ti tude have a di rect i nverse correl a-
ti on; as al ti tude goes up, barometri c goes down. At
key-on, the PCM powers up and l ooks at MAP vol t-
age, and based upon the vol tage i t sees, i t knows the
current barometri c pressure (rel ati ve to al ti tude).
Once the engi ne starts, the PCM l ooks at the vol tage
agai n, conti nuousl y every 12 mi l l i seconds, and com-
pares the current vol tage to what i t was at key-on.
The di fference between current vol tage and what i t
was at key-on, i s mani fol d vacuum.
Duri ng key-on (engi ne not runni ng) the sensor
reads (updates) barometri c pressure. A normal range
can be obtai ned by moni tori ng a known good sensor.
As the al ti tude i ncreases, the ai r becomes thi nner
(l ess oxygen). I f a vehi cl e i s started and dri ven to a
very di fferent al ti tude than where i t was at key-on,
the barometri c pressure needs to be updated. Any
ti me the PCM sees Wi de Open Throttl e (WOT), based
upon Throttl e Posi ti on Sensor (TPS) angl e and RPM,
i t wi l l update barometri c pressure i n the MAP mem-
ory cel l . Wi th peri odi c updates, the PCM can make
i ts cal cul ati ons more effecti vel y.
The PCM uses the MAP sensor i nput to ai d i n cal -
cul ati ng the fol l owi ng:
Mani fol d pressure
Barometri c pressure
Engi ne l oad
Spark-advance programs
Shi ft-poi nt strategi es (certai n automati c trans-
mi ssi ons onl y)
I dl e speed
Decel fuel shutoff
The MAP sensor si gnal i s provi ded from a si ngl e
pi ezoresi sti ve el ement l ocated i n the center of a di a-
phragm. The el ement and di aphragm are both made
of si l i cone. As mani fol d pressure changes, the di a-
phragm moves causi ng the el ement to defl ect, whi ch
stresses the si l i cone. When si l i cone i s exposed to
stress, i ts resi stance changes. As mani fol d vacuum
i ncreases, the MAP sensor i nput vol tage decreases
proporti onal l y. The sensor al so contai ns el ectroni cs
that condi ti on the si gnal and provi de temperature
compensati on.
The PCM recogni zes a decrease i n mani fol d pres-
sure by moni tori ng a decrease i n vol tage from the
readi ng stored i n the barometri c pressure memory
cel l . The MAP sensor i s a l i near sensor; meani ng as
pressure changes, vol tage changes proporti onatel y.
INTAKE AIR TEMPERATURE SENSOR (Continued)
The range of vol tage output from the sensor i s usual l y
between 4.6 vol ts at sea l evel to as l ow as 0.3 vol ts at
26 i n. of Hg. Barometri c pressure i s the pressure
exerted by the atmosphere upon an object. At sea l evel
on a standard day, no storm, barometri c pressure i s
approxi matel y 29.92 i n Hg. For every 100 feet of al ti -
tude, barometri c pressure drops 0.10 i n. Hg. I f a storm
goes through, i t can change barometri c pressure from
what shoul d be present for that al ti tude. You shoul d
know what the average pressure and correspondi ng
barometri c pressure i s for your area.
REMOVAL
2. 4L
mounted i nto the rear of the i ntake mani fol d (Fi g.
17). An o-ri ng i s used to seal the sensor to the i ntake
mani fol d (Fi g. 19).
(1) Di sconnect el ectri cal connector at sensor.
(2) Cl ean area around MAP sensor.
(3) Remove sensor mounti ng screw (TORX head).
(4) Remove MAP sensor from i ntake mani fol d.
3. 7L
mounted i nto the front of the i ntake mani fol d (Fi g.
(1) Di sconnect el ectri cal connector at sensor.
(2) Cl ean area around MAP sensor.
(3) Remove 2 sensor mounti ng screws.
(4) Remove MAP sensor from i ntake mani fol d.
Fig. 17 MAP SENSOR LOCATION-2.4L
1 - REAR OF INTAKE MANIFOLD
2 - MAP SENSOR
3 - ALIGNMENT PIN
4 - MOUNTING BOLT (TORX)
6 - MAIN ENGINE HARNESS CONNECTORS
Fig. 18 MAP SENSOR / ECT SENSOR - 3.7L
1 - MOUNTING SCREWS
2 - MAP SENSOR
3 - ECT SENSOR
Fig. 19 MAP SENSOR O-RING
1 - MAP SENSOR
2 - O-RING
MAP SENSOR (Continued)
INSTALLATION
2. 4L
mounted i nto the rear of the i ntake mani fol d. An
o-ri ng i s used to seal the sensor to the i ntake mani -
fol d (Fi g. 19).
(1) Cl ean MAP sensor mounti ng hol e at i ntake
mani fol d.
(2) Check MAP sensor o-ri ng seal for cuts or tears.
(3) Posi ti on sensor i nto mani fol d.
(4) I nstal l MAP sensor mounti ng screws. Ti ghten
screw to 3 Nm (25 i n. l bs.) torque.
3. 7L
mounted i nto the front of the i ntake mani fol d (Fi g.
(1) Cl ean MAP sensor mounti ng hol e at i ntake
mani fol d.
(2) Check MAP sensor o-ri ng seal for cuts or tears.
(3) Posi ti on sensor i nto mani fol d.
(4) I nstal l MAP sensor mounti ng bol ts (screws).
Ti ghten screws to 3 Nm (25 i n. l bs.) torque.
OXYGEN SENSOR
DESCRIPTION
The Oxygen Sensors (O2S) are attached to, and
protrude i nto the vehi cl e exhaust system. Dependi ng
on the engi ne or emi ssi on package, the vehi cl e may
use a total of ei ther 2 or 4 sensors.
2.4L Engine: Two sensors are used: upstream
(referred to as 1/1) and downstream (referred to as
1/2). Wi th thi s emi ssi on package, the upstream sen-
sor (1/1) i s l ocated just before the mai n catal yti c con-
vertor. The downstream sensor (1/2) i s l ocated just
after the mai n catal yti c convertor.
3.7L V-6 Engine: On thi s emi ssi ons package, 4
sensors are used: 2 upstream (referred to as 1/1 and
2/1) and 2 downstream (referred to as 1/2 and 2/2).
Wi th thi s emi ssi on package, the ri ght upstream sen-
sor (2/1) i s l ocated i n the ri ght exhaust downpi pe just
before the mi ni -catal yti c convertor. The l eft upstream
sensor (1/1) i s l ocated i n the l eft exhaust downpi pe
just before the mi ni -catal yti c convertor. The ri ght
downstream sensor (2/2) i s l ocated i n the ri ght
exhaust downpi pe just after the mi ni -catal yti c con-
vertor, and before the mai n catal yti c convertor. The
l eft downstream sensor (1/2) i s l ocated i n the l eft
exhaust downpi pe just after the mi ni -catal yti c con-
vertor, and before the mai n catal yti c convertor.
OPERATION
An O2 sensor i s a gal vani c battery that provi des
the PCM wi th a vol tage si gnal (0-1 vol t) i nversel y
proporti onal to the amount of oxygen i n the exhaust.
I n other words, i f the oxygen content i s l ow, the vol t-
age output i s hi gh; i f the oxygen content i s hi gh the
output vol tage i s l ow. The PCM uses thi s i nformati on
to adjust i njector pul se-wi dth to achi eve the
14.7to1 ai r/fuel rati o necessary for proper engi ne
operati on and to control emi ssi ons.
The O2 sensor must have a source of oxygen from
outsi de of the exhaust stream for compari son. Cur-
rent O2 sensors recei ve thei r fresh oxygen (outsi de
ai r) suppl y through the O2 sensor case housi ng.
Four wi res (ci rcui ts) are used on each O2 sensor: a
12vol t feed ci rcui t for the sensor heati ng el ement; a
ground ci rcui t for the heater el ement; a l ow-noi se
sensor return ci rcui t to the PCM, and an i nput ci r-
cui t from the sensor back to the PCM to detect sen-
sor operati on.
Oxygen Sensor Heater Relay - 3.7L Engine: On
the 3.7L engi ne, 4 heated oxygen sensors are used. A
separate oxygen sensor rel ay i s used to suppl y vol t-
age to the sensors heati ng el ements for onl y the 1/2
and 2/2 downstream sensors. Vol tage for the other 2
sensor heati ng el ements i s suppl i ed di rectl y from the
Powertrai n Control Modul e (PCM) through a Pul se
Wi dth Modul e (PWM) method.
Pulse Width Module (PWM): Vol tage to the O2
sensor heati ng el ements i s suppl i ed di rectl y from the
Powertrai n Control Modul e (PCM) through two sepa-
rate Pul se Wi dth Modul e (PWM) l ow si de dri vers.
PWM i s used on both the upstream and downstream
O2 sensors on the 2.4L engi ne, and onl y on the 2
upstream sensors (1/1 and 2/1) on the 3.7L engi ne.
The mai n objecti ve for a PWM dri ver i s to avoi d over-
heati ng of the O2 sensor heater el ement. Wi th
exhaust temperatures i ncreasi ng wi th ti me and
engi ne speed, i ts not requi red to have a ful l -vol tage
duty-cycl e on the O2 heater el ements.
To avoi d the l arge si mul taneous current surge
needed to operate al l 4 sensors, power i s del ayed to
the 2 downstream heater el ements by the PCM for
approxi matel y 2 seconds.
Oxygen Sensor Heater Elements:
The O2 sensor uses a Posi ti ve Thermal Co-effi ci ent
(PTC) heater el ement. As temperature i ncreases,
resi stance i ncreases. At ambi ent temperatures
around 70F, the resi stance of the heati ng el ement i s
approxi matel y 4.5 ohms. As the sensors temperature
i ncreases, resi stance i n the heater el ement i ncreases.
Thi s al l ows the heater to mai ntai n the opti mum
operati ng temperature of approxi matel y 930-1100F
(500-600 C). Al though the sensors operate the
same, there are physi cal di fferences, due to the envi -
MAP SENSOR (Continued)
ronment that they operate i n, that keep them from
bei ng i nterchangeabl e.
Mai ntai ni ng correct sensor temperature at al l
ti mes al l ows the system to enter i nto cl osed l oop
operati on sooner. Al so, i t al l ows the system to remai n
i n cl osed l oop operati on duri ng peri ods of extended
i dl e.
I n Cl osed Loop operati on, the PCM moni tors cer-
tai n O2 sensor i nput(s) al ong wi th other i nputs, and
adjusts the i njector pul se wi dth accordi ngl y. Duri ng
Open Loop operati on, the PCM i gnores the O2 sensor
i nput. The PCM adjusts i njector pul se wi dth based
on preprogrammed (fi xed) val ues and i nputs from
other sensors.
Upstream Sensor - 2.4L Engine: The upstream
sensor (1/1) provi des an i nput vol tage to the PCM.
The i nput tel l s the PCM the oxygen content of the
exhaust gas. The PCM uses thi s i nformati on to fi ne
tune fuel del i very to mai ntai n the correct oxygen con-
tent at the downstream oxygen sensor. The PCM wi l l
change the ai r/fuel rati o unti l the upstream sensor
i nputs a vol tage that the PCM has determi ned wi l l
make the downstream sensor output (oxygen content)
correct.
The upstream oxygen sensor al so provi des an i nput
to determi ne catal yti c convertor effi ci ency.
Downstream Sensor - 2.4L Engine: The down-
stream oxygen sensor (1/2) i s al so used to determi ne
the correct ai r-fuel rati o. As the oxygen content
changes at the downstream sensor, the PCM cal cu-
l ates how much ai r-fuel rati o change i s requi red. The
PCM then l ooks at the upstream oxygen sensor vol t-
age and changes fuel del i very unti l the upstream
sensor vol tage changes enough to correct the down-
stream sensor vol tage (oxygen content).
The downstream oxygen sensor al so provi des an
i nput to determi ne catal yti c convertor effi ci ency.
Upstream Sensors - 3.7L Engine: Two upstream
sensors are used (1/1 and 2/1). The 1/1 sensor i s the
fi rst sensor to recei ve exhaust gases from the #1 cyl -
i nder. They provi de an i nput vol tage to the PCM. The
i nput tel l s the PCM the oxygen content of the
exhaust gas. The PCM uses thi s i nformati on to fi ne
tune fuel del i very to mai ntai n the correct oxygen con-
tent at the downstream oxygen sensors. The PCM
wi l l change the ai r/fuel rati o unti l the upstream sen-
sors i nput a vol tage that the PCM has determi ned
wi l l make the downstream sensors output (oxygen
content) correct.
The upstream oxygen sensors al so provi de an i nput
to determi ne mi ni -catal yst effi ci ency. Mai n catal yti c
convertor effi ci ency i s not cal cul ated wi th thi s pack-
age.
Downstream Sensors - 3.7L Engine: Two down-
stream sensors are used (1/2 and 2/2). The down-
stream sensors are used to determi ne the correct ai r-
fuel rati o. As the oxygen content changes at the
downstream sensor, the PCM cal cul ates how much
ai r-fuel rati o change i s requi red. The PCM then l ooks
at the upstream oxygen sensor vol tage, and changes
fuel del i very unti l the upstream sensor vol tage
changes enough to correct the downstream sensor
vol tage (oxygen content).
The downstream oxygen sensors al so provi de an
i nput to determi ne mi ni -catal yst effi ci ency. Mai n cat-
al yti c convertor effi ci ency i s not cal cul ated wi th thi s
package.
Engi nes equi pped wi th ei ther a downstream sen-
sor(s), or a post-catal yti c sensor, wi l l moni tor cata-
l yti c convertor effi ci ency. I f effi ci ency i s bel ow
emi ssi on standards, the Mal functi on I ndi cator Lamp
(MI L) wi l l be i l l umi nated and a Di agnosti c Troubl e
Code (DTC) wi l l be set. Refer to Moni tored Systems
i n Emi ssi on Control Systems for addi ti onal i nforma-
ti on.
REMOVAL
CAUTION: Never apply any type of grease to the
oxygen sensor electrical connector, or attempt any
soldering of the sensor wiring harness.
Refer to (Fi g. 20), (Fi g. 21) or (Fi g. 22) for O2S
(oxygen sensor) l ocati on.
Fig. 20 OXYGEN SENSORS - 2.4L
1 - ELECTRICAL CONNECTORS
2 - UPSTREAM SENSOR (1/1)
4 - DOWNSTREAM SENSOR (1/2)
OXYGEN SENSOR (Continued)
Fig. 21 OXYGEN SENSORS - UPSTREAM - 3.7L
1 - RIGHT UPSTREAM SENSOR (2/1)
3 - LEFT UPSTREAM SENSOR (1/1)
Fig. 22 OXYGEN SENSORS - DOWNSTREAM - 3.7L
3 - LEFT DOWNSTREAM SENSOR (1/2)
4 - RIGHT DOWNSTREAM SENSOR (2/2)
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(2) Di sconnect wi re connector from O2S sensor.
CAUTION: When disconnecting sensor electrical
connector, do not pull directly on wire going into
sensor.
(3) Remove O2S sensor wi th an oxygen sensor
removal and i nstal l ati on tool .
(4) Cl ean threads i n exhaust pi pe usi ng appropri -
ate tap.
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
threads of a new oxygen sensor.
(1) I nstal l O2S sensor. Ti ghten to 30 Nm (22 ft.
l bs.) torque.
(2) Connect O2S sensor wi re connector.
THROTTLE BODY
DESCRIPTION
The throttl e body i s l ocated on the i ntake mani fol d.
Fuel does not enter the i ntake mani fol d through the
throttl e body. Fuel i s sprayed i nto the mani fol d by
the fuel i njectors.
OPERATION
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body. The throttl e body
contai ns an ai r control passage control l ed by an I dl e
Ai r Control (I AC) motor. The ai r control passage i s
used to suppl y ai r for i dl e condi ti ons. A throttl e val ve
(pl ate) i s used to suppl y ai r for above i dl e condi ti ons.
Certai n sensors are attached to the throttl e body.
The accel erator pedal cabl e, speed control cabl e and
transmi ssi on control cabl e (when equi pped) are con-
nected to the throttl e body l i nkage arm.
control l ed by the PCM.
REMOVAL
2. 4L
control l ed by the Powertrai n Control Modul e (PCM).
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at I AC motor and TPS.
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on for removal /i nstal l ati on procedures.
(4) Di sconnect necessary vacuum l i nes at throttl e
body.
(5) Remove 3 throttl e body mounti ng bol ts (Fi g.
23).
(6) Remove throttl e body from i ntake mani fol d.
(7) Check condi ti on of ol d throttl e body-to-i ntake
mani fol d o-ri ng.
3. 7L
control l ed by the Powertrai n Control Modul e (PCM).
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at I AC motor and TPS.
Fig. 23 THROTTLE BODY MOUNTING BOLTS - 2.4L
1 - THROTTLE BODY
2 - IGNITION COIL
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on for removal /i nstal l ati on procedures.
(4) Di sconnect necessary vacuum l i nes at throttl e
body.
(5) Remove 3 throttl e body mounti ng bol ts (Fi g.
24).
(6) Remove throttl e body from i ntake mani fol d.
(7) Check condi ti on of ol d throttl e body-to-i ntake
mani fol d o-ri ng (Fi g. 25).
INSTALLATION
2. 4L
(1) Check condi ti on of throttl e body-to-i ntake man-
i fol d o-ri ng. Repl ace as necessary.
(2) Cl ean mati ng surfaces of throttl e body and
i ntake mani fol d.
(3) I nstal l throttl e body-to-i ntake mani fol d o-ri ng.
(4) I nstal l throttl e body to i ntake mani fol d.
(5) I nstal l 3 mounti ng bol ts. Ti ghten bol ts to 12
(6) I nstal l control cabl es.
(7) I nstal l el ectri cal connectors.
(8) I nstal l necessary vacuum l i nes.
(9) I nstal l ai r cl eaner duct at throttl e body.
3. 7L
(1) Check condi ti on of throttl e body-to-i ntake man-
i fol d o-ri ng. Repl ace as necessary.
(2) Cl ean mati ng surfaces of throttl e body and
i ntake mani fol d.
(3) I nstal l throttl e body-to-i ntake mani fol d o-ri ng.
(4) I nstal l throttl e body to i ntake mani fol d.
(5) I nstal l 3 mounti ng bol ts. Ti ghten bol ts to 12
(6) I nstal l control cabl es.
(7) I nstal l el ectri cal connectors.
(8) I nstal l necessary vacuum l i nes.
(9) I nstal l ai r cl eaner duct at throttl e body.
Fig. 24 THROTTLE BODY MOUNTING BOLTS - 3.7L
1 - THROTTLE BODY
Fig. 25 THROTTLE BODY O-RING - 3.7L
1 - INTAKE MANIFOLD
2 - THROTTLE BODY O-RING
THROTTLE BODY (Continued)
THROTTLE CONTROL CABLE
REMOVAL
2. 4L
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or throttle cable.
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of pedal arm (Fi g. 26).
Pl asti c cabl e retai ner snaps i nto top of pedal arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, remove metal cl i p hol di ng
cabl e to dashpanel (Fi g. 26).
(5) Unsnap cabl e from dashpanel routi ng cl i p.
(6) Remove cabl e housi ng from dash panel and
pul l i nto engi ne compartment.
it will be broken.To remove throttl e cabl e from
throttl e body bracket, sl i de cabl e towards front of
vehi cl e.
(9) Remove throttl e cabl e from vehi cl e.
3. 7L
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or throttle cable.
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of pedal arm (Fi g. 28).
Pl asti c cabl e retai ner snaps i nto top of pedal arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, remove metal cl i p hol di ng
(5) Unsnap cabl e from dashpanel routi ng cl i p.
(6) Remove cabl e housi ng from dash panel and
pul l i nto engi ne compartment.
Fig. 26 ACCELERATOR PEDAL/BRACKET
ASSEMBLY
2 - THROTTLE CABLE
Fig. 27 THROTTLE CABLE, PIN, RELEASE TAB-2.4L
2 - SPEED CONTROL CABLE
3 - THROTTLE CABLE
4 - RELEASE TAB
5 - CABLE PINS
6 - BELLCRANK
it will be broken. Sl i de pl asti c mount (Fi g. 30)
towards ri ght si de of vehi cl e to remove throttl e cabl e
from throttl e body bracket.
(9) Remove throttl e cabl e from vehi cl e.
INSTALLATION
(1) Sl i de accel erator cabl e pl asti c mount i nto throt-
tl e body mounti ng bracket. Conti nue sl i di ng unti l
rel ease tab (Fi g. 30) i s al i gned to hol e i n mounti ng
bracket.
i n thi s posi ti on, sl i de throttl e cabl e pi n (Fi g. 29) i nto
(3) Push cabl e housi ng i nto rubber grommet and
through openi ng i n dash panel .
(4) From i nsi de vehi cl e, i nstal l metal cl i p hol di ng
(5) From i nsi de vehi cl e, sl i de throttl e cabl e core
wi re i nto openi ng (sl ot) i n top of pedal arm.
(6) Push pl asti c cabl e retai ner (cl i p) i nto pedal arm
openi ng unti l i t snaps i n pl ace.
(7) I nstal l ai r box to throttl e body.
Fig. 28 ACCELERATOR PEDAL/BRACKET
ASSEMBLY
2 - THROTTLE CABLE
Fig. 29 THROTTLE CABLE PIN-3.7L
1 - THROTTLE CABLE PIN
3 - PUSH UP HERE
Fig. 30 THROTTLE CABLE RELEASE TAB-3.7L
1 - THROTTLE CABLE
2 - RELEASE TAB
3 - PICK OR SCREWDRIVER
THROTTLE CONTROL CABLE (Continued)
THROTTLE POSITION SENSOR
DESCRIPTION
The 3wi re Throttl e Posi ti on Sensor (TPS) i s
mounted on the throttl e body and i s connected to the
throttl e bl ade shaft.
OPERATION
The 3wi re TPS provi des the Powertrai n Control
Modul e (PCM) wi th an i nput si gnal (vol tage) that
represents the throttl e bl ade posi ti on of the throttl e
body. The sensor i s connected to the throttl e bl ade
shaft. As the posi ti on of the throttl e bl ade changes,
the output vol tage of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from .26
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.49 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
The PCM needs to i denti fy the acti ons and posi ti on
of the throttl e bl ade at al l ti mes. Thi s i nformati on i s
needed to assi st i n performi ng the fol l owi ng cal cul a-
ti ons:
I gni ti on ti mi ng advance
Fuel i njecti on pul se-wi dth
I dl e (l earned val ue or mi ni mum TPS)
Off-i dl e (0.06 vol t)
Wi de Open Throttl e (WOT) open l oop (2.608
vol ts above l earned i dl e vol tage)
Decel erati on fuel l ean out
Fuel cutoff duri ng cranki ng at WOT (2.608 vol ts
above l earned i dl e vol tage)
A/C WOT cutoff (certai n automati c transmi s-
si ons onl y)
REMOVAL
2. 4L
The Throttl e Posi ti on Sensor (TPS) i s mounted to
the throttl e body (Fi g. 31).
(1) Di sconnect TPS el ectri cal connector.
(2) Remove 2 TPS mounti ng screws.
(3) Remove TPS.
2 - MOUNTING SCREWS
4 - MOUNTING SCREWS
3. 7L
the throttl e body (Fi g. 32), or (Fi g. 33).
(1) Di sconnect TPS el ectri cal connector.
(2) Remove 2 TPS mounti ng screws.
(3) Remove TPS.
INSTALLATION
2. 4L
the rear of the throttl e body.
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 33). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. (I f
sensor wi l l not rotate, i nstal l sensor wi th throttl e
shaft on other si de of socket tangs). The TPS wi l l be
under sl i ght tensi on when rotated.
(1) I nstal l TPS and retai ni ng screws.
(2) Ti ghten screws to 7 Nm (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate throttl e (by hand) to check
for any TPS bi ndi ng before starti ng engi ne.
(5) I nstal l ai r cl eaner tube to throttl e body.
3. 7L
the throttl e body (Fi g. 32).
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 33). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. (I f
sensor wi l l not rotate, i nstal l sensor wi th throttl e
shaft on other si de of socket tangs). The TPS wi l l be
under sl i ght tensi on when rotated.
(1) I nstal l TPS and retai ni ng screws.
(2) Ti ghten screws to 7 Nm (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate throttl e (by hand) to check
for any TPS bi ndi ng before starti ng engi ne.
(5) I nstal l ai r cl eaner tube to throttl e body.
2 - MOUNTING SCREWS
4 - MOUNTING SCREWS
Fig. 33 TPS INSTALLATION - 3.7
1 - THROTTLE BODY
2 - TPS
3 - THROTTLE BODY SHAFT
4 - SOCKET LOCATING TANGS
THROTTLE POSITION SENSOR (Continued)
STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . 1
STEERING FLOW AND PRESSURE . . . . . . . . 3
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
STEERING
DESCRIPTION
Power steeri ng systems consi st of:
Steeri ng col umn & I ntermedi ate Shaft
Rack and pi ni on steeri ng gear
Bel t dri ven hydraul i c steeri ng pump
Pump pressure, suppl y and return hoses
Oi l Cool er
OPERATION
The steeri ng col umn i ntermedi ate shaft attaches
the steeri ng col umn to the gear pi ni on. The rotati on
of the pi ni on moves the gear rack from si de-to-si de.
Thi s l ateral acti on of the rack pushes and pul l s the
ti e rods to change the di recti on of the front wheel s.
Power assi st i s provi ded by an engi ne mounted
hydraul i c pump. The pump suppl i es hydraul i c fl ui d
to the steeri ng gear. Al l vehi cl es are equi pped wi th
an oi l cool er.
DIAGNOSIS AND TESTING - POWER STEERING SYSTEM
STEERING NOISE
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at a
standsti l l /parki ng, or when the steeri ng i s at the end of i ts travel . Hi ss i s a hi gh frequency noi se si mi l ar to that
of a water tap bei ng cl osed sl owl y. The noi se i s present i n al l val ves that have a hi gh vel oci ty fl ui d passi ng through
an ori fi ce. There i s no rel ati onshi p between thi s noi se and steeri ng performance.
OBJECTIONAL HISS OR
WHISTLE
1. Steering intermediate shaft to dash panel
seal.
1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components.
2. Inspect and repair suspension.
3. Internal gear noise. 3. Replace steering gear.
4. Loose or damaged intermediate shaft or
column.
4. Inspect and repair or replace.
MOAN Pressure hose in contact with other
components.
Reposition hose.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
KJ STEERING 19 - 1
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.
2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.
2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
5. Reservoir cap not installed correctly. 5. Install reservoir cap correctly.
SCRUBBING OR
KNOCKING
1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
3. Tire Pressure 3. Adjust Tire Pressure
BINDING AND STICKING
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
2. Tire pressure. 2. Adjust tire pressure.
3. Steering components (ball
joints/tie rod ends).
3 Inspect and repair as necessary.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column Intermediate shaft
binding.
6. Replace Intermediate Shaft.
7. Steering gear worn. 7. Replace gear.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT
3. Loose belt. 3. Adjust or replace.
4. Low pump pressure. 4. Pressure test and repair as
necessary.
5. Internal gear leak. 5. Replace gear.
STEERING WHEEL DOES NOT
WANT TO RETURN TO CENTER
POSITION
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate suspension
compnents.
4. High friction in steering gear. 4. Replace gear.
19 - 2 STEERING KJ
STEERING (Continued)
LOOSE STEERING AND VEHICLE LEAD
EXCESSIVE PLAY IN STEERING
WHEEL
1. Worn or loose suspension or
steering components.
1. Inspect and repair as necessary.
2. Worn or loose wheel bearings. 2. Inspect and replace bearings.
3. Steering gear mounting. 3. Tighten / replace gear mounting
bolts/ isolators to specification.
4. Gear out of adjustment. 4. Replace gear.
5. Worn or loose steering
intermediate shaft.
necessary.
VEHICLE PULLS, DRIFTS OR
LEADS TO ONE SIDE.
1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
DIAGNOSIS AND TESTING - POWER STEERING
FLOW AND PRESSURE
The fol l owi ng procedure i s used to test the opera-
ti on of the power steeri ng system on the vehi cl e. Thi s
test wi l l provi de the gal l ons per mi nute (GPM) or
fl ow rate of the power steeri ng pump al ong wi th the
maxi mum rel i ef pressure. Perform test any ti me a
power steeri ng system probl em i s present. Thi s test
wi l l determi ne i f the power steeri ng pump or power
steeri ng gear i s not functi oni ng properl y. The fol l ow-
i ng pressure and fl ow test i s performed usi ng Power
Steeri ng Anal yzer Tool ki t 6815 and (Fi g. 1) Adapter
Ki t 6893.
FLOW AND PRESSURE TEST
(1) Check the power steeri ng bel t to ensure i t i s i n
good condi ti on and adjusted properl y.
(2) Connect pressure gauge hose from the Power
Steeri ng Anal yzer to Tube 6844.
(3) Connect Adapter 6826 to Power Steeri ng Ana-
l yzer test val ve end.
(4) Di sconnect the hi gh pressure hose from the
power steeri ng pump.
(5) Connect the tube to the pump hose fi tti ng.
(6) Connect the power steeri ng hose from the
steeri ng gear to the adapter.
(7) Open the test val ve compl etel y.
(8) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
gauge and to get ai r out of the fl ui d. Then shut off
engi ne.
(9) Check fl ui d l evel , add fl ui d as necessary. Start
engi ne agai n and l et i dl e.
(10) Check for ai r bubbl es, Evacuate i f necessary
(11) Gauge shoul d read bel ow 862 kPa (125 psi ), i f
above, i nspect the hoses for restri cti ons and repai r as
necessary. The i ni ti al pressure readi ng shoul d be i n
the range of 345-552 kPa (50-80 psi ).
(12) I ncrease the engi ne speed to 1500 RPM and
read the fl ow meter. I f the fl ow rate (GPM) i s bel ow
speci fi cati on, (refer to pump speci fi cati on chart for
GPM) the pump shoul d be repl aced.
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than three seconds as the pump could be
damaged.
Fig. 1 Analyzer With Tube and Adapter
1 - TUBE
2 - ADAPTER FITTINGS
3 - ANALYZER
4 - GAUGE HOSE
KJ STEERING 19 - 3
(13) Cl ose val ve ful l y three ti mes and record hi gh-
est pressure i ndi cated each ti me. All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
Pressures above speci fi cati ons but not wi thi n
345 kPa (50 psi ) of each other, repl ace pump.
Pressures wi thi n 345 kPa (50 psi ) of each other
but bel ow speci fi cati ons, repl ace pump.
(14) Open the test val ve and turn the steeri ng
wheel to the extreme l eft and ri ght posi ti ons three
ti mes agai nst the stops. Record the hi ghest pressure
readi ng at each posi ti on. Compare readi ngs to the
pump speci fi cati ons chart. I f pressures readi ngs are
not wi thi n 50 psi of each other, the gear i s l eaki ng
i nternal l y and must be repl aced.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 3 seconds at a time
because, pump damage will result.
PUMP SPECIFICATION
ENGINE
RELIEF PRESSURE
50
FLOW RATE
(GPM) AT 1500
RPM
3.7L,
2.4L &
2.5L
10342 kPa (1450 psi) 2.4 - 2.8
19 - 4 STEERING KJ
COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION - SERVICE PRECAUTIONS . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . 8
IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - IGNITION
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL
IGNITION SWITCH REMOVAL . . . . . . . . . . . . . 9
INSTALLATION
IGNITION SWITCH INSTALLATION . . . . . . . . . 9
KEY-IN IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - KEY-IN IGNITION
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
INTERMEDIATE SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
STEERING WHEEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
COLUMN
DESCRIPTION
The standard non-ti l t and ti l t steeri ng col umn has
been desi gned to be servi ced as an assembl y. The col -
umn i s connected to the steeri ng gear wi th a one
pi ece shaft. The upper hal f has a support beari ng
mounted to a bracket. The bracket mounts to the
frame rai l wi th two nuts. The shaft i s servi ceabl e.
The key cyl i nder, swi tches, cl ock spri ng, tri m shrouds
and steeri ng wheel are servi ced separatel y.
OPERATION - SERVICE PRECAUTIONS
Safety goggl es shoul d be worn at al l ti mes when
worki ng on steeri ng col umns.
To servi ce the steeri ng wheel , swi tches or ai rbag,
refer to El ectri cal - Restrai nts and fol l ow al l WARN-
I NGS and CAUTI ONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
REMOVAL
(1) Posi ti on front wheel s straight ahead.
(2) Remove and i sol ate the negati ve ground cabl e
from the battery.
(3) Remove the ai rbag, (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - REMOVAL).
NOTE: If equipped with cruise control, disconnect
clock spring harness from the cruise switch har-
ness on the steering wheel.
KJ COLUMN 19 - 5
(4) Remove the steeri ng wheel wi th an appropri ate
pul l er (Fi g. 1) (Refer to 19 - STEERI NG/COLUMN/
STEERI NG WHEEL - REMOVAL).
(5) Remove knee bl ocker cover and knee bl ocker,
(Refer to 23 - BODY/I NSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL). (Fi g. 2)
(6) Remove screws from the l ower col umn shroud
(Fi g. 3) and remove both the upper and l ower
shrouds.
(7) Turn i gni ti on key to the on posi ti on.
(8) I f vehi cl e i s equi pped wi th automati c transmi s-
si on, di sconnect shi fter i nterl ock cabl e from the col -
umn.
(9) Remove the steeri ng coupl er bol t and col umn
mounti ng nuts and bol ts (Fi g. 4) then l ower col umn
off the mounti ng studs.
(10) Di sconnect and remove the wi ri ng harness
from the col umn (Fi g. 5).
(11) Sl i de the shi fter i nterl ock cabl e from the ti e
straps.
(12) Remove col umn.
(13) Transfer the necessary parts i f needed.
(14) Remove cl ock spri ng (Fi g. 6), swi tches, (SKI M
i f equi pped) (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - REMOVAL).
Fig. 1 Steering Wheel Puller
1 - PULLER C-3894-A
2 - STEERING WHEEL
Fig. 2 KNEE BLOCKER
Fig. 3 SHROUD REMOVAL/INSTALL
1 - Upper Shroud
2 - Lower Shroud
Fig. 4 STEERING COLUMN MOUNTING
1 - Steering Column
2 - Mounting Holes
19 - 6 COLUMN KJ
COLUMN (Continued)
INSTALLATION
(1) Al i gn and i nstal l col umn i nto the steeri ng cou-
pl er.
(2) I nstal l col umn harness and connect harness to
swi tches.
(3) Reroute the shi fter i nterl ock cabl e through the
ti e straps.
(4) I nstal l the col umn onto the mounti ng studs.
(5) I nstal l the two mounti ng nuts and the two
mounti ng bol ts al l fi nger ti ght.
CAUTION: Lower nuts must be installed and tight-
ened first then the upper nuts in order to prevent
damage to the capsules.
(6) Ti ghten the l ower mounti ng nuts to 17 Nm
(150 i n. l bs.).
(7) Ti ghten the upper mounti ng nuts to 17 Nm
(150 i n. l bs.).
(8) I nstal l the steeri ng col umn coupl er bol t and
(9) Reconnect the shi fter i nterl ock cabl e.
(10) Center the cl ock spri ng (i f necessary) and
i nstal l i t on the col umn, (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/CLOCKSPRI NG - I NSTALLATI ON).
(11) Snap together the col umn shrouds and i nstal l
the mounti ng screws.
(12) I nstal l the knee bl ocker and the knee bl ocker
cover, (Refer to 23 - BODY/I NSTRUMENT PANEL/
KNEE BLOCKER - I NSTALLATI ON).
(13)
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.Install the
steering wheel and tighten bolt to 54 Nm (40 ft.
lbs.) (Refer to 19 - STEERING/COLUMN/STEERING
WHEEL - INSTALLATION).
NOTE: If equipped with cruise control, connect
clock spring harness to cruise switch harness on
the steering wheel.
(14) I nstal l the ai rbag, (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - I NSTALLATI ON).
(15) I nstal l the negati ve battery termi nal .
Fig. 5 WIRING HARNESS COLUMN
1 - Column Wiring Harness
2 - Multi-function Switch
3 - Ignition Switch
4 - Steering Column
Fig. 6 CLOCK SPRING
1 - Tilt Lever
2 - Ignition Switch
3 - Clockspring
4 - Steering Column
5 - SKIM
KJ COLUMN 19 - 7
COLUMN (Continued)
SPECIFICATIONS
TORQUE CHART
Tilt Steering Column
Steering Wheel Bolt
54 40
Mounting Bolts
17 150
Coupler Bolt
49 36
Non-Tilt Steering Column
Steering Wheel Bolt
54 40
Mounting Bolts
17 150
Coupler Bolt
49 36
Ignition Switch Screws 2 17
SPECIAL TOOLS
STEERING COLUMN
IGNITION SWITCH
DESCRIPTION
The el ectri cal i gni ti on swi tch i s l ocated on the
steeri ng col umn. I t i s used as the mai n on/off swi tch-
i ng devi ce for most el ectri cal components. The
mechani cal key l ock cyl i nder i s used to engage/di sen-
gage the el ectri cal i gni ti on swi tch.
DIAGNOSIS AND TESTING - IGNITION SWITCH
ELECTRICAL DIAGNOSIS
For i gni ti on swi tch el ectri cal schemati cs, Refer to
the appropri ate secti on for the component.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
Vehicles equipped with an automatic trans-
mission and a floor mounted shifter: a cabl e i s
used to connect the i nterl ock devi ce i n the steeri ng
col umn assembl y, to the transmi ssi on fl oor shi ft
l ever. Thi s i nterl ock system i s used to l ock the trans-
mi ssi on shi fter i n the PARK posi ti on when the key
l ock cyl i nder i s rotated to the LOCKED or ACCES-
SORY posi ti on. I f the i gni ti on key i s di ffi cul t to
rotate to or from the LOCK or ACCESSORY posi ti on,
i t may not be the faul t of the key cyl i nder or the
steeri ng col umn components. The brake transmi ssi on
shi ft i nterl ock cabl e may be out of adjustment. (Refer
to 21 - TRANSMI SSI ON/TRANSAXLE/AUTOMATI C
- 30RH/GEAR SHI FT CABLE - ADJUSTMENTS).
The i nterl ock system wi thi n the steeri ng col umn i s
not servi ceabl e. I f repai r i s necessary, the steeri ng
col umn assembl y must be repl aced. (Refer to 19 -
STEERI NG/COLUMN - REMOVAL).
Vehicles equipped with a manual transmis-
sion and a floor mounted shifter: on certai n mod-
el s, a button i s l ocated on the steeri ng col umn behi nd
the i gni ti on key l ock cyl i nder. The button must be
manual l y depressed to al l ow rotati on of the i gni ti on
key l ock cyl i nder to the LOCK or ACCESSORY posi -
ti on. I f i t i s di ffi cul t to rotate the key to the LOCK or
ACCESSORY posi ti on, the l ever mechani sm may be
defecti ve. Thi s mechani sm i s not servi ceabl e. I f
repai r i s necessary, the steeri ng col umn assembl y
must be repl aced.(Refer to 19 - STEERI NG/COL-
UMN - REMOVAL).
Puller C-3894-A
19 - 8 COLUMN KJ
COLUMN (Continued)
REMOVAL
IGNITION SWITCH REMOVAL
The i gni ti on key must be i n the key cyl i nder for
cyl i nder removal . The key cyl i nder must be removed
fi rst before removi ng i gni ti on swi tch.
(1) Remove l ower steeri ng col umn cover screws
and remove cover.
(2) Remove l ock cyl i nder.(Refer to 19 - STEERI NG/
COLUMN/KEY/LOCK CYLI NDER - REMOVAL).
(3) Remove the mul ti -functi on swi tch.
(4) Di sconnect the el ectri cal connector at the rear
of the i gni ti on swi tch.
(5) Remove the i gni ti on swi tch mounti ng screw
(Fi g. 7). Use tamper proof torx bi t to remove the
screw.
(6) Pul l the i gni ti on swi tch strai ght out to remove
from the l ocki ng tabs (Fi g. 8)
INSTALLATION
IGNITION SWITCH INSTALLATION
cyl i nder i nstal l ati on. The key cyl i nder must be
al i gned wi th the i gni ti on swi tch for i nstal l ati on.
(1) Before i nstal l i ng i gni ti on swi tch, rotate the sl ot
i n the swi tch to the ON posi ti on (Fi g. 9).
(2) Connect the el ectri cal connector to rear of i gni -
ti on swi tch. Make sure that l ocki ng tab i s ful l y
seated i nto wi ri ng connector.
(3) Posi ti on the swi tch to the col umn and i nstal l
tamper proof screw. Ti ghten screw to 2 Nm (17 i n.
l bs.).
(4) I nstal l the l ock cyl i nder (Refer to 19 - STEER-
I NG/COLUMN/KEY/LOCK CYLI NDER - I NSTALLA-
TI ON).
(5) Test the operati on of the l ock cyl i nder for
smooth rotati ng.
(6) I nstal l the mul ti -functi on swi tch.
(7) I nstal l steeri ng col umn l ower cover.
Fig. 7 IGNITION SWITCH MOUNTING SCREW
1 - Tamper Proof Torx Screw
2 - Ignition Switch
Fig. 8 IGNITION SWITCH TABS
1 - Ignition Switch
2 - Locking Tabs
Fig. 9 IGNITION SWITCH ON POSITION
1 - Ignition Switch
2 - Rotate to On Position
KJ COLUMN 19 - 9
IGNITION SWITCH (Continued)
KEY-IN IGNITION SWITCH
DESCRIPTION
The key-i n i gni ti on swi tch i s i ntegral to the i gni -
ti on swi tch, whi ch i s mounted on the l eft si de of the
steeri ng col umn, opposi te the i gni ti on l ock cyl i nder.
I t cl oses a path to ground for the i nstrument cl uster
chi me warni ng ci rcui try when the i gni ti on key i s
i nserted i n the i gni ti on l ock cyl i nder and the dri ver
door jamb swi tch i s cl osed (dri ver door i s open). The
key-i n i gni ti on swi tch opens the ground path when
the key i s removed from the i gni ti on l ock cyl i nder.
The key-i n i gni ti on swi tch cannot be repai red and,
i f faul ty or damaged, the enti re i gni ti on swi tch must
be repl aced. (Refer to 19 - STEERI NG/COLUMN/I G-
NI TI ON SWI TCH - REMOVAL).
DIAGNOSIS AND TESTING - KEY-IN IGNITION
SWITCH
For ci rcui t descri pti ons and di agrams, Refer to the
appropri ate secti ons on the i ndi vi dual components.
BAGS, REFER TO ELECTRICAL - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
INJURY.
cabl e. Remove the steeri ng col umn shrouds. Unpl ug
the key-i n i gni ti on swi tch wi re harness connector
from the i gni ti on swi tch.
(2) Check for conti nui ty between the key-i n swi tch
sense ci rcui t and the l eft front door jamb swi tch
sense ci rcui t termi nal s of the key-i n i gni ti on swi tch.
There shoul d be conti nui ty wi th the key i n the i gni -
ti on l ock cyl i nder, and no conti nui ty wi th the key
removed from the i gni ti on l ock cyl i nder. I f OK, go to
Step 3. I f not OK, repl ace the faul ty i gni ti on swi tch
assembl y.
(3) Check for conti nui ty between the l eft front door
jamb swi tch sense ci rcui t cavi ty of the key-i n i gni ti on
swi tch wi re harness connector and a good ground.
There shoul d be conti nui ty wi th the dri ver door open,
and no conti nui ty wi th the dri ver door cl osed. I f OK,
see the di agnosi s for I nstrument Cl uster i n thi s
group. I f not OK, repai r the ci rcui t to the dri ver door
jamb swi tch as requi red.
LOCK CYLINDER
REMOVAL
cyl i nder removal . The key cyl i nder must be removed
fi rst before removi ng i gni ti on swi tch.
(1) I f equi pped wi th an automati c transmi ssi on,
pl ace shi fter i n PARK posi ti on.
(2) Remove the l ower shroud cover.
(3) Remove the remote keyl ess entry (R.K.E.) mod-
ul e.
(4) Remove the hal o ri ng around the l ock cyl i nder.
(5) Rotate key to ON posi ti on.
(6) A rel ease tang i s l ocated on bottom of key cyl -
i nder (Fi g. 10).
(7) Posi ti on a smal l screwdri ver or pi n punch i nto
tang access hol e on bottom of steeri ng col umn (Fi g.
11).
(8) Push the pi n punch up whi l e pul l i ng key cyl i n-
der from steeri ng col umn.
Fig. 10 LOCK CYLINDER RELEASE TANG
1 - Lock Cylinder
2 - Release Tang
19 - 10 COLUMN KJ
INSTALLATION
cyl i nder i nstal l ati on.
(1) I nstal l the l ock cyl i nder i nto the housi ng usi ng
care to al i gn the end of the l ock cyl i nder wi th the
i gni ti on swi tch.
(2) Push the l ock cyl i nder i n unti l i t cl i cks.
(3) Rotate the key to the l ock posi ti on.
(4) i nstal l the hal o ri ng around the l ock cyl i nder
housi ng.
(5) I nstal l the R.K.E. modul e.
(6) I nstal l the l ower shroud cover.
INTERMEDIATE SHAFT
REMOVAL
(1) Di sconnect the negati ve battery cabl e.
(2) Remove knee bl ocker cover and knee bl ocker,
(Refer to 23 - BODY/I NSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(3) Lock the steeri ng wheel wi th the ti res i n the
strai ght ahead posi ti on.
(4) Remove the l ower col umn pi nch bol t (Fi g. 12).
(5) Lower the steeri ng coupl er shaft from the col -
umn.
(6) Remove the i ntermedi ate shaft seal by pushi ng
i n the four tangs securi ng i t to the panel (Fi g. 12).
(7) Remove the center support beari ng bracket
from the mount on the shock tower.
(8) Remove the l ower coupl er pi nch bol t at the
steeri ng gear (Fi g. 12).
(9) Remove the coupl er at the steeri ng gear (Fi g.
12).
(10) Remove the i ntermedi ate shaft from the vehi -
cl e (Fi g. 12).
(11) Remove the center support bracket from the
steeri ng shaft (i f repl aci ng the i ntermedi ate shaft).
INSTALLATION
(1) I nstal l the center support bracket to the steer-
i ng shaft (i f removed).
(2) I nstal l the i ntermedi ate shaft to the vehi cl e
(Fi g. 12).
(3) I nstal l the coupl er at the steeri ng gear (Fi g.
12).
(4) I nstal l the l ower coupl er pi nch bol t at the
steeri ng gear and ti ghten the bol t to 49 Nm (36 ft.
l bs.) (Fi g. 12).
(5) I nstal l the center support beari ng bracket to
the mounti ng hol es on the shock tower.
(6) I nstal l the i ntermedi ate shaft seal by pushi ng
i t i n securi ng the four tangs to the panel (Fi g. 12).
(7) I nstal l the steeri ng coupl er shaft to the col umn.
(8) I nstal l the l ower col umn pi nch bol t and ti ghten
the bol t to 49 Nm (36 ft. l bs.) (Fi g. 12).
(9) Unl ock the steeri ng wheel .
(10) I nstal l the knee bl ocker cover and knee
bl ocker (Refer to 23 - BODY/I NSTRUMENT PANEL/
KNEE BLOCKER - I NSTALLATI ON).
(11) Reconnect the negati ve battery cabl e.
Fig. 11 LOCK CYLINDER RELEASE
1 - LOCK CYLINDER
2 - KEY
3 - PIN PUNCH
Fig. 12 STEERING COUPLER
1 - PINCH BOLT
2 - STEERING SHAFT
3 - STEERING COUPLER
4 - PINCH BOLT
KJ COLUMN 19 - 11
LOCK CYLINDER (Continued)
STEERING WHEEL
REMOVAL
(1) Di sabl e and remove the dri vers si de ai rbag.(Re-
fer to 8 - ELECTRI CAL/RESTRAI NTS/DRI VER AI R-
BAG - REMOVAL).
(2) Parti al l y remove the steeri ng wheel bol t and
l eave the bol t i n the col umn.
(3) I nstal l pul l er C-3894A or equi val ent usi ng the
top of the bol t to push on. (Fi g. 13)
(4) Remove the steeri ng wheel .
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
(1) I nstal l steeri ng wheel to the col umn
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.
(2) I nstal l the new steeri ng wheel bol t. Ti ghten the
bol t to 54 Nm (40 ft. l bs.).
(3) I nstal l the dri vers si de ai r bag. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/DRI VER AI RBAG -
I NSTALLATI ON).
Fig. 13 Steering Wheel Puller
1 - PULLER C-3894-A
2 - STEERING WHEEL
19 - 12 COLUMN KJ
GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL
REMOVAL - 4WD . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL - 2WD . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION
INSTALLATION - 4WD . . . . . . . . . . . . . . . . . . 14
INSTALLATION - 2WD . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL TOOLS
OUTER TIE ROD END REMOVAL TOOL . . . . 15
GEAR
DESCRIPTION
A rack and pi ni on steeri ng gear (Fi g. 1) i s made up
of two mai n components, the pi non shaft and the
rack. The gear cannot be adjusted or i nternal l y ser-
vi ced. I f a mal functi on or a fl ui d l eak occurs, the gear
must be repl aced as an assembl y.
OPERATION
The steeri ng col umn i ntermedi ate shaft i s attached
to the gear pi ni on. The rotati on of the pi ni on moves
the gear rack from si de-to-si de. Thi s l ateral acti on of
the rack pushes and pul l s the ti e rods, whi ch are
connected to the steeri ng knuckl es to change the
di recti on of the front wheel s.
REMOVAL
REMOVAL - 4WD
(1) Si phon the power steeri ng fl ui d from the power
steeri ng reservoi r.
(2) Lock the steeri ng wheel to prevent spi nni ng of
the cl ockspri ng.
(4) Remove the ski d pl ate from under the front
end to gai n access to the gear (Refer to 13 - FRAME
& BUMPERS/FRAME/FRONT SKI D PLATE -
REMOVAL).
(5) Remove the front ti re and wheel assembl i es.
NOTE: Mark the alignment adjusting cams for eas-
ier installation.
(6) Remove the l ower control arms. (Refer to 2 -
REMOVAL).
(7) Remove the front axl e. (Refer to 3 - DI FFER-
ENTI AL & DRI VELI NE/FRONT AXLE - REMOV-
AL).
(8) Remove the ti e rod end nuts.
(9) Separate ti e rod ends from the knuckl es wi th
Pul l er C-3894-A.
(10) Remove the i ntermedi ate shaft l ower coupl er
bol t and sl i de the coupl er off the gear (Fi g. 2).
(11) Remove power steeri ng pressure hose bracket
(Fi g. 3).
(12) Remove the power steeri ng l i nes from the
gear (Fi g. 2).
(13) Remove the mounti ng bol ts from the gear to
the front cradl e (Fi g. 3).
(14) Remove the steeri ng gear from the vehi cl e.
Fig. 1 Rack & Pinion Steering Gear
1 - TIE ROD - INNER
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER LH
4 - BOOTS
5 - TIE ROD END - OUTER RH
KJ GEAR 19 - 13
REMOVAL - 2WD
(1) Si phon the power steeri ng fl ui d from the power
steeri ng reservoi r.
(2) Lock the steeri ng wheel to prevent spi nni ng of
the cl ockspri ng.
(4) Remove the ski d pl ate from under the front
end to gai n access to the gear(Refer to 13 - FRAME
& BUMPERS/FRAME/FRONT SKI D PLATE -
REMOVAL).
NOTE: Mark the alignment adjusting cams and tie
rod end jam nuts on the steering gear for easier
installation.
(6) Remove the ti e rod end nuts.
(7) Separate ti e rod ends from the knuckl es wi th
Pul l er C-3894-A.
(8) Remove the l ower i ntermedi ate shaft coupl er
bol t and sl i de the coupl er off the gear (Fi g. 2).
(9) Remove power steeri ng pressure hose bracket
(Fi g. 3).
(10) Remove the power steeri ng l i nes from the
gear (Fi g. 2).
(11) Remove the mounti ng bol ts from the gear to
the front cradl e (Fi g. 3).
(12) Remove the steeri ng gear from the vehi cl e.
INSTALLATION
INSTALLATION - 4WD
(1) Transfer the ti e rod ends to the new steeri ng
gear (i f needed).
(2) I nstal l the steeri ng gear to the vehi cl e.
(3) I nstal l the gear mounti ng bol ts to the front cra-
dl e. (Fi g. 3). Ti ghten the gear mounti ng bol ts to 162
Nm (120 ft.l bs.)
(4) I nstal l the power steeri ng l i nes to the gear
(Fi g. 2).
(5) I nstal l the power steeri ng pressure hose
bracket (Fi g. 3).
(6) I nstal l the l ower coupl er bol t and sl i de the cou-
pl er on to the gear (Fi g. 2).
(7) I nstal l the ti e rod end to the knuckl e and
ti ghten the nuts.
(8) I nstal l the front axl e. (Refer to 3 - DI FFEREN-
TI AL & DRI VELI NE/FRONT AXLE - I NSTALLA-
TI ON).
(9) I nstal l the l ower control arms. (Refer to 2 -
I NSTALLATI ON).
(10) I nstal l the ti re and wheel assembl y. (Refer to
22 - TI RES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(11) I nstal l the ski d pl ate (Refer to 13 - FRAME &
BUMPERS/FRAME/FRONT SKI D PLATE - I NSTAL-
LATI ON).
(14) Fi l l the power steeri ng fl ui d (Refer to 19 -
STEERI NG/PUMP - STANDARD PROCEDURE).
(15) Reset the toe and center the steeri ng wheel
(Refer to 2 - SUSPENSI ON/WHEEL ALI GNMENT -
INSTALLATION - 2WD
(1) Transfer the outer ti e rod ends to the new
steeri ng gear (i f needed).
(2) I nstal l the steeri ng gear to the vehi cl e.
(3) I nstal l the gear mounti ng bol ts to the front cra-
dl e. (Fi g. 3). Ti ghten the gear mounti ng bol ts to 162
Nm (120 ft.l bs.)
(4) I nstal l the power steeri ng l i nes to the gear
(Fi g. 2).
Fig. 2 COUPLER BOLT
Fig. 3 RACK & PINION
19 - 14 GEAR KJ
GEAR (Continued)
(5) I nstal l the power steeri ng pressure hose
bracket (Fi g. 3).
(6) I nstal l the l ower coupl er bol t and sl i de the cou-
pl er on to the gear (Fi g. 2).
(7) I nstal l the ti e rod end to the knuckl e and
ti ghten the nuts.
CEDURE).
(9) I nstal l the ski d pl ate(Refer to 13 - FRAME &
BUMPERS/FRAME/FRONT SKI D PLATE - I NSTAL-
LATI ON).
(12) Fi l l the power steeri ng fl ui d (Refer to 19 -
SPECIFICATIONS
TORQUE CHART
Rack and Pinion Steering
Gear
Gear to Frame Bolts
162 120
Rack and Pinion Steering
Gear
Intermediate Shaft Bolt
49 36
Tie Rod End
Knuckle Nut
108 80
Tie Rod End
Jam Nut
75 55
Power Steering Line
Pressure Line
35 25
Power Steering Line
Return Line
35 25
SPECIAL TOOLS
OUTER TIE ROD END REMOVAL TOOL
Puller C-3894-A
KJ GEAR 19 - 15
GEAR (Continued)
LINKAGE
TABLE OF CONTENTS
page page
LINKAGE
STANDARD PROCEDURE - STEERING
LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TIE ROD END
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
LINKAGE
STANDARD PROCEDURE - STEERING LINKAGE
The ti e rod end and bal l stud seal s shoul d be
i nspected duri ng al l oi l changes. I f a seal i s damaged,
repl ace the ti e rod.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
TIE ROD END
REMOVAL
NOTE: Mark the tie rod end jam nuts on the steer-
ing gear for easier installation.
(3) Loosen the ti e rod end jam nut (Fi g. 1).
(4) Remove the ti e rod end nut (Fi g. 1).
(5) Seperate the ti e rod end from the knuckl e
usi ng tool C3894A.
NOTE: Count the number of turns when removing.
(6) Remove the ti e rod end from the rack (Fi g. 1).
INSTALLATION
(1) I nstal l the ti e rod end to the rack to the exact
number of turns that i t was removed (Fi g. 1).
(2) I nstal l the ti e rod end to the knuckl e. Ti ghten
the nut to 108 Nm (80 ft.l bs).
(3) Ti ghten the jam nut to 76 Nm (55 ft.l bs). (Fi g.
1).
CEDURE).
Fig. 1 TIE ROD END
1 - JAM NUT
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER
19 - 16 LINKAGE KJ
PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION . . . . 18
REMOVAL
REMOVAL - 3.7L . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION
INSTALLATION - 3.7L . . . . . . . . . . . . . . . . . . 19
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 19
SPECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . 20
FLUID COOLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
HOSES
REMOVAL
REMOVAL - PRESSURE HOSE . . . . . . . . . . . 21
REMOVAL - RETURN HOSE (GEAR TO THE
COOLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL - RETURN HOSE (RESERVOIR
TO THE COOLER) . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION
INSTALLATION - PRESSURE HOSE . . . . . . . 21
INSTALLATION - RETURN HOSE (GEAR TO
THE COOLER) . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION - RETURN HOSE
(RESERVOIR TO THE COOLER) . . . . . . . . . . 22
POWER STEERING PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
PULLEY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
RESERVOIR
REMOVAL
REMOVAL - 3.7L . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION
INSTALLATION - 3.7L . . . . . . . . . . . . . . . . . . 24
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . 24
PUMP
DESCRIPTION
Hydraul i c pressure for the power steeri ng system
i s provi ded by a bel t dri ven power steeri ng pump
(Fi g. 1). The pump shaft has a pressed-on hi gh
strength pl asti c dri ve pul l ey that i s bel t dri ven by
the crankshaft pul l ey. The i ntegral reservoi r used on
the 3.7L onl y i s attached to the pump body wi th
spri ng cl i ps (Fi g. 1). The 2.4L uses a remote fl ui d res-
ervoi r (Fi g. 2). The power steeri ng pump i s connected
to the steeri ng gear by the pressure and return
hoses.
OPERATION
The power steeri ng pump i s a constant fl ow rate
and di spl acement, vane-type pump. The pump i nter-
nal parts operate submerged i n fl ui d. The fl ow con-
trol ori fi ce i s part of the hi gh pressure l i ne fi tti ng.
The pressure rel i ef val ve i nsi de the fl ow control val ve
l i mi ts the pump pressure.
Fig. 1 POWER STEERING PUMP ASSEMBLY
1 - RESERVOIR
2 - CAP
3 - PULLEY
4 - PUMP BODY
5 - RESERVOIR RETAINING CLIPS
KJ PUMP 19 - 17
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal ambi ent temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two mi nutes.
(2) Rai se the front wheel s off the ground.
(3) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(4) Check the fl ui d l evel add i f necessary.
(5) Lower the vehi cl e, start the engi ne and turn
the steeri ng wheel sl owl y from l ock to l ock.
(6) Stop the engi ne and check the fl ui d l evel and
refi l l as requi red.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
(7) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
(8) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
REMOVAL
REMOVAL - 3. 7L
(1) Si phon out as much power steeri ng fl ui d as
possi bl e.
(2) Remove the radi ator cross member (Refer to 23
- BODY/EXTERI OR/RADI ATOR CROSSMEMBER -
REMOVAL).
(3) Remove the engi ne cool i ng fan (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR FAN - REMOVAL).
(4) Remove the fan shroud
(5) Remove the serpenti ne dri ve bel t (Refer to 7 -
REMOVAL).
(6) Remove the power steeri ng hi gh pressure hose
at the pump.
(7) Remove the return hose at the pump.
(8) Remove the three bol ts securi ng the pump to
the bracket thru the hol es i n the pul l ey. (Fi g. 3)
(9) Remove the pump from the vehi cl e.
REMOVAL - 2. 4L
CAUTION: On vehicles equipped with the 2.4L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
possi bl e.
(2) Remove the serpenti ne dri ve bel t.
(3) Remove the power steeri ng hi gh pressure hose
at the pump usi ng care not to remove the fl ow con-
trol val ve.
(4) Remove the return hose at the pump.
Fig. 2 FLUID RESERVOIR - 2.4L
Fig. 3 POWER STEERING PUMP - 3.7L
1 - MOUNTING BOLTS
2 - RESERVOIR
3 - STEEL PULLEY
19 - 18 PUMP KJ
PUMP (Continued)
(5) Remove the two nuts securi ng the wi re l oom
behi nd the pump bracket.
(6) Remove the three bol ts securi ng the pump to
the bracket thru the hol es i n the pul l ey. (Fi g. 4)
(7) Remove the pump from the vehi cl e.
INSTALLATION
(1) I nstal l the pump to the vehi cl e.
(2) I nstal l the three bol ts securi ng the pump to the
engi ne. (Fi g. 3) Ti ghten the bol ts to 47 Nm (35
ft.l bs.).
(3) I nstal l the power steeri ng hoses.
(4) I nstal l the serpenti ne bel t (Refer to 7 - COOL-
LATI ON).
(5) I nstal l the fan shroud
(6) I nstal l the engi ne cool i ng fan (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR FAN - I NSTALLA-
TI ON).
(7) I nstal l the radi ator crossmember (Refer to 23 -
BODY/EXTERI OR/RADI ATOR CROSSMEMBER -
I NSTALLATI ON).
(8) Refi l l the power steeri ng fl ui d and check for
l eaks (Refer to 19 - STEERI NG/PUMP - STANDARD
PROCEDURE).
(1) I nstal l the pump to the vehi cl e.
(2) I nstal l the three bol ts securi ng the pump to the
engi ne. (Fi g. 4) Ti ghten the bol ts to 47 Nm (35
ft.l bs.).
(3) I nstal l the two nuts securi ng the wi re l oom to
the pump bracket.
(4) I nstal l the power steeri ng pressure and suppl y
hoses.
LATI ON).
PROCEDURE).
SPECIFICATIONS
TORQUE CHART
Power Steering Pump
Bracket to Pump
28 21
Power Steering Pump
Bracket to Engine
47 35
Power Steering Pump
Flow Control Valve
75 55
Power Steering Pump
Pressure Line
28 21
Power Steering Pump
Pressure Line Bracket
12 9 105
Fig. 4 POWER STEERING PUMP - 2.4L
1 - MOUNTING BOLTS
2 - PULLEY
KJ PUMP 19 - 19
PUMP (Continued)
SPECIAL TOOLS
POWER STEERING PUMP
FLUID COOLER
DESCRIPTION
The power steeri ng fl ui d cool er i s l ocated at the
front of the vehi cl e. I t i s mounted to the radi ator
l ower support just forward of the ai r-condi ti oni ng
condenser and just rearward of the front fasci a. The
cool er i s posi ti oned so i t i s i n the ai r fl ow through the
front fasci a of the vehi cl e (Fi g. 5)
OPERATION
The purpose of the power steeri ng fl ui d cool er i s to
keep the temperature of the power steeri ng system
fl ui d from ri si ng to a l evel that woul d affect the per-
formance of the power steeri ng system.
The cool er used on thi s vehi cl e i s referred to as a
fl ui d-to-ai r type cool er. Thi s means that the ai r fl ow
across the fi n/tubes of the cool er i s used to extract
the heat from the cool er whi ch i t has absorbed from
the power steeri ng fl ui d fl owi ng through i t. The
cool er i s pl aced i n seri es wi th the power steeri ng
fl ui d return l i ne, between the steeri ng gear and the
power steeri ng fl ui d reservoi r. Thi s l owers the tem-
perature of the power steeri ng fl ui d pri or to i t enter-
i ng the power steeri ng fl ui d reservoi r where i t i s
resuppl i ed to the power steeri ng pump.
REMOVAL
(1) Remove the return l i ne at the gear.
(2) Remove the return l i ne at the reservoi r.
(3) Remove the gri l l e (Refer to 23 - BODY/EXTE-
RI OR/GRI LLE - REMOVAL).
(4) Remove the two cool er mounti ng bol ts. (Fi g. 5)
(5) Remove the cool er from the vehi cl e.
INSTALLATION
(1) I nstal l the cool er to the vehi cl e.
(2) I nstal l the two cool er mounti ng bol ts. (Fi g. 5).
(3) I nstal l the gri l l e (Refer to 23 - BODY/EXTERI -
OR/GRI LLE - I NSTALLATI ON).
(4) I nstal l the return l i ne at the reservoi r.
(5) I nstal l the return l i ne at the gear.
PROCEDURE).
Analyzer Set, Power Steering Flow/Pressure 6815
Adapters, Power Steering Flow/Pressure Tester
6893
Puller C-4333
Installer, Power Steering Pulley C-4063B
Fig. 5 FLUID COOLER
1 - FLUID COOLER
2 - MOUNTING BOLTS
19 - 20 PUMP KJ
PUMP (Continued)
HOSES
REMOVAL
REMOVAL - PRESSURE HOSE
(1) Si phon the power steeri ng fl ui d from the reser-
voi r.
(2) Remove the radi ator crossmember (Refer to 23
REMOVAL).
(3) Remove the fan (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR FAN - REMOVAL).
(4) Remove the fan shroud.
(5) Remove the serpenti ne bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - REMOV-
AL).
(6) Remove the pressure hose at the pump.
(7) Di sconnect the pressure swi tch el ectri cal con-
nector from the pressure hose.
(8) Remove the pressure hose from the gear.
(9) Remove the pressure hose mounti ng bracket
bol ts from behi nd the headl amp assembl y. (Fi g. 6)
(10) Remove the pressure hose from the vehi cl e
and transfer power steeri ng pressure swi tch i f neces-
sary.
REMOVAL - RETURN HOSE (GEAR TO THE
COOLER)
voi r.
(2) Remove the radi ator crossmember (Refer to 23
REMOVAL).
(3) Remove the fan (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR FAN - REMOVAL).
(4) Remove the fan shroud.
(5) Remove the serpenti ne bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - REMOV-
AL).
(6) Remove the return hose from the gear.
(7) Remove the return hose at the cool er.
(8) Remove the return hose mounti ng bracket bol ts
from the front cradl e. (Fi g. 7)
(9) Remove the return hose from the vehi cl e.
REMOVAL - RETURN HOSE (RESERVOIR TO
THE COOLER)
voi r.
(2) Remove the return hose from the pump reser-
voi r.
(3) Remove the return hose at the cool er.
(4) Remove the return hose from the vehi cl e.
INSTALLATION
INSTALLATION - PRESSURE HOSE
(1) I nstal l the pressure hose to the vehi cl e. (Fi g. 8)
(2) I nstal l the pressure hose mounti ng bracket
bol ts behi nd the headl amp assembl y. Ti ghten to to 12
Nm (9 ft.l bs.).
(3) I nstal l the pressure hose to the gear. Ti ghten
the hose to28 Nm (21 ft.l bs.).
(4) I nstal l the pressure swi tch el ectri cal connector.
(5) I nstal l the pressure hose at the pump. Ti ghten
the hose to28 Nm (21 ft.l bs.).
Fig. 6 MOUNTING BRACKET
1 - HIGH PRESSURE POWER STEERING HOSE
Fig. 7 RETURN HOSE TO COOLER
1 - MOUNTING BRACKETS
2 - FLUID COOLER
3 - PRESSURE SWITCH
4 - RETURN HOSE
KJ PUMP 19 - 21
LATI ON).
(8) I nstal l the fan (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR FAN - I NSTALLATI ON).
I NSTALLATI ON).
(10) Refi l l the power steeri ng fl ui d (Refer to 19 -
INSTALLATION - RETURN HOSE (GEAR TO THE
COOLER)
(1) I nstal l the return hose to the vehi cl e. (Fi g. 7)
(2) I nstal l the return hose mounti ng bracket bol ts
to the front cradl e.
(3) I nstal l the return hose at the cool er.
(4) I nstal l the return hose at the gear 28 Nm (21
ft.l bs.).
LATI ON).
(7) I nstal l the fan (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR FAN - I NSTALLATI ON).
I NSTALLATI ON).
INSTALLATION - RETURN HOSE (RESERVOIR
TO THE COOLER)
(1) I nstal l the return hose to the vehi cl e.
(2) I nstal l the return hose to the pump reservoi r.
(3) I nstal l the return hose at the cool er.
POWER STEERING PRESSURE
SWITCH
DESCRIPTION
A pressure sensi ng swi tch i s used i n the power
steeri ng system. I t i s mounted on the hi gh-pressure
steeri ng hose. Thi s swi tch wi l l be used wi th both
2.4L and 3.7L engi nes.
OPERATION
The swi tch i s used on both the 2.4L 4cyl i nder and
3.7L V-6 engi nes.
The power steeri ng pressure swi tch provi des an
i nput to the Powertrai n Control Modul e (PCM). Thi s
i nput i s provi ded duri ng peri ods of hi gh steeri ng
pump l oad and l ow engi ne rpm; such as duri ng park-
i ng maneuvers. The PCM i ncreases the i dl e speed
through the I dl e Ai r Control (I AC) motor. Thi s i s
done to prevent the engi ne from stal l i ng under the
i ncreased l oad.
When steeri ng pump pressure exceeds 3275 kPa
690 kPa (475 psi 100 psi ), the Normal l y Cl osed
(NC) swi tch wi l l open and the PCM wi l l i ncrease the
engi ne i dl e speed. Thi s wi l l prevent the engi ne from
stal l i ng.
When pump pressure drops to approxi matel y 1379
kPa (200 psi ), the swi tch ci rcui t wi l l re-cl ose and
engi ne i dl e speed wi l l return to i ts previ ous setti ng.
REMOVAL
The power steeri ng pressure swi tch i s i nstal l ed i n
the power steeri ng hi gh-pressure hose (Fi g. 9).
(1) Remove the hi gh pressure power steeri ng
hose(Refer to 19 - STEERI NG/PUMP/HOSES -
REMOVAL).
(2) Di sconnect el ectri cal connector from power
steeri ng pressure swi tch.
(3) Pl ace a smal l contai ner or shop towel beneath
swi tch to col l ect any excess fl ui d.
(4) Remove swi tch. Use back-up wrench on power
steeri ng l i ne to prevent l i ne bendi ng.
INSTALLATION
(1) I nstal l power steeri ng swi tch i nto power steer-
i ng l i ne. (Fi g. 9)
(2) Ti ghten to 9.6 Nm (85 i n. l bs.) torque.
Fig. 8 HIGH PRESSURE HOSE ASSEMBLY
3 - POWER STEERING PRESURE SWITCH
19 - 22 PUMP KJ
HOSES (Continued)
(3) I nstal l the hi gh pressure power steeri ng hose
(Refer to 19 - STEERI NG/PUMP/HOSES - I NSTAL-
LATI ON).
(4) Connect el ectri cal connector to swi tch.
(5) Check power steeri ng fl ui d and add as neces-
sary (Refer to 19 - STEERI NG/PUMP - STANDARD
PROCEDURE).
(6) Start engi ne and agai n check power steeri ng
fl ui d. Add fl ui d i f necessary.
PULLEY
REMOVAL
CAUTION: On vehicles equipped with the 2.4L, Do
not reuse the old power steering pump pulley it is
not intended for reuse. A new pulley must be
installed if removed.
(1) Remove pump assembl y. (Refer to 19 - STEER-
I NG/PUMP - REMOVAL).
(2) Remove pul l ey from pump wi th Pul l er C-4333
or equi val ent pul l er (Fi g. 10).
INSTALLATION
NOTE: The pulley is marked front for installation.
(1) Repl ace pul l ey i f bent, cracked, or l oose.
(2) I nstal l pul l ey on pump wi th I nstal l er C-4063-B
or equi val ent i nstal l er (Fi g. 11). The pul l ey must be
fl ush wi th the end of the shaft. Ensure the tool and
pul l ey are al i gned wi th the pump shaft.
(3) I nstal l pump assembl y. (Refer to 19 - STEER-
I NG/PUMP - I NSTALLATI ON)
(4) Wi th Serpenti ne Bel t, run engi ne unti l warm (5
mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be
careful that pulley does not contact mounting
bolts.
Fig. 9 POWER STEERING PRESSURE SWITCH
2 - O-RING
3 - POWER STEERING PRESSURE SWITCH
Fig. 10 Pulley Removal
1 - POWER STEERING PUMP DRIVE PULLEY
Fig. 11 Pulley Installation
1 - POWER STEERING PUMP DRIVE PULLEY
2 - SPECIAL TOOL C-4063B
KJ PUMP 19 - 23
POWER STEERING PRESSURE SWITCH (Continued)
RESERVOIR
REMOVAL
REMOVAL - 3. 7L
(1) Remove the power steeri ng pump. (Refer to 19
- STEERI NG/PUMP - REMOVAL).
(2) Secure the pump i n a hol di ng fi xture.
(3) Remove the retai ni ng cl i ps by pryi ng the l ock
tab upwards and tap the retai ni ng cl i ps off the pump
body. (Fi g. 12)
(4) Remove the reservoi r from the pump body.
REMOVAL - 2. 4L
possi bl e.
(2) Remove the power steeri ng hoses.
(3) Remove the bol t securi ng the reservoi r to the
mounti ng bracket. (Fi g. 13)
(4) Remove the reservoi r.
INSTALLATION
(1) I nstal l the reservoi r to the pump body.
(2) I nstal l the retai ni ng cl i ps to the pump and res-
ervoi r.
(3) I nstal l the pump to the engi ne. (Refer to 19 -
STEERI NG/PUMP - I NSTALLATI ON).
PROCEDURE).
(1) I nstal l the reservoi r to the mounti ng bracket.
(2) I nstal l and ti ghten the bol t to
(3) I nstal l the hoses.
PROCEDURE). (Fi g. 13)
Fig. 12 FLUID RESERVOIR
1 - FLUID RESERVOIR
2 - RETAINING CLIP
3 - PULLEY
4 - PUMP BODY
Fig. 13 FLUID RESERVOIR - 2.4L
19 - 24 PUMP KJ
TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRES AND
WHEEL RUNOUT . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE ROTATION . 2
STANDARD PROCEDURE - MATCH
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - WHEEL
BALANCING . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TIRES
DESCRIPTION
DESCRIPTION - TIRES . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - RADIAL-PLY TIRES . . . . . . . . 6
DESCRIPTION - SPARE TIRE
&TEMPORARY . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - REPLACEMENT TIRES . . . . . 7
DIAGNOSIS AND TESTING - TIRE
INFLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - TIRE NOISE
OR VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - REPAIRING
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8
SPARE TIRE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WHEELS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - WHEELS . . . . . . . 10
STANDARD PROCEDURE
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . 10
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . 11
STUDS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRES AND
WHEEL RUNOUT
Radi al runout i s the di fference between the hi gh
and l ow poi nts on the ti re or wheel (Fi g. 1).
Lateral runout i s the wobble of the ti re or wheel .
Radi al runout of more than 1.5 mm (.060 i nch)
measured at the center l i ne of the tread may cause
the vehi cl e to shake.
Lateral runout of more than 2.0 mm (.080 i nch)
measured near the shoul der of the ti re may cause the
vehi cl e to shake.
Someti mes radi al runout can be reduced. Rel ocate
the wheel and ti re assembl y on the mounti ng studs
(See Method 1). I f thi s does not reduce runout to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
Fig. 1 Checking Tire/Wheel/Hub Runout
1 - RADIAL RUNOUT
2 - LATERAL RUNOUT
KJ TIRES/WHEELS 22 - 1
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Dri ve vehi cl e a short di stance to el i mi nate ti re
fl at spotti ng from a parked posi ti on.
(2) Check wheel beari ngs and adjust i f adjustabl e
or repl ace i f necessary.
(3) Check the wheel mounti ng surface.
(4) Rel ocate wheel on the mounti ng, two studs
over from the ori gi nal posi ti on.
(5) Ti ghten wheel nuts unti l al l are properl y
torqued, to el i mi nate brake di storti on.
(6) Check radi al runout. I f sti l l excessi ve, mark
ti re si dewal l , wheel , and stud at poi nt of maxi mum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
(1) Remove ti re from wheel and mount wheel on
servi ce dynami c bal ance machi ne.
(2) Check wheel radi al runout (Fi g. 2) and l ateral
runout (Fi g. 3).
STEEL WHEELS: Radi al runout 0.024 i n., Lat-
eral runout 0.030 i n. (average)
ALUMI NUM WHEELS: Radi al runout 0.014 i n.,
Lateral runout 0.020 i n. (average)
(3) I f poi nt of greatest wheel l ateral runout i s near
ori gi nal chal k mark, remount ti re 180 degrees.
Recheck runout, (Refer to 22 - TI RES/WHEELS -
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE ROTATION
Ti res on the front and rear operate at di fferent
l oads and perform di fferent steeri ng, dri vi ng, and
braki ng functi ons. For these reasons they wear at
unequal rates and tend to devel op i rregul ar wear
patterns. These effects can be reduced by rotati ng
the ti res at regul ar i nterval s. The benefi ts of ti re
rotati on are:
I ncrease tread l i fe
Mai ntai n tracti on l evel s
A smooth, qui et ri de
The suggested method of ti re rotati on i s (Fi g. 4).
Other rotati on methods can be used, but they wi l l
not provi de al l the ti re l ongevi ty benefi ts.
Fig. 2 Radial Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 3 Lateral Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 4 Tire Rotation Pattern
22 - 2 TIRES/WHEELS KJ
TIRES/WHEELS (Continued)
STANDARD PROCEDURE - MATCH MOUNTING
Ti res and wheel s are currentl y match mounted at
the factory. Match mounti ng i s a techni que used to
reduce runout i n the wheel /ti re assembl y. Thi s means
that the hi gh spot of the ti re i s al i gned wi th the l ow
spot on the wheel ri m. The hi gh spot on the ti re i s
marked wi th a pai nt mark or a bri ght col ored adhe-
si ve l abel on the outboard si dewal l . The l ow spot on
the ri m i s i denti fi ed wi th a l abel on the outsi de of the
ri m and a dot on the i nsi de of the ri m. I f the outsi de
l abel has been removed the ti re wi l l have to be
removed to l ocate the dot on the i nsi de of the ri m.
Before di smounti ng a ti re from i ts wheel , a refer-
ence mark shoul d be pl aced on the ti re at the val ve
stem l ocati on. Thi s reference wi l l ensure that i t i s
remounted i n the ori gi nal posi ti on on the wheel .
(1) Use a di al i ndi cator to l ocate the hi gh spot of
the ti re on the center tread ri b (Fi g. 5). Record the
i ndi cator readi ng and mark the hi gh spot on the ti re.
Pl ace a mark on the ti re at the val ve stem l ocati on
(Fi g. 6).
(2) Break down the ti re and remount i t 180
degrees on the ri m (Fi g. 7).
(3) Measure the total runout agai n and mark the
ti re to i ndi cate the hi gh spot.
(4) I f runout i s sti l l excessi ve use the fol l owi ng
procedures.
(a) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot and i s sti l l excessi ve, repl ace the
ti re.
(b) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot on the wheel , the wheel may be out
of speci fi cati ons,(Refer to 22 - TI RES/WHEELS -
Fig. 5 Dial Indicator
Fig. 6 First Measurement On Tire
1 - REFERENCE MARK
2 - 1ST MEASUREMENT HIGH SPOT MARK TIRE AND RIM
3 - WHEEL
4 - VALVE STEM
Fig. 7 Remount Tire 180 Degrees
1 - VALVE STEM
2 - REFERENCE MARK
(c) I f the hi gh spot i s NOT wi thi n 101.6 mm (4.0
i n.) of ei ther hi gh spot, draw an arrow on the tread
from second hi gh spot to fi rst. Break down the ti re
and remount i t 90 degrees on ri m i n that di recti on
(Fi g. 8). Thi s procedure wi l l normal l y reduce the
runout to an acceptabl e amount.
STANDARD PROCEDURE - WHEEL BALANCING
I t i s recommended that a two pl ane servi ce
dynami c bal ancer be used when a ti re and wheel
assembl y requi re bal anci ng. Refer to bal ancer opera-
ti on i nstructi ons for proper cone mounti ng proce-
dures. Typi cal l y use front cone mounti ng method for
steel wheel s. For al umi num wheel use back cone
mounti ng method wi thout cone spri ng.
NOTE: Static should be used only when a two plane
balancer is not available.
NOTE: Cast aluminum and forged aluminum wheels
require coated balance weights and special align-
ment equipment.
Wheel bal anci ng can be accompl i shed wi th ei ther
on or off vehi cl e equi pment. When usi ng on-vehi cl e
bal anci ng equi pment, remove the opposi te wheel /ti re.
Off-vehi cl e bal anci ng i s recommended.
For stati c bal anci ng, fi nd l ocati on of heavy spot
causi ng the i mbal ance. Counter bal ance wheel
di rectl y opposi te the heavy spot. Determi ne wei ght
requi red to counter bal ance the area of i mbal ance.
Pl ace hal f of thi s wei ght on the inner ri m fl ange and
the other hal f on the outer ri m fl ange (Fi g. 9).
For dynami c bal anci ng, the bal anci ng equi pment i s
desi gned to l ocate the amount of wei ght to be appl i ed
to both the i nner and outer ri m fl ange (Fi g. 10).
Fig. 8 Remount Tire 90 Degrees In Direction of
Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE
Fig. 9 Static Unbalance & Balance
1 - HEAVY SPOT
2 - CENTER LINE OF SPINDLE
3 - ADD BALANCE WEIGHTS HERE
4 - CORRECTIVE WEIGHT LOCATION
5 - TIRE OR WHEEL TRAMP, OR WHEEL HOP
Fig. 10 Dynamic Unbalance & Balance
1 - CENTER LINE OF SPINDLE
2 - ADD BALANCE WEIGHTS HERE
3 - CORRECTIVE WEIGHT LOCATION
4 - HEAVY SPOT WHEEL SHIMMY AND VIBRATION
TIRES
DESCRIPTION
DESCRIPTION - TIRES
Ti res are desi gned and engi neered for each speci fi c
vehi cl e. They provi de the best overal l performance
for normal operati on. The ri de and handl i ng charac-
teri sti cs match the vehi cl es requi rements. Wi th
proper care they wi l l gi ve excel l ent rel i abi l i ty, trac-
ti on, ski d resi stance, and tread l i fe.
Dri vi ng habi ts have more effect on ti re l i fe than
any other factor. Careful dri vers wi l l obtai n i n most
cases, much greater mi l eage than severe use or care-
l ess dri vers. A few of the dri vi ng habi ts whi ch wi l l
shorten the l i fe of any ti re are:
Rapi d accel erati on
Severe brake appl i cati ons
Hi gh speed dri vi ng
Excessi ve speeds on turns
Stri ki ng curbs and other obstacl es
Radi al -pl y ti res are more prone to i rregul ar tread
wear. I t i s i mportant to fol l ow the ti re rotati on i nter-
val ,(Refer to 22 - TI RES/WHEELS - STANDARD
PROCEDURE). Thi s wi l l hel p to achi eve a greater
tread l i fe.
TIRE IDENTIFICATION
Ti re type, si ze, aspect rati o and speed rati ng are
encoded i n the l etters and numbers i mpri nted on the
si de wal l of the ti re. Refer to the chart to deci pher
the ti re i denti fi cati on code (Fi g. 11).
Performance ti res have a speed rati ng l etter after
the aspect rati o number.
LETTER SPEED RATING
S 180 km/h (112 mph)
T 190 km/h (118 mph)
U 200 km/h (124 mph)
H 210 km/h (130 mph)
V 240 km/h (149 mph)
W 270 km/h (168 mph)
Y 300 km/h (186 mph)
The speed rati ng i s not al ways pri nted on the ti re
si dewal l .
TIRE CHAINS
Ti re snow chai ns may be used on certain model s.
Refer to the Owners Manual for more i nformati on.
DESCRIPTION - RADIAL-PLY TIRES
Radi al -pl y ti res i mprove handl i ng, tread l i fe and
ri de qual i ty, and decrease rol l i ng resi stance.
Radi al -pl y ti res must al ways be used i n sets of
four. Under no ci rcumstances shoul d they be used on
the front onl y. They may be mi xed wi th temporary
spare ti res when necessary. A maxi mum speed of 50
MPH i s recommended whi l e a temporary spare i s i n
use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
The use of oversi zed ti res, ei ther i n the front or
rear of the vehi cl e, can cause vehi cl e dri ve trai n fai l -
ure. Thi s coul d al so cause i naccurate wheel speed
si gnal s when the vehi cl e i s equi pped wi th Anti -Lock
Brakes.
The use of ti res from di fferent manufactures on the
same vehi cl e i s NOT recommended. The proper ti re
pressure shoul d be mai ntai ned on al l four ti res.
DESCRIPTION - SPARE TIRE &TEMPORARY
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
or repl aced at the fi rst opportuni ty, then rei nstal l ed.
Do not exceed speeds of 50 M.P.H. when usi ng the
temporary spare ti re. Refer to Owners Manual for
compl ete detai l s.
Fig. 11 Tire Identification
DESCRIPTION - REPLACEMENT TIRES
The ori gi nal equi pment ti res provi de a proper bal -
ance of many characteri sti cs such as:
Ri de
Noi se
Handl i ng
Durabi l i ty
Tread l i fe
Tracti on
Rol l i ng resi stance
Speed capabi l i ty
I t i s recommended that ti res equi val ent to the ori g-
i nal equi pment ti res be used when repl acement i s
needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi -
cl e.
The use of oversi ze ti res may cause i nterference
wi th vehi cl e components. Under extremes of suspen-
si on and steeri ng travel , i nterference wi th vehi cl e
components may cause ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DIAGNOSIS AND TESTING - TIRE INFLATION
Under i nfl ati on wi l l cause rapi d shoul der wear, ti re
fl exi ng, and possi bl e ti re fai l ure (Fi g. 12).
Over i nfl ati on wi l l cause rapi d center wear and
l oss of the ti res abi l i ty to cushi on shocks (Fi g. 13).
I mproper i nfl ati on can cause:
Uneven wear patterns
Reduced tread l i fe
Reduced fuel economy
Unsati sfactory ri de
Vehi cl e dri ft
For proper ti re pressure speci fi cati on refer to the
Ti re I nfl ati on Pressure Chart provi ded wi th the vehi -
cl e.
Ti re pressures have been chosen to provi de safe
operati on, vehi cl e stabi l i ty, and a smooth ri de. Ti re
pressure shoul d be checked col d once a month. The
spare ti re pressure shoul d be check at l east twi ce
annual l y. Ti re pressure decreases as the ambi ent
temperature drops. Check ti re pressure frequentl y
when ambi ent temperature vari es wi del y.
I nfl ati on pressures speci fi ed on the pl acards are
col d i nfl ati on pressure. The vehi cl e must si t for at
l east 3 hours to obtai n the correct col d i nfl ati on pres-
sure readi ng. Or dri ven l ess than one mi l e after si t-
ti ng for 3 hours. Ti re i nfl ati on pressures may
i ncrease from 2 to 6 pounds per square i nch (psi )
duri ng operati on, due to i ncreased ti re temperature.
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING AND TREAD WEAR.
THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY,
RESULTING IN LOSS OF VEHICLE CONTROL.
Fig. 12 Under Inflation
1 - THIN TIRE THREAD AREAS
Fig. 13 Over Inflation Wear
1 - THIN TIRE THREAD AREA
TIRES (Continued)
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom
of the tread grooves. When tread depth i s 1.6 mm
(1/16 i n.), the tread wear i ndi cators wi l l appear as a
13 mm (1/2 i n.) band (Fi g. 14).
Ti re repl acement i s necessary when i ndi cators
appear i n two or more grooves or i f l ocal i zed bal di ng
occurs.
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under i nfl ati on wi l l cause wear on the shoul ders of
ti re. Over i nfl ati on wi l l cause wear at the center of
ti re.
Excessi ve camber causes the ti re to run at an
angl e to the road. One si de of tread i s then worn
more than the other (Fi g. 15).
Excessi ve toe-i n or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fi g. 15).
DIAGNOSIS AND TESTING - TIRE NOISE OR
VIBRATION
Radi al -pl y ti res are sensi ti ve to force i mpul ses
caused by i mproper mounti ng, vi brati on, wheel
defects, or possi bl y ti re i mbal ance.
To fi nd out i f ti res are causi ng the noi se or vi bra-
ti on, dri ve the vehi cl e over a smooth road at varyi ng
speeds. Note the noi se l evel duri ng accel erati on,
decel erati on and sl i ght l eft and ri ght steeri ng i nputs.
STANDARD PROCEDURE - REPAIRING LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Repai rs shoul d onl y be made i f the
defect, or puncture, i s i n the tread area (Fi g. 16). The
ti re shoul d be repl aced i f the puncture i s l ocated i n
the si dewal l .
Defl ate ti re compl etel y before removi ng the ti re
from the wheel . Use l ubri cati on such as a mi l d soap
sol uti on when di smounti ng or mounti ng ti re. Use
tool s free of burrs or sharp edges whi ch coul d dam-
age the ti re or wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
i s removed from the ri m bead and repai nt i f neces-
sary.
I nstal l wheel on vehi cl e, and ti ghten to proper
CLEANING
Remove the protecti ve coati ng on the ti res before
del i very of a vehi cl e. Thi s coati ng may cause deteri -
orati on of the ti res.
To remove the protecti ve coati ng, appl y warm
water and l et i t soak for a few mi nutes. Afterwards,
scrub the coati ng away wi th a soft bri stl e brush.
Steam cl eani ng may al so be used to remove the coat-
i ng.
NOTE: DO NOT use gasoline, mineral oil, oil-based
solvent or a wire brush for cleaning.
SPECIFICATIONS
SPECIFICATIONS
Tire P215/75R16
Tire P235/70R16
Spare Tire P215/75D16
POLYSPARE ONLY ON
16
SPARE TIRE
REMOVAL
(1) Rai se the l i cense pl ate.
(2) Remove the two bol ts securi ng the wheel cover
to the wheel .
(3) Remove the two l ug nuts and the one wheel
l ock (i f equi pped) securi ng the ti re/wheel to the spare
ti re carri er.
(4) Remove the spare ti re.
Fig. 14 Tread Wear Indicators
1 - TREAD ACCEPTABLE
2 - TREAD UNACCEPTABLE
3 - WEAR INDICATOR
TIRES (Continued)
INSTALLATION
(1) I nstal l the spare ti re onto the studs on the car-
ri er.
(2) I nstal l the two l ug nuts and one wheel l ock (i f
equi pped). Ti ghten the nuts to 115 Nm (85 ft.l bs.)
(3) Cl ose the pl asti c wheel cover and i nstal l the
two mounti ng bol ts. Ti ghten the nuts to 115 Nm (85
ft.l bs.)
(4) Cl ose the l i cense pl ate to cover the bol ts and
l atch.
WHEELS
DESCRIPTION
The ri m si ze i s on the vehi cl e safety certi fi cati on
l abel l ocated on the dri vers door shut face. The si ze
of the ri m i s determi ned by the dri vetrai n package.
Ori gi nal equi pment wheel s/ri ms are desi gned for
operati on up to the speci fi ed maxi mum vehi cl e capac-
i ty.
Al l model s use stamped steel , cast al umi num or
forged al umi num wheel s. Every wheel has rai sed sec-
ti ons between the ri m fl anges and ri m drop wel l
cal l ed safety humps (Fi g. 17).
Fig. 15 Tire Wear Patterns
Fig. 16 Tire Repair Area
1 - REPAIRABLE AREA
Fig. 17 Safety Rim
1 - FLANGE
2 - RIDGE
3 - WELL
SPARE TIRE (Continued)
I ni ti al i nfl ati on of the ti re forces the bead over
these rai sed secti ons. I n case of rapi d l oss of ai r pres-
sure, the rai sed secti ons hel p hol d the ti re on the
wheel .
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. Al l al umi num and some steel wheel s
have wheel stud nuts wi th an enl arged nose. Thi s
enl arged nose i s necessary to ensure proper retenti on
of the wheel s. Do not use repl acement studs or nuts
wi th a di fferent desi gn or l esser qual i ty.
DIAGNOSIS AND TESTING - WHEELS
I nspect wheel s for:
Excessi ve run out
Dents or cracks
Damaged wheel l ug nut hol es
Ai r Leaks from any area or surface of the ri m
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
I f a wheel i s damaged an ori gi nal equi pment
repl acement wheel shoul d be used. When obtai ni ng
repl acement wheel s, they shoul d be equi val ent i n
l oad carryi ng capaci ty. The di ameter, wi dth, offset,
pi l ot hol e and bol t ci rcl e of the wheel shoul d be the
same as the ori gi nal wheel .
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE. USED WHEELS ARE NOT RECOM-
MENDED. THE SERVICE HISTORY OF THE WHEEL
MAY HAVE INCLUDED SEVERE TREATMENT OR
VERY HIGH MILEAGE. THE RIM COULD FAIL WITH-
OUT WARNING.
STANDARD PROCEDURE
REPLACEMENT
Wheel s must be repl aced i f they have:
Excessi ve runout
Bent or dented
Leak ai r through wel ds
Have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Ori gi nal equi pment wheel s are avai l abl e through
your deal er. Repl acement wheel s from any other
source shoul d be equi val ent i n:
Load carryi ng capaci ty
Di ameter
Wi dth
Offset
Mounti ng confi gurati on
Fai l ure to use equi val ent repl acement wheel s may
affect the safety and handl i ng of your vehi cl e.
Repl acement wi th used wheel s i s not recommended.
Thei r servi ce hi story may have i ncl uded severe treat-
ment.
STANDARD PROCEDURE - WHEEL MOUNTING
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
NOTE: Do not use chrome plated lug nuts with
chrome plated wheels.
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
contact. I mproper i nstal l ati on coul d cause l ooseni ng
of wheel nuts. Thi s coul d affect the safety and han-
dl i ng of your vehi cl e.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface. Al l wheel nuts shoul d then be
ti ghtened just snug. Gradual l y ti ghten them i n
sequence to the proper torque speci fi cati on (Fi g. 18).
Never use oil or grease on studs or nuts.
Fig. 18 Lug Nut Tightening Pattern
WHEELS (Continued)
SPECIFICATIONS
SPECIFICATION
Lug Nut 1/2 X 20 with 60
Cone
115-155 85-115
STUDS
REMOVAL
CAUTION: Do not use a hammer to remove wheel
studs.
(3) Remove brake cal i per, cal i per adapter and
rotor,(Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/DI SC BRAKE CALI PERS - REMOVAL).
(4) Remove stud from hub wi th Remover C-4150A
(Fi g. 19).
INSTALLATION
CAUTION: Do not use a hammer to remove wheel
studs.
(1) I nstal l new stud i nto hub fl ange.
(2) I nstal l three washers onto stud, then i nstal l
l ug nut wi th the fl at si de of the nut agai nst the
washers.
(3) Ti ghten l ug nut unti l the stud i s pul l ed i nto
the hub fl ange. Veri fy that the stud i s properl y
seated i nto the fl ange.
(4) Remove l ug nut and washers.
(5) I nstal l the brake rotor, cal i per adapter, and cal -
i per, (Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/ROTORS - I NSTALLATI ON).
(6) I nstal l wheel and ti re assembl y (Refer to 22 -
TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE), use new l ug nut on stud or studs that were
repl aced.
Fig. 19 Wheel Stud Removal
1 - REMOVER
2 - WHEEL STUD
WHEELS (Continued)
BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING - WATER LEAKS . 2
DIAGNOSIS AND TESTING - WIND NOISE . . . 3
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - HEAT STAKING . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BODY STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . 6
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
DOOR - FRONT . . . . . . . . . . . . . . . . . . . . . . . . 121
DOORS - REAR . . . . . . . . . . . . . . . . . . . . . . . . 128
SWING GATE . . . . . . . . . . . . . . . . . . . . . . . . . . 135
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 147
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . 172
SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
WEATHERSTRIP/SEALS . . . . . . . . . . . . . . . . . . 185
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOLBASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use
when welding.
Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.
Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
Dai ml erChrysl er Corporati on uses many di fferent
types of push-i n fasteners to secure the i nteri or and
exteri or tri m to the body. Most of these fasteners can
be reused to assembl e the tri m duri ng vari ous repai r
procedures. At ti mes, a push-i n fastener cannot be
removed wi thout damagi ng the fastener or the com-
ponent i t i s hol di ng. I f i t i s not possi bl e to remove a
fastener wi thout damagi ng a component or body, cut
or break the fastener and use a new one when
i nstal l i ng the component. Never pry or pound on a
pl asti c or pressed-board tri m component. Usi ng a
sui tabl e fork-type pryi ng devi ce, pry the fastener
from the retai ni ng hol e behi nd the component bei ng
removed. When i nstal l i ng, veri fy fastener al i gnment
wi th the retai ni ng hol e by hand. Push di rectl y on or
over the fastener unti l i t seats. Appl y a l ow-force pul l
to the panel to veri fy that i t i s secure.
When i t i s necessary to remove components to ser-
vi ce another, i t shoul d not be necessary to appl y
excessi ve force or bend a component to remove i t.
Before damagi ng a tri m component, veri fy hi dden
fasteners or captured edges hol di ng the component i n
pl ace.
KJ BODY 23 - 1
DIAGNOSIS AND TESTING - WATER LEAKS
Water l eaks can be caused by poor seal i ng,
i mproper body component al i gnment, body seam
porosi ty, mi ssi ng pl ugs, or bl ocked drai n hol es. Cen-
tri fugal and gravi tati onal force can cause water to
dri p from a l ocati on away from the actual l eak poi nt,
maki ng l eak detecti on di ffi cul t. Al l body seal i ng
poi nts shoul d be water ti ght i n normal wet-dri vi ng
condi ti ons. Water fl owi ng downward from the front of
the vehi cl e shoul d not enter the passenger or l uggage
compartment. Movi ng seal i ng surfaces wi l l not
al ways seal water ti ght under al l condi ti ons. At
ti mes, si de gl ass or door seal s wi l l al l ow water to
enter the passenger compartment duri ng hi gh pres-
sure washi ng or hard dri vi ng rai n (severe) condi -
ti ons. Overcompensati ng on door or gl ass
adjustments to stop a water l eak that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After compl eti ng
a repai r, water test vehi cl e to veri fy l eak has stopped
before returni ng vehi cl e to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Veri fy that fl oor and body pl ugs are i n pl ace, body
drai ns are cl ear, and body components are properl y
al i gned and seal ed. I f component al i gnment or seal -
i ng i s necessary, refer to the appropri ate secti on of
thi s group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the condi ti ons causi ng a water l eak have
been determi ned, si mul ate the condi ti ons as cl osel y
as possi bl e.
I f a l eak occurs wi th the vehi cl e parked i n a
steady l i ght rai n, fl ood the l eak area wi th an open-
ended garden hose.
I f a l eak occurs whi l e dri vi ng at hi ghway speeds
i n a steady rai n, test the l eak area wi th a reasonabl e
vel oci ty stream or fan spray of water. Di rect the
spray i n a di recti on comparabl e to actual condi ti ons.
I f a l eak occurs when the vehi cl e i s parked on an
i ncl i ne, hoi st the end or si de of the vehi cl e to si mu-
l ate thi s condi ti on. Thi s method can be used when
the l eak occurs when the vehi cl e accel erates, stops or
turns. I f the l eak occurs on accel erati on, hoi st the
front of the vehi cl e. I f the l eak occurs when braki ng,
hoi st the back of the vehi cl e. I f the l eak occurs on l eft
turns, hoi st the l eft si de of the vehi cl e. I f the l eak
occurs on ri ght turns, hoi st the ri ght si de of the vehi -
cl e. For hoi sti ng recommendati ons refer to Group 0,
Lubri cati on and Mai ntenance, General I nformati on
secti on.
WATER LEAK DETECTION
To detect a water l eak poi nt-of-entry, do a water
test and watch for water tracks or dropl ets formi ng
on the i nsi de of the vehi cl e. I f necessary, remove i nte-
ri or tri m covers or panel s to gai n vi sual access to the
l eak area. I f the hose cannot be posi ti oned wi thout
bei ng hel d, have someone hel p do the water test.
Some water l eaks must be tested for a consi derabl e
l ength of ti me to become apparent. When a l eak
appears, fi nd the hi ghest poi nt of the water track or
drop. The hi ghest poi nt usual l y wi l l show the poi nt of
entry. After l eak poi nt has been found, repai r the
l eak and water test to veri fy that the l eak has
stopped.
Locati ng the entry poi nt of water that i s l eaki ng
i nto a cavi ty between panel s can be di ffi cul t. The
trapped water may spl ash or run from the cavi ty,
often at a di stance from the entry poi nt. Most water
l eaks of thi s type become apparent after accel erati ng,
stoppi ng, turni ng, or when on an i ncl i ne.
MIRROR INSPECTION METHOD
When a l eak poi nt area i s vi sual l y obstructed, use
a sui tabl e mi rror to gai n vi sual access. A mi rror can
al so be used to defl ect l i ght to a l i mi ted-access area
to assi st i n l ocati ng a l eak poi nt.
BRIGHT LIGHT LEAK TEST METHOD
Some water l eaks i n the l uggage compartment can
be detected wi thout water testi ng. Posi ti on the vehi -
cl e i n a bri ghtl y l i t area. From i nsi de the darkened
l uggage compartment i nspect around seal s and body
seams. I f necessary, have a hel per di rect a drop l i ght
over the suspected l eak areas around the l uggage
compartment. I f l i ght i s vi si bl e through a normal l y
seal ed l ocati on, water coul d enter through the open-
i ng.
PRESSURIZED LEAK TEST METHOD
When a water l eak i nto the passenger compart-
ment cannot be detected by water testi ng, pressuri ze
the passenger compartment and soap test exteri or of
the vehi cl e. To pressuri ze the passenger compart-
ment, cl ose al l doors and wi ndows, start engi ne, and
set heater control to hi gh bl ower i n HEAT posi ti on. I f
engi ne can not be started, connect a charger to the
battery to ensure adequate vol tage to the bl ower.
Wi th i nteri or pressuri zed, appl y di sh detergent sol u-
ti on to suspected l eak area on the exteri or of the
vehi cl e. Appl y detergent sol uti on wi th spray devi ce or
soft bri stl e brush. I f soap bubbl es occur at a body
seam, joi nt, seal or gasket, the l eak entry poi nt coul d
be at that l ocati on.
23 - 2 BODY KJ
BODY (Continued)
DIAGNOSIS AND TESTING - WIND NOISE
Wi nd noi se i s the resul t of most ai r l eaks. Ai r l eaks
can be caused by poor seal i ng, i mproper body compo-
nent al i gnment, body seam porosi ty, or mi ssi ng pl ugs
i n the engi ne compartment or door hi nge pi l l ar areas.
Al l body seal i ng poi nts shoul d be ai rti ght i n normal
dri vi ng condi ti ons. Movi ng seal i ng surfaces wi l l not
al ways seal ai rti ght under al l condi ti ons. At ti mes,
si de gl ass or door seal s wi l l al l ow wi nd noi se to be
noti ced i n the passenger compartment duri ng hi gh
cross wi nds. Over compensati ng on door or gl ass
adjustments to stop wi nd noi se that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After a repai r pro-
cedure has been performed, test vehi cl e to veri fy
noi se has stopped before returni ng vehi cl e to use.
Wi nd noi se can al so be caused by i mproperl y fi tted
exteri or mol di ngs or body ornamentati on. Loose
mol di ngs can fl utter, creati ng a buzzi ng or chatteri ng
noi se. An open cavi ty or protrudi ng edge can create a
whi stl i ng or howl i ng noi se. I nspect the exteri or of the
vehi cl e to veri fy that these condi ti ons do not exi st.
VISUAL INSPECTION BEFORE TESTS
Veri fy that fl oor and body pl ugs are i n pl ace and
body components are al i gned and seal ed. I f compo-
nent al i gnment or seal i ng i s necessary, refer to the
appropri ate secti on of thi s group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Dri ve the vehi cl e to veri fy the general l ocati on
of the wi nd noi se.
(2) Appl y 50 mm (2 i n.) maski ng tape i n 150 mm
(6 i n.) l engths al ong weatherstri ps, wel d seams or
mol di ngs. After each l ength i s appl i ed, dri ve the vehi -
cl e. I f noi se goes away after a pi ece of tape i s appl i ed,
remove tape, l ocate, and repai r defect.
POSSIBLE CAUSE OF WIND NOISE
Mol di ngs standi ng away from body surface can
catch wi nd and whi stl e.
Gaps i n seal ed areas behi nd overhangi ng body
fl anges can cause wi nd-rushi ng sounds.
Mi sal i gned movabl e components.
Mi ssi ng or i mproperl y i nstal l ed pl ugs i n pi l l ars.
Wel d burn through hol es.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
Al l mechani sms and l i nkages shoul d be l ubri cated
when necessary. Thi s wi l l mai ntai n ease of operati on
and provi de protecti on agai nst rust and excessi ve
wear. The weatherstri p seal s shoul d be l ubri cated to
prol ong thei r l i fe as wel l as to i mprove door seal i ng.
Al l appl i cabl e exteri or and i nteri or vehi cl e operat-
i ng mechani sms shoul d be i nspected and cl eaned.
Pi vot/sl i di ng contact areas on the mechani sms shoul d
then be l ubri cated.
(1) When necessary, l ubri cate the operati ng mech-
ani sms wi th the speci fi ed l ubri cants.
(2) Appl y si l i cone l ubri cant to a cl oth and wi pe i t
on door seal s to avoi d over-spray that can soi l pas-
sengers cl othi ng.
(3) Before appl yi ng l ubri cant, the component
shoul d be wi ped cl ean. After l ubri cati on, any excess
l ubri cant shoul d be removed.
(4) The hood l atch, l atch rel ease mechani sm, l atch
stri ker, and safety l atch shoul d be l ubri cated peri od-
i cal l y.
(5) The door l ock cyl i nders shoul d be l ubri cated
twi ce each year (preferabl y autumn and spri ng).
Spray a smal l amount of l ock cyl i nder l ubri cant
di rectl y i nto the l ock cyl i nder.
Appl y a smal l amount to the key and i nsert i t
i nto the l ock cyl i nder.
Rotate i t to the l ocked posi ti on and then back to
the unl ocked posi ti on several ti mes.
Remove the key. Wi pe the l ubri cant from i t wi th
a cl ean cl oth to avoi d soi l i ng of cl othi ng.
STANDARD PROCEDURE - HEAT STAKING
(1) Remove tri m panel .
(2) Bend or move the tri m panel components at
the heat staked joi nts. Observe the heat staked l oca-
ti ons and/or component seams for l ooseness.
(3) Heat stake the components.
(a) I f the heat staked or component seam l oca-
ti on i s l oose, hol d the two components ti ghtl y
together and usi ng a sol deri ng gun wi th a fl at ti p,
mel t the materi al securi ng the components
together. Do not over heat the affected area, dam-
age to the exteri or of the tri m panel may occur.
(b) I f the heat staked materi al i s broken or mi ss-
i ng, use a hot gl ue gun to appl y new materi al to
the area to be repai red. The panel s that are bei ng
heat staked must be hel d together whi l e the appl y-
i ng the gl ue. Once the new materi al i s i n pl ace, i t
may be necessary to use a sol deri ng gun to mel t
the newl y appl i ed materi al . Do not over heat the
affected area, damage to the exteri or of the tri m
panel may occur.
(4) Al l ow the repai red area to cool and veri fy the
repai r.
(5) I nstal l tri m panel .
KJ BODY 23 - 3
BODY (Continued)
SPECIFICATIONS
FENDER BOLTS 12 9
FLIP-UP GLASS HINGE BOLTS 7 60
FRONT DOOR CHECK STRAP NUTS 12 9
FRONT DOOR CHECK STRAP TO A-PILLAR BOLTS 12 9
FRONT DOOR GLASS RUN CHANNEL BOLTS 9 80
FRONT DOOR HINGE TO A-PILLAR BOLTS 28 21
FRONT DOOR HINGE TO DOOR NUTS 23 17
FRONT DOOR LATCH SCREW 11 8
FRONT DOOR LATCH STRIKER SCREWS 28 21
FRONT DOOR OUTSIDE HANDLE NUTS 6 55
FRONT DOOR REGULATOR BOLTS 9 80
FRONT SEAT BACK RECLINER BOLTS 28 21
FRONT SEAT BOLTS/NUT 43 32
FRONT SEAT RISER BOLTS 28 21
FRONT SEAT TRACK BOLTS 28 21
HOOD HINGE TO BODY BOLTS 28 21
HOOD HINGE TO HOOD BOLTS 12 9
HOOD LATCH NUTS 12 9
HOOD LATCH SUPPORT BOLTS 10 85
INSTRUMENT PANEL CENTER SUPPORT BRACKET
BOLTS
23 17
INSTRUMENT PANEL HVAC NUTS/BOLTS 6 55
INSTRUMENT PANEL ROLL DOWN BOLTS 54 40
INSTRUMENT PANEL TOP BOLTS 28 21
OUTSIDE MIRROR NUTS 7 65
RADIATOR CROSSMEMBER BOLTS 12 9
REAR DOOR CHECK STRAP NUTS 12 9
REAR DOOR CHECK STRAP TO A-PILLAR BOLTS 12 9
REAR DOOR GLASS RUN CHANNEL BOLTS 9 80
REAR DOOR HINGE TO B-PILLAR BOLTS 28 21
REAR DOOR HINGE TO DOOR NUTS 23 17
REAR DOOR LATCH SCREW 11 8
REAR DOOR LATCH STRIKER SCREWS 28 21
REAR DOOR OUTSIDE HANDLE NUTS 6 55
REAR SEAT BACK HINGE BOLTS 28 21
REAR SEAT LATCH/LOCK ASSEMBLY BOLTS 28 21
REAR SEAT OUTBOARD NUTS 43 32
REAR SEAT OUTER SEAT CUSHION LEG BOLTS 35 26
ROOF RACK BOLTS 8 75
23 - 4 BODY KJ
BODY (Continued)
SIDE VIEW MIRROR NUTS 7 65
SWING GATE EXTERIOR HANDLE NUTS 6 55
SWING GATE HINGE BOLTS 31 23
SWING GATE HINGE TO D-PILLAR BOLTS 31 23
SWING GATE LATCH SCREWS 11 8
SWING GATE LATCH STRIKER SCREWS 11 8
WASHER BOTTLE BOLT 10 85
SPECIAL TOOLS
BODY
Trim Stick C-4755
Torx Bit Set C-4794-B
Molding Remover C-4829
KJ BODY 23 - 5
BODY (Continued)
BODY STRUCTURE
TABLE OF CONTENTS
page page
ASSEMBLY
SPECIFICATIONS
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . 6
WELD AND STRUCTURAL ADHESIVE
LOCATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 9
SEALER LOCATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 87
OPENING DIMENSIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 111
GAP AND FLUSH
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 116
ASSEMBLY
SPECIFICATIONS
SPECIFICATION
INDEX
DESCRIPTION FIGURE
COMPLETE BODY STRUCTURE VIEWS ( 1 )
BODY STRUCTURE - SECTIONS ( 2 )
23 - 6 BODY STRUCTURE KJ
Fig. 1 COMPLETE BODY STRUCTURE VIEWS
KJ BODY STRUCTURE 23 - 7
ASSEMBLY (Continued)
Fig. 2 BODY STRUCTURE - SECTIONS
ASSEMBLY (Continued)
WELD AND STRUCTURAL
ADHESIVE LOCATIONS
SPECIFICATIONS
Fig. 3 BODY IN WHITE - SECTIONS
INDEX
DESCRIPTION FIGURE
FRONT END ASSEMBLY
INNER FRONT PANELS ( 4 )
INNER WHEELHOUSE ASSEMBLIES ( 5 )
INNER WHEEL HOUSES & LOWER REINFORCEMENTS ( 6 )
FRONT BUMPER CROSSMEMBER ASSEMBLY ( 7 )
INNER FRONT WHEELHOUSE ASSEMBLY ( 8 )
FRONT INNER RAIL ASSEMBLY ( 9 )
FRONT INNER RAILS AND BRACKET WELD POINTS ( 10 )
FRONT INNER RAILS AND BRACKET WELD POINTS ( 11 )
FRONT OUTER RAIL & TORQUE BOX ( 12 )
FRONT OUTER RAIL ASSEMBLIES ( 13 )
FRONT OUTER RAILS AND BRACKET WELD POINTS ( 14 )
INNER FRONT WHEELHOUSE ASSEMBLY - COMPLETE ( 15 )
INNER FRONT WHEELHOUSE TO RAILS ( 16 )
COWL SIDE PANEL ASSEMBLIES ( 17 )
PLENUM ASSEMBLY ( 18 )
PLENUM BAFFLE & PLENUM CLOSURE PANEL ( 19 )
PLENUM BAFFLE & STEERING COLUMN REINFORCEMENT ( 20 )
FRONT END ASSEMBLY/UNDERBODY
FLOOR PAN ASSEMBLY ( 21 )
FLOOR PAN AND DASH PANEL ( 22 )
DASH PANEL AND PLENUM ( 23 )
WHEELHOUSE, FLOOR PAN, DASH PANEL AND PLENUM ASSEMBLY ( 24 )
COWL SIDE PANEL ( 25 )
REAR FRAME RAILS
REAR FRAME RAIL ASSEMBLY ( 26 )
REAR CONTROL ARM AND SHOCK MOUNTING BRACKETS ( 27 )
REAR SPRING MOUNTING BRACKETS AND REINFORCEMENTS ( 28 )
REAR SPRING REINFORCEMENTS, SHOCK MOUNTING, FUEL PASS AND EXHAUST
HANGER BRACKET
( 29 )
REAR WHEELHOUSE ASSEMBLIES ( 30 )
FRONT AND REAR RAIL REINFORCEMENTS ( 31 )
REAR FLOOR PAN ASSEMBLY
REAR FLOOR PAN, COMPRESSION AND ANCHOR PLATE ASSEMBLY ( 32 )
SWING GATE AND BUMPER REINFORCEMENT ( 33 )
FLOOR PAN AND REAR RAIL ASSEMBLIES ( 34 )
FLOOR PAN AND REAR RAIL ADHESIVE LOCATIONS ( 35 )
FLOOR PAN AND REAR RAIL WELD LOCATIONS ( 36 )
REAR FLOOR PAN, CROSSMEMBERS AND FUEL TANK REINFORCEMENTS ( 38 )
WELD AND STRUCTURAL ADHESIVE LOCATIONS (Continued)
DESCRIPTION FIGURE
FULL FLOOR PAN ASSEMBLY
FULL FLOOR PAN ASSEMBLIES ( 39 )
FLOOR PAN AND RAIL ASSEMBLY ADHESIVE LOCATIONS ( 40 )
FLOOR PAN AND RAIL ASSEMBLY WELD LOCATIONS ( 41 )
FLOOR PAN, BODY SIDE SILL, COWL SIDE PANEL AND CROSSMEMBERS ( 42 )
WHEELHOUSE ADHESIVE LOCATIONS ( 43 )
WHEELHOUSE WELD LOCATIONS ( 44 )
BODY SIDE PANELS AND SUB ASSEMBLIES
A-PILLAR AND HEADER MOUNTING REINFORCEMENTS ( 45 )
B-PILLAR REINFORCEMENTS ( 46 )
C-PILLAR AND SEAT BACK MOUNTING REINFORCEMENTS ( 47 )
D-PILLAR REINFORCEMENTS ( 48 )
TAIL LAMP MOUNTING PANEL AND GATE STRIKER REINFORCEMENT ( 49 )
TAIL LAMP MOUNTING PANEL AND TAIL LAMP EXTENSION ( 50 )
SWING GATE OPENING PANEL AND ROOF HEADER ( 51 )
BODY SIDE PANELS
BODY SIDE PANEL ASSEMBLY ( 52 )
BODY SIDE OUTER, INNER FENDER REINFORCEMENT AND FENDER ASSEMBLY ( 53 )
BODY SIDE OUTER AND INNER PANELS; A-PILLAR ( 54 )
LOWER INNER BODY SIDE PANELS AND UPPER A-PILLARS ( 55 )
BODY SIDE PANEL ASSEMBLIES AND B-PILLAR. ( 56 )
BODY SIDE PANEL ASSEMBLIES AND C-PILLAR REINFORCEMENT ( 57 )
QUARTER WINDOW OPENING; SEAT BACK ATTACH REINFORCEMENT; C-PILLAR
REINFORCEMENT
( 58 )
BODY SIDE PANEL ASSEMBLIES AND OUTER REAR WHEELHOUSES ( 59 )
OUTER REAR WHEELHOUSE WELDS AND ADHESIVE LOCATIONS ( 60 )
D-PILLAR AND TAIL LAMP ASSEMBLY WELD AND ADHESIVE LOCATIONS ( 61 )
SWING GATE STRIKER REINFORCEMENT WELDS AND ADHESIVE LOCATIONS ( 62 )
REAR WHEELHOUSE WELDS AND TAIL LAMP ADHESIVE LOCATIONS ( 63 )
FENDER ASSEMBLIES
INNER FENDER REINFORCEMENT AND GUSSETS ( 64 )
INNER FENDER REINFORCEMENT, GUSSETS, PLENUM AND WHEELHOUSES ( 65 )
INNER FENDER REINFORCEMENT AND WHEELHOUSES ( 66 )
PLENUM ASSEMBLY AND INNER SIDE PANELS ( 67 )
ROOF PANEL ASSEMBLIES
ROOF PANEL ASSEMBLY ( 68 )
ROOF PANEL AND BODY SIDE WELD AND ADHESIVE LOCATIONS ( 69 )
ROOF PANEL AND BODY SIDE WELD AND ADHESIVE LOCATIONS - SUNROOF
EQUIPPED
( 70 )
ROOF AND HEADER PANEL ASSEMBLY ( 71 )
DESCRIPTION FIGURE
BODY SIDE PANELS & FLOOR PAN ASSEMBLIES
BODY SIDE PANEL AND FLOOR PAN ASSEMBLIES ( 72 )
BODY SIDE SILLS AND REAR WHEELHOUSES ( 73 )
ROOF HEADER AND WHEELHOUSE WELDS AND ADHESIVE LOCATIONS ( 74 )
SWING GATE OPENING PANEL; GATE STRIKER REINFORCEMENT; D-PILLAR
REINFORCEMENT ADHESIVE AND WELD LOCATIONS
( 75 )
SWING GATE OPENING PANEL; D-PILLAR LOWER TO FLOOR GUSSET; GATE
OPENING REINFORCEMENT
( 76 )
REAR FLOOR PAN AND CROSSMEMBER; TAIL LAMP MOUNTING; SWING GATE
OPENING PANEL;
( 77 )
FRONT END ASSEMBLY
Fig. 4 INNER FRONT PANELS
Fig. 5 INNER WHEEL HOUSES
Fig. 6 INNER WHEEL HOUSES
Fig. 7 FRONT BUMPER CROSSMEMBER
Fig. 8 INNER FRONT WHEELHOUSE
Fig. 9 FRONT INNER RAILS
Fig. 12 FRONT OUTER RAIL
Fig. 13 FRONT OUTER RAILS
Fig. 14 FRONT OUTER RAILS
Fig. 15 INNER FRONT WHEELHOUSE/FRONT INNER RAIL
Fig. 16 INNER FRONT WHEELHOUSE/FRONT INNER RAIL
Fig. 17 COWL SIDE PANEL
Fig. 18 PLENUM ASSEMBLY
FRONT END ASSEMBLY/UNDERBODY
Fig. 21 FLOOR PAN ASSEMBLY
Fig. 22 FLOOR PAN ASSEMBLY
Fig. 23 DASH PANEL ASSEMBLY
Fig. 24 DASH PANEL/WHEELHOUSE ASSEMBLY
Fig. 25 COWL SIDE PANEL
REAR FRAME RAILS
Fig. 26 REAR FRAME RAILS
Fig. 27 REAR MOUNTING BRACKETS
Fig. 28 REAR SPRING MOUNTINGS
Fig. 29 REAR SPRING, SHOCK, FUEL PASS AND EXHAUST BRACKETS
Fig. 30 REAR WHEELHOUSE ASSEMBLIES
Fig. 31 RAIL ASSEMBLIES FRONT/REAR
REAR FLOOR PAN ASSEMBLY
Fig. 32 REAR FLOOR PAN ASSEMBLY
Fig. 33 BUMPER AND SWING GATE REINFORCEMENT
Fig. 34 REAR FLOOR PAN
Fig. 38 REAR CROSSMEMBERS AND REINFORCEMENTS
FULL FLOOR PAN ASSEMBLY
Fig. 39 FLOOR PAN ASSEMBLIES
Fig. 40 FRONT RAILS ADHESIVE LOCATIONS
Fig. 41 FRONT RAILS WELD LOCATIONS
Fig. 42 SIDE SILLS
Fig. 43 WHEELHOUSES ADHESIVE LOCATIONS
Fig. 44 WHEELHOUSES WELD LOCATIONS
BODY SIDE PANELS AND SUB ASSEMBLIES
Fig. 45 A-PILLAR
Fig. 46 B-PILLAR
Fig. 47 C-PILLAR
Fig. 48 D-PILLAR
Fig. 49 TAIL LAMP MOUNTING PANEL
Fig. 50 TAIL LAMP MOUNTING PANEL
Fig. 51 SWING GATE OPENING
BODY SIDE PANELS
Fig. 52 BODY SIDE PANEL ASSEMBLY
Fig. 53 FENDER REINFORCEMENT
Fig. 54 A-PILLAR; FENDER REINFORCEMENT
Fig. 55 UPPER AND LOWER BODY SIDE PANEL
Fig. 56 B-PILLAR
Fig. 57 C-PILLAR
Fig. 58 QUARTER WINDOW OPENING
Fig. 59 OUTER REAR WHEELHOUSE
Fig. 60 OUTER REAR WHEELHOUSE
Fig. 61 D-PILLAR
Fig. 62 SWING GATE STRIKER REINFORCEMENT
Fig. 63 REAR WHEELHOUSE AND TAIL LAMP
FENDER ASSEMBLIES
Fig. 64 FENDERS
Fig. 65 FENDER ASSEMBLY
Fig. 66 INNER FENDER
Fig. 67 FRONT INNER SIDE PANELS
ROOF PANEL ASSEMBLIES
Fig. 68 ROOF PANEL ASSEMBLY
Fig. 70 ROOF PANEL
Fig. 71 ROOF PANEL
BODY SIDE PANELS & FLOOR PAN ASSEMBLIES
Fig. 73 BODY SIDE PANEL
Fig. 74 BODY SIDE PANEL
Fig. 75 D-PILLAR
Fig. 76 D-PILLAR
SEALER LOCATIONS
SPECIFICATIONS
INDEX
DESCRIPTION FIGURE
SEALER APPLICATION METHODS ( 78 )
REAR FLOOR PAN AND FUEL TANK ACCESS DOOR ( 79 )
FLOOR PANS; BODY SIDE SILLS; DASH PANEL; COWL AND PLENUM ASSEMBLY ( 80 )
FRONT FLOOR PAN; DASH; BODY SIDE SILL AND COWL PANELS ( 81 )
FLOOR PANS AND SIDE SILLS ( 82 )
BODY SIDE, PLENUM AND DASH PANELS ASSEMBLIES ( 83 )
A-PILLAR AND DASH PANEL ( 84 )
PLENUM AND DASH PANEL ( 85 )
BODY SIDE PANEL ASSEMBLIES ( 86 )
BODY SIDE SILL; WHEELHOUSE; B-PILLAR ( 87 )
TAIL LAMP MOUNTING AND SWING GATE STRIKER REINFORCEMENT ASSEMBLIES ( 88 )
ROOF PANEL; SWING GATE OPENING ASSEMBLIES ( 89 )
ROOF PANEL; SWING GATE OPENING ( 90 )
ROOF PANEL; SWING GATE OPENING ( 91 )
BODY SIDE PANEL; SWING GATE OPENING; FLOOR PAN ASSEMBLY ( 92 )
SWING GATE OPENING ( 93 )
WHEELHOUSES ( 94 )
BODY SIDE PANEL; FLOOR PAN; SWING GATE OPENING ASSEMBLIES ( 95 )
WHEELHOUSES ( 96 )
WHEELHOUSES ( 97 )
WHEELHOUSE ( 98 )
ROOF PANEL ASSEMBLY ( 99 )
REAR ROOF HEADER AND ROOF PANEL ( 100 )
Fig. 78 APPLICATION METHODS
SEALER LOCATIONS (Continued)
Fig. 80 FULL FLOOR PAN
Fig. 81 FRONT FLOOR PAN & DASH PANEL
Fig. 82 FLOOR PAN
Fig. 84 A-PILLAR & DASH PANEL
Fig. 85 PLENUM AND DASH PANEL
Fig. 86 BODY SIDE PANEL ASSEMBLIES
Fig. 87 WHEELHOUSES
Fig. 88 TAIL LAMP MOUNTING
Fig. 89 ROOF PANEL & BODY SIDE SILL ASSEMBLY
Fig. 91 ROOF PANEL; SWING GATE OPENING
Fig. 94 WHEELHOUSES
Fig. 96 WHEELHOUSES
Fig. 97 WHEELHOUSES
Fig. 98 WHEELHOUSE
Fig. 100 ROOF PANEL/REAR ROOF HEADER
OPENING DIMENSIONS
SPECIFICATIONS
INDEX
DESCRIPTION FIGURE
ENGINE COMPARTMENT ( 101 )
WINDSHIELD OPENING ( 102 )
BODY SIDE OPENINGS ( 103 )
SWING GATE OPENING ( 104 )
Fig. 101 ENGINE COMPARTMENT
OPENING DIMENSIONS (Continued)
Fig. 102 WINDSHIELD OPENING
F
i
g
.
1
0
3
B
O
D
Y
S
I
D
E
O
P
E
N
I
N
G
S
GAP AND FLUSH
SPECIFICATIONS
GAP & FLUSH DIMENSIONS INDEX
DESCRIPTION FIGURE
FRONT QUADRANT ( 105 )
REAR QUADRANT ( 106 )
Fig. 105 GAP & FLUSH/FRONT QUADRANT
NOTE:
All measurements are in mm.
U/F = Under Fl ush
DIMENSION GAP FLUSH DIMENSION GAP FLUSH
A 6.0 +/- 2.0 O/F 12.0 +/- 2.0 E 5.0 +/- 1.5 O/F 3.0 +/- 1.5
B 5.0 +/- 1.0 O/F 0.5 +/- 1.5 F 6.0 +/- 2.0 U/F 18.5 +/- 1.5
C 6.0 +/- 1.5 O/F 3.0 +/- 2.0 G 5.0 +/- 1.5 O/F 3.0 +/- 1.5
D 5.0 +/- 1.5 O/F 5.0 +/- 1.5 H 6.0 +/- 2.0 U/F 18.5 +/- 1.5
GAP AND FLUSH (Continued)
Fig. 106 GAP & FLUSH/REAR QUADRANT
NOTE:
All measurements are in mm.
U/F = Under Fl ush
DIMENSION GAP FLUSH DIMENSION GAP FLUSH
I 5.0 +/- 1.0 0.0 +/- 1.5 M 6.0 +/- 1.5 U/F 4.7 +2.5/-1.0
J 5.0 +/- 1.0 0.0 +/- 1.5 N 6.0 +/- 1.5 U/F 4.0 +2.5/-1.0
K 5.0 +/- 1.0 0.0 +/- 1.5 O 6.0 +/- 1.5
L 5.0 +/- 1.0 0.0 +/- 1.5 P 5.0 +/- 1.0 U/F 0.5 +/- 1.0
GAP AND FLUSH (Continued)
HOOD
TABLE OF CONTENTS
page page
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 119
HOOD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 119
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 119
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 120
LATCH RELEASE CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 120
SUPPORT CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 120
LATCH RELEASE HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 120
HINGE
REMOVAL
NOTE: It is not necessary to remove the hood to
replace one or both hinges. The hinges can be
replaced one at a time.
(1) Rai se and support hood.
(2) Usi ng a grease penci l or equi val ent, mark posi -
ti on of hi nge.
(3) Remove hood support cyl i nder. (Refer to 23 -
BODY/HOOD/SUPPORT CYLI NDER - REMOVAL)
(4) Remove nuts attachi ng hi nge to hood.
(5) Remove bol ts attachi ng hi nge to body.
(6) Separate hi nge from vehi cl e.
INSTALLATION
(1) Posi ti on hi nge on vehi cl e and al i gn reference
marks.
(2) I nstal l bol ts attachi ng hi nge to body and
(3) I nstal l nuts attachi ng hi nge to hood 12 Nm (9
ft. l bs.).
(4) I nstal l hood hi nge support cyl i nder. (Refer to
23 - BODY/HOOD/SUPPORT CYLI NDER - I NSTAL-
LATI ON)
HOOD
REMOVAL
(1) Rai se hood.
(2) Usi ng a grease penci l or equi val ent, mark l oca-
ti on of hood hi nges on hood for i nstal l ati on al i gn-
ment.
(3) Remove bol ts attachi ng hi nges to hood.
(4) Wi th the ai d of a hel per, remove hood from
vehi cl e.
INSTALLATION
(1) Posi ti on hood on hi nges.
(2) I nstal l bol ts fi nger-ti ght.
(3) Al i gn hi nges wi th i nstal l ati on reference marks
and ti ghten bol ts to 12 Nm (9 ft. l bs.).
(4) I nspect hood for proper al i gnment and adjust
as necessary.
ADJ USTMENTS
ADJUSTMENT
(1) I f hood i s l ow i n rel ati on to cowl panel , i nsert
shi ms between hi nge and hood.
(2) Adjust hood bumper i n or out to adjust hood-
to-fender hei ght al i gnment.
(3) Adjust the hood l atch as necessary. Ti ghten the
(4) Al i gn the l atch stri ker so that stri ker enters
the l atch squarel y and wi thout bi ndi ng.
KJ HOOD 23 - 119
LATCH
REMOVAL
(1) Remove the gri l l . (Refer to 23 - BODY/EXTERI -
OR/GRI LLE - REMOVAL)
(2) Remove the l atch support bracket bol ts and
posi ti on the l atch assembl y asi de. (Fi g. 1)
(3) Remove the two l atch nuts.
(4) Di sconnect the rel ease cabl e.
INSTALLATION
(1) Connect the rel ease cabl e and i nstal l the l atch
onto the support bracket.
(2) I nstal l the two nuts and ti ghten to 12 Nm (9
ft. l bs.).
(3) I nstal l the support bracket and the bol ts.
(4) Ti ghten the bol ts to 12 Nm (9 ft. l bs.).
(5) I nstal l the gri l l . (Refer to 23 - BODY/EXTERI -
LATCH RELEASE CABLE
REMOVAL
(1) Remove the battery. (Refer to 8 - ELECTRI -
CAL/BATTERY SYSTEM/BATTERY - REMOVAL)
(2) Remove the hood l atch. (Refer to 23 - BODY/
HOOD/LATCH - REMOVAL)
(3) Remove the powertrai n control modul e. (Refer
to 8 - ELECTRI CAL/ELECTRONI C CONTROL
MODULES/POWERTRAI N CONTROL MODULE -
REMOVAL)
(4) Remove the hood rel ease handl e. (Refer to 23 -
BODY/HOOD/LATCH RELEASE HANDLE -
REMOVAL)
(5) Di sconnect the attachi ng cl i ps and remove the
cabl e from the i nsi de.
INSTALLATION
(1) I nstal l the cabl e from the i nsi de and attach the
retai ni ng cl i ps.
(2) I nstal l the hood l atch rel ease handl e. (Refer to
23 - BODY/HOOD/LATCH RELEASE HANDLE -
I NSTALLATI ON)
(3) I nstal l the powertrai n control modul e. (Refer to
8 - ELECTRI CAL/ELECTRONI C CONTROL MOD-
ULES/POWERTRAI N CONTROL MODULE -
I NSTALLATI ON)
(4) I nstal l the hood l atch. (Refer to 23 - BODY/
HOOD/LATCH - I NSTALLATI ON)
(5) I nstal l the battery. (Refer to 8 - ELECTRI CAL/
BATTERY SYSTEM/BATTERY - I NSTALLATI ON)
SUPPORT CYLINDER
REMOVAL
(1) Open the hood and support.
(2) Rel ease the upper and l ower cl i ps.
(3) Remove the support cyl i nder.
INSTALLATION
(1) I nstal l the support cyl i nder over the bal l studs
wi th the thi n end down.
(2) I nstal l the retai ni ng cl i ps and remove the sup-
port from the hood.
LATCH RELEASE HANDLE
REMOVAL
(1) Remove the cowl tri m panel . (Refer to 23 -
BODY/I NTERI OR/COWL TRI M COVER -
REMOVAL)
(2) Remove the three screws and remove the han-
dl e.
(3) Di sconnect the hood rel ease cabl e.
INSTALLATION
(1) Connect the hood rel ease cabl e to the handl e.
(2) I nstal l the handl e and i nstal l the three screws.
(3) I nstal l the cowl tri m cover. (Refer to 23 -
BODY/I NTERI OR/COWL TRI M COVER - I NSTAL-
LATI ON)
Fig. 1 RADIATOR CROSSMEMBER
1 - CROSSMEMBER
2 - BOLTS (2)
3 - BOLTS (4)
4 - BOLTS (2)
5 - HOOD LATCH SUPPORT
23 - 120 HOOD KJ
DOOR - FRONT
TABLE OF CONTENTS
page page
CHECK STRAP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 121
DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 122
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 122
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123
GLASS RUN CHANNEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 124
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 125
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
WINDOW REGULATOR - MANUAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
WINDOW REGULATOR - ELECTRIC
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
CHECK STRAP
REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Remove screws attachi ng door check to A-pi l l ar.
(3) Remove the two nuts and remove the door
check strap. (Fi g. 1)
INSTALLATION
NOTE: Make sure the proper orientation of the
check strap is maintained using the R and L on
the top.
(1) I nstal l the check strap through the speaker
hol e.
(2) I nstal l the nuts and ti ghten to 12 Nm (9 ft.
l bs.).
(3) Connect the strap to the A-pi l l ar and ti ghten
the bol ts to 12 Nm (9 ft. l bs.).
(4) I nstal l the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - I NSTALLATI ON)
Fig. 1 CHECK STRAP
1 - NUTS
2 - CHECK STRAP
3 - SPEAKER OPENING
KJ DOOR - FRONT 23 - 121
DOOR
REMOVAL
(1) Di sconnect the door wi re harness el ectri cal con-
nector at the A-pi l l ar.
(2) Support the door wi th a sui tabl e l i fti ng devi ce.
(3) Remove the bol ts attachi ng the check strap to
the a-pi l l ar.
NOTE: The epoxy washers should not be removed
from the hinge. If the washers are removed the door
may have to be re-adjusted.
(4) Remove the nuts attachi ng the door hi nges to
the door. (Fi g. 2)
INSTALLATION
(1) Support the door wi th a sui tabl e l i fti ng devi ce
and i nstal l the door onto the hi nges.
(2) I nstal l the nuts and washers i f they were
removed previ ousl y and ti ghten to 23 Nm (17 ft.
l bs.).
(3) Connect the door wi re harness el ectri cal con-
nector.
(4) Connect the check strap to the a-pi l l ar and
i nstal l the bol ts.
(5) Ti ghten the check strap bol ts to 12 Nm (9 ft.
l bs.).
(6) Adjust the door as necessary. (Refer to 23 -
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECI FI CATI ONS)
DOOR GLASS
REMOVAL
(1) Remove the outer bel t mol di ng. (Refer to 23 -
BODY/WEATHERSTRI P/SEALS/FRONT DOOR
OUTER BELT MOLDI NG - REMOVAL)
(3) Rai se the gl ass to the posi ti on shown and usi ng
a l ong fl at bl ade or hook type tool , di sengage cl i ps
attachi ng gl ass retai ner to regul ator l i ft pl ate. (Fi g.
3)
(4) Di sconnect the gl ass from the regul ator l i ft
pl ate and re-i nstal l the cl i ps.
(5) Rotate the top of the gl ass toward the front
and remove the gl ass from the wi ndow openi ng.
INSTALLATION
(1) I nstal l the gl ass through the wi ndow openi ng
and al i gn the mounti ng pl ate to the l i ft pl ate.
(2) Engage the gl ass to the regul ator l i ft pl ate.
(3) I nstal l the outer bel t mol di ng. (Refer to 23 -
OUTER BELT MOLDI NG - I NSTALLATI ON)
Fig. 2 HINGES
1 - NUTS (4)
2 - EPOXY WASHERS (2) (NOT REMOVABLE)
3 - HINGES
4 - DOOR
Fig. 3 DOOR GLASS/REGULATOR
1 - DOOR GLASS ATTACHMENT CLIP (2)
2 - DOOR OPENING
3 - REGULATOR LIFT PLATE
4 - DOOR GLASS
23 - 122 DOOR - FRONT KJ
EXTERIOR HANDLE
REMOVAL
(1) Remove the door gl ass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Di sconnect the l ock swi tch el ectri cal connector,
i f equi pped. (Fi g. 4)
(3) Di sconnect the handl e rod at the handl e and
the key cyl i nder rod at the l atch.
(4) Remove the screws.
(5) Remove the nuts and remove the handl e.
INSTALLATION
(1) Posi ti on the handl e on the door and sl i de ful l y
toward the rear of the door.
(2) I nstal l the nuts and ti ghten to 6 Nm (55 i n.
l bs.).
(3) I nstal l the screws and ti ghten to 6 Nm (55 i n.
l bs.).
(4) Connect the handl e rod at the handl e and the
key cyl i nder rod at the l atch.
(5) Connect the l ock swi tch el ectri cal connector, i f
equi pped.
(6) I nstal l the door gl ass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - I NSTALLATI ON)
GLASS RUN CHANNEL
REMOVAL
(1) Posi ti on the wi ndow i nto the down posi ti on.
(4) Remove the front and rear bol ts. (Fi g. 5)
(5) Peal the weatherstri p out of the door frame
and remove the run channel through the wi ndow
openi ng.
INSTALLATION
(1) I nstal l the run channel through the wi ndow
openi ng and i nto the door frame.
(2) I nstal l the front, rear bol ts and ti ghten to 9
Nm (80 i n. l bs.).
HINGE
REMOVAL
(1) Remove the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - REMOVAL)
(2) Usi ng a grease penci l or equi val ent, mark the
hi nge l ocati on and remove the bol ts.
INSTALLATION
(1) I nstal l the hi nges and bol ts.
(2) Ti ghten bol ts to 28 Nm (21 ft. l bs.).
(3) I nstal l the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - I NSTALLATI ON)
Fig. 4 EXTERIOR HANDLE
1 - EXTERIOR HANDLE
2 - NUTS
3 - SCREWS
Fig. 5 GLASS RUN CHANNEL
1 - WINDOW OPENING
2 - REAR BOLTS (2)
3 - GLASS RUN CHANNEL
4 - FRONT BOLTS (2)
LATCH
REMOVAL
(2) Di sconnect the exteri or handl e rod at the han-
dl e.
(3) Di sconnect the l ock and l ock cyl i nder rods at
the l atch.
(4) Remove the screws and remove the l atch
assembl y. (Fi g. 6)
(5) Di sconnect the el ectri cal connectors.
INSTALLATION
(1) Connect the l atch el ectri cal connectors.
(2) I nstal l the l atch assembl y i nto the door and
i nstal l the screws.
(3) Ti ghten the l atch screws to 11 Nm (95 i n. l bs.).
(4) Connect the l ock cyl i nder and l ock actuator
rods at the l atch.
(5) Connect the exteri or handl e actuator rod at the
handl e.
(6) Adjust the l atch as needed. (Refer to 23 -
BODY/DOOR - FRONT/LATCH - ADJUSTMENTS)
ADJ USTMENTS
ADJUSTMENT
(1) Locate access hol e and remove the myl ar tape
coveri ng i t. (Fi g. 7)
(2) I nsert a 5/32-i nch hex-wrench through hol e and
i nto adjustment screw. Loosen screw.
(3) Operate outsi de handl e several ti mes to rel ease
any restri cti on because of mi s-al i gnment.
(4) Ti ghten adjustment screw to 3 Nm (30 i n.
l bs.).
(5) Test handl e and l ock cyl i nder for proper opera-
ti on.
LATCH STRIKER
REMOVAL
(1) Remove the bol ts. (Fi g. 8)
(2) Remove the l atch stri ker and the spacer, i f
equi pped.
INSTALLATION
(1) I nstal l the stri ker and spacer, i f equi pped.
l bs.).
SPECI FI CATI ONS)
Fig. 6 LATCH
1 - LOCK ACTUATOR ROD
2 - PLASTIC COVER
3 - LATCH ASSEMBLY
4 - DOOR
5 - SCREWS
Fig. 7 LATCH ADJUSTMENT SCREW
1 - DOOR LATCH
2 - MYLAR TAPE
3 - ADJUSTMENT SCREW
LOCK CYLINDER
REMOVAL
(1) Remove the exteri or handl e. (Refer to 23 -
BODY/DOOR - FRONT/EXTERI OR HANDLE -
REMOVAL)
(2) Remove the cl i p and remove the l ock cyl i nder
l ever and swi tch, i f equi pped.
(3) Remove the screw and remove the l ock cyl i n-
der. (Fi g. 9)
INSTALLATION
(1) I nstal l the l ock cyl i nder and i nstal l the retai n-
i ng screw.
(2) I nstal l the l ock cyl i nder swi tch, i f equi pped,
l ever and retai ni ng cl i p.
(3) I nstal l the exteri or handl e. (Refer to 23 -
BODY/DOOR - FRONT/EXTERI OR HANDLE -
I NSTALLATI ON)
TRIM PANEL
REMOVAL
(1) Remove the i nsi de handl e screw pl ug and
remove the screw. (Fi g. 10)
(2) Remove the pul l handl e screw.
(3) Usi ng a tri m sti ck C-4755 or equi val ent, di sen-
gage the tri m panel cl i ps and remove the tri m panel .
(4) Di sconnect the el ectri cal connectors and the
i nsi de handl e actuator rod. (Fi g. 11)
Fig. 8 LATCH STRIKER
1 - B-PILLAR
2 - SPACER
3 - STRIKER
4 - BOLTS (2)
Fig. 9 LOCK CYLINDER
1 - SCREW
2 - LOCK CYLINDER ASSEMBLY
3 - EXTERIOR HANDLE
Fig. 10 TRIM PANEL
1 - ALIGNMENT PIN HOLES
2 - LATCH ACTUATOR ROD
3 - SCREWS (2)
4 - TRIM PANEL CLIPS
5 - INSIDE HANDLE SCREW PLUG
LATCH STRIKER (Continued)
INSTALLATION
(1) Connect the i nsi de handl e actuator rod and the
el ectri cal connectors.
(2) Posi ti on the tri m panel and seat the cl i ps ful l y.
(3) I nstal the screws and i nstal l the screw pl ug.
WATERDAM
REMOVAL
(1) Remove the tri m panel . (Refer to 23 - BODY/
DOOR - FRONT/TRI M PANEL - REMOVAL)
(2) Remove the door speaker.
(3) Peal waterdam away from i nner door panel
and off of the l atch l i nkages (Fi g. 12).
INSTALLATION
(1) Posi ti on the wi re harness and actuator rods
through the hol es i n the waterdam.
(2) Pl ace waterdam onto the door.
(3) I nstal l the tri m panel . (Refer to 23 - BODY/
DOOR - FRONT/TRI M PANEL - I NSTALLATI ON)
WINDOW REGULATOR -
MANUAL
REMOVAL
(2) Loosen the bol ts. (Fi g. 13)
(3) Di sconnect the runout tube cl i p and remove the
regul ator.
INSTALLATION
(1) I nstal l the regul ator assembl y.
(2) Ti ghten the bol ts to 9 Nm (80 i n. l bs.) usi ng
the sequence shown. (Fi g. 14)
DOOR - FRONT/DOOR GLASS - I NSTALLATI ON)
WINDOW REGULATOR -
ELECTRIC
REMOVAL
(2) Loosen the bol ts. (Fi g. 15)
(3) Di sconnect the runout tube cl i p.
(4) Di sconnect the el ectri cal connector and remove
the regul ator.
INSTALLATION
Fig. 11 TRIM PANEL CONNECTIONS
2 - ALIGNMENT PINS
4 - TRIM PANEL
Fig. 12 FRONT DOOR WATERDAM
1 - DOOR
2 - LOCK ACTUATOR ROD
3 - INSIDE HANDLE ACTUATOR ROD AND HOLE
TRIM PANEL (Continued)
(4) Connect the runout tube cl i p.
(5) I nstal l the gl ass. (Refer to 23 - BODY/DOOR -
FRONT/DOOR GLASS - I NSTALLATI ON)
Fig. 13 FRONT DOOR REGULATOR - MANUAL
1 - BOLTS
2 - BOLTS
3 - RUNOUT TUBE
4 - RUNOUT TUBE CLIP
5 - BOLTS
Fig. 14 REGULATOR TIGHTENING SEQUENCE
Fig. 15 WINDOW REGULATOR - ELECTRIC
1 - BOLTS (3)
2 - BOLT
3 - BOLT
5 - BOLTS (2)
6 - REGULATOR ASSEMBLY
WINDOW REGULATOR - ELECTRIC (Continued)
DOORS - REAR
TABLE OF CONTENTS
page page
CHECK STRAP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 128
DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 129
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 129
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 130
GLASS RUN CHANNEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 130
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 131
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 131
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 131
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 132
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 132
WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 133
WINDOW REGULATOR - MANUAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 133
WINDOW REGULATOR - ELECTRIC
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 134
CHECK STRAP
REMOVAL
DOORS - REAR/WATERDAM - REMOVAL)
(2) Remove screws attachi ng door check to b-pi l l ar.
(3) Remove the two nuts and remove the door
check strap. (Fi g. 1)
INSTALLATION
NOTE: Make sure the proper orientation of the
check strap is maintained using the R and L on
the top.
(1) I nstal l the check strap through the speaker
hol e.
l bs.).
(3) Connect the strap to the b-pi l l ar and ti ghten
the bol ts to 12 Nm (9 ft. l bs.).
DOORS - REAR/WATERDAM - I NSTALLATI ON)
Fig. 1 CHECK STRAP
1 - NUTS
2 - CHECK STRAP
3 - SPEAKER OPENING
23 - 128 DOORS - REAR KJ
DOOR
REMOVAL
(1) Di sconnect the door wi re harness el ectri cal con-
nector at the b-pi l l ar.
(2) Di sconnect the check strap from the b-pi l l ar.
(Refer to 23 - BODY/DOORS - REAR/CHECK STRAP
- REMOVAL)
(3) Support the door wi th a sui tabl e l i fti ng devi ce.
NOTE: The epoxy washers should not be removed
from the hinge. If the washers are removed the door
may have to be re-adjusted.
(4) Remove the nuts attachi ng the door hi nges to
the door. (Fi g. 2)
INSTALLATION
(1) Support the door wi th a sui tabl e l i fti ng devi ce
and i nstal l the door onto the b-pi l l ar.
(2) I nstal l the nuts, washers and ti ghten to 23
Nm (17 ft. l bs.).
(3) Connect the door wi re harness el ectri cal con-
nector.
(4) Connect the check strap to the b-pi l l ar. (Refer
to 23 - BODY/DOORS - REAR/CHECK STRAP -
I NSTALLATI ON)
SPECI FI CATI ONS)
DOOR GLASS
REMOVAL
(2) Rai se the gl ass and l i ne up the l i ft pl ate cl i p
wi th the hol e i n the door panel shown. (Fi g. 3)
(3) Usi ng a l ong fl at bl ade or hook type tool , di s-
engage the cl i p attachi ng gl ass retai ner to regul ator
l i ft pl ate.
(4) Di sconnect the gl ass from the regul ator l i ft
pl ate and re-i nstal l the cl i p.
(5) Posi ti on the gl ass i nto the bottom of the door.
(6) Remove the gl ass di vi si on bar bol t. (Fi g. 4)
(7) Twi st the di vi si on bar towards the i nsi de of the
door and di sengage the door gl ass.
(8) Remove the gl ass from the wi ndow openi ng.
INSTALLATION
(1) I nstal l the gl ass through the wi ndow openi ng.
(2) Posi ti on the front of the gl ass i nto the gl ass
run channel .
Fig. 2 HINGES
1 - DOOR
2 - HINGES
3 - EPOXY WASHERS (2) (NOT REMOVABLE)
4 - NUTS
Fig. 3 DOOR GLASS POSITION
1 - GLASS DIVISION BAR
2 - DOOR PANEL SIGHT HOLE
3 - DOOR GLASS
KJ DOORS - REAR 23 - 129
(3) Twi st the gl ass di vi si on bar towards the i nsi de
of the door and posi ti on the door gl ass i nto the rear
run channel .
(4) Li ft gl ass up i n the wi ndow and engage the pi n
i nto the regul ator l i ft pl ate.
(5) Rai se the gl ass i nto the cl osed posi ti on and
i nstal l the di vi si on bar bol t.
(6) Ti ghten the bol t to 9 Nm (80 i n. l bs.).
EXTERIOR HANDLE
REMOVAL
(2) Di sconnect the actuator rod.
(3) Remove the nuts and remove the handl e. (Fi g.
5)
INSTALLATION
(1) I nstal l the handl e.
l bs.).
(3) Connect the actuator rod.
GLASS RUN CHANNEL
REMOVAL
DOORS - REAR/DOOR GLASS - REMOVAL)
BODY/WEATHERSTRI P/SEALS/REAR DOOR
(3) Remove the front and rear bol ts. (Fi g. 6)
(4) Peal the weatherstri p and quarter gl ass out of
the door frame and remove the run channel through
the wi ndow openi ng as an assembl y.
INSTALLATION
(1) I nstal l the run channel and quarter gl ass
assembl y through the wi ndow openi ng and i nto the
door frame.
(2) I nstal l the front, rear bol ts and ti ghten to 9
Nm (80 i n. l bs.).
BODY/WEATHERSTRI P/SEALS/REAR DOOR
DOORS - REAR/DOOR GLASS - I NSTALLATI ON)
Fig. 4 GLASS DIVISION BAR
1 - STATIONARY DOOR GLASS
2 - DIVISION BAR BOLT (1)
3 - DOOR
4 - GLASS DIVISION BAR
1 - NUTS (2)
2 - EXTERIOR HANDLE
DOOR GLASS (Continued)
HINGE
REMOVAL
(1) Remove the door. (Refer to 23 - BODY/DOORS
- REAR/DOOR - REMOVAL)
(2) Remove the upper b-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/B-PI LLAR UPPER TRI M -
REMOVAL)
(3) Remove the two door hi nge bol ts from the
i nsi de of the b-pi l l ar.
(4) Remove the exteri or bol ts attachi ng the door
hi nges to the b-pi l l ar.
INSTALLATION
(1) I nstal l the hi nges.
(2) I nstal l the exteri or bol ts and ti ghten to 28 Nm
(21 ft. l bs.).
(3) I nstal l the two i nner hi nge bol ts and ti ghten to
28 Nm (21 ft. l bs.).
SPECI FI CATI ONS)
(5) I nstal l the upper b-pi l l ar tri m. (Refer to 23 -
I NSTALLATI ON)
(6) I nstal l the door. (Refer to 23 - BODY/DOORS -
REAR/DOOR - I NSTALLATI ON)
LATCH
REMOVAL
(2) Di sconnect the actuator rods.
(3) Remove the screws and remove the l atch
(4) Di sconnect the el ectri cal connectors.
INSTALLATION
(1) Connect the l atch el ectri cal connectors.
(2) I nstal l the l atch assembl y i nto the door and
(3) Ti ghten the l atch screws to 11 Nm (95 i n. l bs.).
(4) Connect the actuator rods.
(6) Adjust the l atch as needed. (Refer to 23 -
BODY/DOORS - REAR/LATCH - ADJUSTMENTS)
ADJ USTMENTS
ADJUSTMENT
(1) Locate access hol e and remove the myl ar tape
coveri ng i t. (Fi g. 8)
(2) I nsert a 5/32-i nch hex-wrench through hol e and
i nto adjustment screw. Loosen screw.
(3) Operate outsi de handl e several ti mes to rel ease
any restri cti on because of mi s-al i gnment.
(4) Ti ghten adjustment screw to 3 Nm (30 i n.
l bs.).
(5) Test handl e and l ock cyl i nder for proper opera-
ti on.
Fig. 6 GLASS RUN CHANNEL
1 - BOLTS (3)
2 - QUARTER GLASS
3 - GLASS RUN CHANNEL ASSEMBLY
Fig. 7 LATCH
1 - LATCH
2 - SCREWS (4)
GLASS RUN CHANNEL (Continued)
LATCH STRIKER
REMOVAL
(2) Remove the l atch stri ker and the spacer, i f
equi pped.
INSTALLATION
(1) I nstal l the stri ker and spacer.
l bs.).
SPECI FI CATI ONS)
TRIM PANEL
REMOVAL
(1) Remove the i nsi de handl e screw pl ug and
remove the screw. (Fi g. 10)
(2) Remove the pul l handl e screw.
gage the tri m panel cl i ps and remove the tri m panel .
(4) Di sconnect the el ectri cal connectors and the
i nsi de handl e actuator rod. (Fi g. 11)
INSTALLATION
(1) Connect the i nsi de handl e actuator rod and the
el ectri cal connectors.
(2) Posi ti on the tri m panel and seat the cl i ps ful l y.
(3) I nstal the screws and i nstal l the screw pl ug.
Fig. 8 LATCH ADJUSTMENT SCREW
1 - DOOR LATCH
2 - MYLAR TAPE
3 - ADJUSTMENT SCREW
Fig. 9 LATCH STRIKER
1 - C-PILLAR
2 - SPACER
3 - STRIKER
4 - SCREWS
Fig. 10 A REAR TRIM PANEL
1 - WATERDAM
2 - TRIM PANEL CLIP HOLES
3 - INTERIOR HANDLE AND ACTUATOR ROD
4 - SCREWS (2)
5 - TRIM PANEL CLIPS
6 - INTERIOR HANDLE SCREW PLUG
LATCH (Continued)
WATERDAM
REMOVAL
DOORS - REAR/TRI M PANEL - REMOVAL)
(2) Remove the door speaker.
(3) Peal waterdam away from i nner door panel
and off of the l atch l i nkages (Fi g. 12).
INSTALLATION
(1) Posi ti on the wi re harness and actuator rods
through the hol es i n the waterdam.
(2) Pl ace waterdam onto the door.
DOORS - REAR/TRI M PANEL - I NSTALLATI ON)
WINDOW REGULATOR -
MANUAL
REMOVAL
regul ator.
INSTALLATION
(1) Loosel y i nstal l the bol ts onto the regul ator
assembl y.
Fig. 11 A REAR DOOR TRIM PANEL CONNECTIONS
1 - TRIM PANEL
2 - INTERIOR LATCH HANDLE
Fig. 12 REAR DOOR WATERDAM
1 - WATERDAM
2 - LOCK ACTUATOR RODS
3 - LOCK ACTUATOR ROD AND HOLES
4 - DOOR
5 - INSIDE HANDLE ACTUATOR ROD AND HOLES
Fig. 13 WINDOW REGULATOR - MANUAL
2 - BOLTS (2)
3 - BOLTS (2)
4 - BOLT (1)
TRIM PANEL (Continued)
(3) I nstal l the runout tube cl i p.
WINDOW REGULATOR -
ELECTRIC
REMOVAL
regul ator.
(4) Di sconnect the el ectri cal connector.
INSTALLATION
(2) Loosel y i nstal l the bol ts onto the regul ator
assembl y.
(5) I nstal l the gl ass. (Refer to 23 - BODY/DOORS -
REAR/GLASS RUN CHANNEL - I NSTALLATI ON)
Fig. 14 REGULATOR TIGHTEN SEQUENCE
Fig. 15 WINDOW REGULATOR - REAR
1 - REGULATOR ASSEMBLY
2 - BOLTS (2)
3 - BOLTS (2)
5 - BOLT
WINDOW REGULATOR - MANUAL (Continued)
SWING GATE
TABLE OF CONTENTS
page page
CHECK STRAP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 135
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 136
FLIP-UP GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 136
FLIP-UP GLASS LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 136
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138
SWING GATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138
LATCH - ACCESS PANEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 139
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 139
FLIP-UP GLASS SUPPORT CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 139
CHECK STRAP
REMOVAL
(1) Remove the swi ng gate tri m panel . (Refer to 23
- BODY/SWI NG GATE/TRI M PANEL - REMOVAL)
(2) Remove the quarter tri m panel . (Refer to 23 -
BODY/I NTERI OR/QUARTER TRI M PANEL -
REMOVAL)
(3) Remove the bol ts attachi ng the check strap to
the d-pi l l ar. (Fi g. 1)
(4) Peel back the waterdam.
(5) Remove the nuts and remove the check strap
from the swi ng gate.
INSTALLATION
(1) I nstal l the check strap.
l bs.).
(3) Reposi ti on the waterdam.
SWI NG GATE/TRI M PANEL - I NSTALLATI ON)
(5) I nstal l the bol ts attachi ng the check strap to
the d-pi l l ar and ti ghten to 11 Nm (8 ft. l bs.).
(6) I nstal l the quarter tri m panel . (Refer to 23 -
I NSTALLATI ON)
Fig. 1 CHECK STRAP
1 - CHECK STRAP
2 - NUTS (2)
3 - BOLTS (2)
4 - D-PILLAR
KJ SWING GATE 23 - 135
EXTERIOR HANDLE
REMOVAL
(1) Remove the tri m panel and waterdam. (Refer
to 23 - BODY/SWI NG GATE/TRI M PANEL -
REMOVAL)
(2) Di sconnect the l ock swi tch and fl i p-up gl ass
rel ease el ectri cal connectors.
(3) Uncl i p the threaded cl i ps and di sconnect the
actuator rods. (Fi g. 2)
(4) Remove the screws.
(5) Remove the nuts and remove the handl e.
INSTALLATION
(1) I nstal l the handl e and hol d ti ghtl y agai nst the
gate and support bracket.
l bs.).
(3) I nstal l the screws.
(4) Connect the actuator rods and el ectri cal con-
nectors.
(5) I nstal l the tri m panel and waterdam. (Refer to
23 - BODY/SWI NG GATE/TRI M PANEL - I NSTAL-
LATI ON)
FLIP-UP GLASS
REMOVAL
(1) Open the fl i p-up gl ass and di sconnect the el ec-
tri cal connectors.
(2) Remove the support cyl i nders. (Refer to 23 -
BODY/SWI NG GATE/FLI P-UP GLASS SUPPORT
CYLI NDER - REMOVAL)
(3) Open the gl ass to the ful l travel wi th the sup-
port cyl i nders off.
(4) Remove the bol ts and remove the gl ass. (Fi g. 3)
INSTALLATION
(1) I nstal l the fl i p-up gl ass and i nstal l the hi nge
bol ts.
(2) I nstal l the support cyl i nders. (Refer to 23 -
BODY/SWI NG GATE/FLI P-UP GLASS SUPPORT
CYLI NDER - I NSTALLATI ON)
(4) Adjust fl i p-up gl ass fi t i f necessary and ti ghten
the hi nge bol ts to 7 Nm (60 i n. l bs.). (Refer to 23 -
SPECI FI CATI ONS)
FLIP-UP GLASS LATCH
REMOVAL
SWI NG GATE/TRI M PANEL - REMOVAL)
(2) Di sconnect the el ectri cal connectors. (Fi g. 4)
(3) Usi ng a tri m sti ck C-4755 or equi val ent, mark
the l ocati on of the l atch assembl y for i nstal l ati on.
(4) Remove the nuts and remove the l atch assem-
bl y.
INSTALLATION
(1) I nstal l the l atch assembl y.
1 - LOCK CYLINDER SCREW
2 - LATCH ACTUATOR ROD CONNECTOR
3 - EXTERIOR HANDLE
4 - NUTS (2)
5 - SCREWS (2)
Fig. 3 FLIP-UP GLASS
1 - BOLTS (4)
2 - HINGE MOUNTING HOLES
3 - DEFROSTER WIRE HARNESS
4 - DEFROSTER ELECTRICAL CONNECTOR
5 - FLIPPER GLASS
23 - 136 SWING GATE KJ
l bs.).
SWI NG GATE/TRI M PANEL - I NSTALLATI ON)
(5) Adjust the l atch to achi eve the best gl ass fi t.
(Refer to 23 - BODY/BODY STRUCTURE/GAP AND
FLUSH - SPECI FI CATI ONS)
HINGE
REMOVAL
(1) Remove the swi ng gate. (Refer to 23 - BODY/
SWI NG GATE/SWI NG GATE - REMOVAL)
(2) Remove the bol ts and remove the hi nges.
INSTALLATION
(1) I nstal l the hi nges.
l bs.).
(3) I nstal l the swi ng gate. (Refer to 23 - BODY/
SWI NG GATE/ SWI NG GATE - I NSTALLATI ON)
LATCH
REMOVAL
(1) Remove the tri m panel and waterdam. (Refer
to 23 - BODY/SWI NG GATE/TRI M PANEL -
REMOVAL)
(2) Di sconnect the el ectri cal connector and actua-
tor rod at the threaded cl i p. (Fi g. 5)
(3) Remove the screws and remove the l atch.
INSTALLATION
(1) Connect the el ectri cal connector and i nstal l the
l atch.
(2) I nstal l the screws and ti ghten to 11 Nm (8 ft.
l bs.).
(3) Connect the actuator rod.
(4) I nstal l the tri m panel and waterdam. (Refer to
23 - BODY/SWI NG GATE/TRI M PANEL - I NSTAL-
LATI ON)
LATCH STRIKER
REMOVAL
(1) Open the gate and remove the screws attachi ng
the stri ker to the d-pi l l ar.
INSTALLATION
(1) I nstal l the stri ker and i nstal l the nuts.
(2) Ti ghten the nuts to 28 Nm (21 ft. l bs.).
(3) Adjust the swi ng gate as necessary. (Refer to
23 - BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECI FI CATI ONS)
LOCK CYLINDER
REMOVAL
(1) Remove the exteri or handl e. (Refer to 23 -
BODY/SWI NG GATE/EXTERI OR HANDLE -
REMOVAL)
Fig. 4 FLIP-UP GLASS LATCH
1 - NUTS (2)
3 - SWING GATE
5 - FLIP-UP GLASS LATCH
Fig. 5 LATCH
1 - SWING GATE
2 - LATCH ASSEMBLY
4 - SCREWS
FLIP-UP GLASS LATCH (Continued)
(2) Remove the cl i p and remove the l ock cyl i nder
swi tch.
(3) Remove the screw and remove the l ock cyl i n-
der. (Fi g. 6)
INSTALLATION
(1) I nstal l the l ock cyl i nder.
(2) I nstal l the screw and ti ghten to 6 Nm (50 i n.
l bs.).
(3) I nstal l the l ock cyl i nder swi tch and retai ni ng
cl i p.
(4) I nstal l the exteri or handl e. (Refer to 23 -
BODY/SWI NG GATE/EXTERI OR HANDLE -
I NSTALLATI ON)
SWING GATE
REMOVAL
(1) Remove the spare ti re. (Refer to 22 - TI RES/
WHEELS/TI RES/SPARE TI RE - REMOVAL)
REMOVAL)
(3) Support the swi ng gate wi th a sui tabl e l i fti ng
devi ce.
(4) Di sconnect the wi re harness.
(5) Di sconnect the check strap from the d-pi l l ar.
(Refer to 23 - BODY/SWI NG GATE/CHECK STRAP -
REMOVAL)
(6) Remove the bol ts and remove the swi ng gate.
INSTALLATION
(1) I nstal l the swi ng gate and i nstal l the bol ts.
(3) Adjust the swi ng gate as needed addi ng 4 mm
on the ri ght si de to compensate for sag after the
spare ti re i s i nstal l ed. (Refer to 23 - BODY/BODY
STRUCTURE/GAP AND FLUSH - SPECI FI CA-
TI ONS)
(4) Connect the wi re harness el ectri cal connector.
(5) Connect the check strap. (Refer to 23 - BODY/
SWI NG GATE/CHECK STRAP - I NSTALLATI ON)
I NSTALLATI ON)
(7) I nstal l the spare ti re. (Refer to 22 - TI RES/
WHEELS/TI RES/SPARE TI RE - I NSTALLATI ON)
TRIM PANEL
REMOVAL
(1) Usi ng a tri m sti ck C-4755 or equi val ent,
rel ease the push pi n fasteners. (Fi g. 7)
(2) Li ft tri m panel up off of the upper tri m panel
cl i ps
INSTALLATION
(1) Posi ti on the tri m panel and seat the upper
cl i ps.
(2) Ful l y seat the l ower tri m panel cl i ps
Fig. 6 LOCK CYLINDER
1 - SCREW
2 - LOCK CYLINDER
3 - EXTERIOR HANDLE
Fig. 7 SWING GATE TRIM PANEL
1 - TRIM PANEL
2 - UPPER TRIM PANEL CLIPS
3 - UPPER TRIM CLIP HOLES
4 - TRIM PANEL LOCATOR HOLES
5 - SWING GATE LOCATOR PINS
6 - PUSH IN FASTENERS
23 - 138 SWING GATE KJ
LOCK CYLINDER (Continued)
LATCH - ACCESS PANEL
DESCRIPTION
Thi s panel provi des access to the gate l atch i f gate
power fai l s. The gate can be unl ocked by reachi ng i n
and pushi ng the l ock l ever down.
REMOVAL
remove the access panel .
INSTALLATION
(1) Posi ti on and i nstal l the access panel .
FLIP-UP GLASS SUPPORT
CYLINDER
REMOVAL
(1) Open the fl i p-up gl ass and support.
(2) Rel ease the upper and l ower cl i ps.
(3) Remove the support cyl i nder.
INSTALLATION
(1) I nstal l the support cyl i nder over the bal l studs
wi th the thi n end connected to the gl ass.
(2) I nstal l the retai ni ng cl i ps and remove the sup-
port from the fl i p-up gl ass.
EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 140
COWL GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 140
EXTERIOR NAME PLATES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 141
FRONT FENDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 141
FUEL FILL DOOR/HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 141
GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 142
GRILLE OPENING REINFORCEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 142
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 143
LUGGAGE RACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 144
REAR WHEELHOUSE SPLASH SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 144
SIDE VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 145
FRONT WHEEL OPENING FLARE MOLDINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 145
REAR WHEEL OPENING FLARE MOLDINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 145
RADIATOR CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 146
BODY SIDE MOLDINGS
REMOVAL
remove and di scard the mol di ng from the outsi de of
the door.
INSTALLATION
(1) Thoroughl y cl ean al l resi due from the body si de
mol di ng attachment area of the door.
(2) Wi pe area cl ean wi th a 50% sol uti on of water
and al cohol and wi pe dry.
(3) Appl y new body si de mol di ng usi ng the l ocators
i n the door and appl y pressure of approxi matel y 40
p.s.i . over the enti re surface of the mol di ng.
COWL GRILLE
REMOVAL
(1) Remove the hood seal .
(2) Remove the wi per arms. (Refer to 8 - ELEC-
TRI CAL/WI PERS/WASHERS/WI PER ARMS -
REMOVAL)
(3) Remove the four pl asti c retai ners and remove
the cowl gri l l .
INSTALLATION
(1) Posi ti on the cowl gri l l and engage the ni ne
cl i ps to the bottom of the wi ndshi el d.
(2) I nstal l the fi ve pl asti c retai ners.
(3) I nstal l the wi per arms. (Refer to 8 - ELECTRI -
CAL/WI PERS/WASHERS/WI PER ARMS - I NSTAL-
LATI ON)
(4) I nstal l the hood seal .
EXTERIOR NAME PLATES
REMOVAL
NOTE: Exterior nameplates are attached to body
panels with adhesive tape.
(1) Appl y a l ength of maski ng tape on the body,
paral l el to the top edge of the namepl ate to use as a
gui de, i f necessary.
(2) I f temperature i s bel ow 21C (70F) warm
embl em wi th a heat l amp or gun. Do not exceed 52C
(120F) when heati ng embl em.
(3) Usi ng a tri m sti ck C-4755 or equi val ent, behi nd
the embl em to separate the adhesi ve backi ng from
the body.
23 - 140 EXTERIOR KJ
(4) Cl ean adhesi ve resi due from body wi th MOPAR
Super Cl ean sol vent or equi val ent.
INSTALLATION
(1) Remove protecti ve cover from adhesi ve tape on
back of embl em.
(2) Posi ti on embl em properl y on body.
(3) Press embl em fi rml y to body wi th pal m of
hand.
(4) I f temperature i s bel ow 21C (70F) warm
embl em wi th a heat l amp or gun to assure adhesi on.
Do not exceed 52C (120F) when heati ng embl em.
FRONT FENDER
REMOVAL
(1) Remove the wheel openi ng spl ash shi el d. (Refer
to 23 - BODY/EXTERI OR/FRONT WHEELHOUSE
SPLASH SHI ELD - REMOVAL)
(2) Remove the fasci a assembl y. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT FASCI A -
REMOVAL)
(3) Remove the fender support bracket bol ts. (Fi g.
1)
(4) Remove the bol ts and remove the fender. (Fi g.
2)
INSTALLATION
(1) I nstal l the fender assembl y and i nstal l the
bol ts
(2) I nstal l the fender support bracket and i nstal l
the bol ts.
(3) Al i gn the fender wi th adjacent body parts and
ti ghten the bol ts to 12 Nm (9 ft. l bs.). (Refer to 23 -
SPECI FI CATI ONS)
(4) I nstal l the fasci a assembl y. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT FASCI A -
I NSTALLATI ON)
(5) I nstal l the wheel house spl ash shi el d. (Refer to
23 - BODY/EXTERI OR/FRONT WHEELHOUSE
SPLASH SHI ELD - I NSTALLATI ON)
FUEL FILL DOOR/HOUSING
REMOVAL
(1) Remove the fuel cap.
(2) Remove the three screws connecti ng the fuel
door/housi ng to the fi l l er neck.
(3) Reach i n through the openi ng and depress the
tabs at the upper and bottom ri ght of the door/hous-
i ng. (Fi g. 3)
(4) Remove the fuel door/housi ng from the vehi cl e.
INSTALLATION
(1) Posi ti on the fuel fi l l er door/housi ng i nto the
vehi cl e and ful l y seat the tabs.
Fig. 1 FENDER SUPPORT BRACKET
1 - FENDER BOLTS (2)
2 - FENDER
3 - FENDER SUPPORT BRACKET
4 - SUPPORT BRACKET BOLTS (2)
5 - U-NUTS (2)
Fig. 2 FRONT FENDER
1 - HYDRAFORM
2 - U-NUTS
3 - BOLTS (3)
4 - FENDER
5 - BOLTS (2)
6 - BOLTS (2)
KJ EXTERIOR 23 - 141
EXTERIOR NAME PLATES (Continued)
(2) I nstal l the three screws.
(3) I nstal l the fuel cap.
GRILLE
REMOVAL
(1) Remove the upper screws. (Fi g. 4)
(2) Rol l the gri l l e forward and di sengage the two
gri l l e hooks under the headl amp uni ts.
(3) Li ft the gri l l e forward and up off of the l ocati on
tabs at the bottom and remove.
INSTALLATION
(1) I nstal l the gri l l e onto the l ocati ng tabs at the
bottom.
(2) Push the gri l l e back and snap i nto the hooks i n
the gri l l e openi ng rei nforcement.
(3) Check that the bl ack wel ts at the outboard
ends of the gri l l e have a uni form appearance rel ati ve
to the fender and i nstal l the screws.
GRILLE OPENING
REINFORCEMENT
REMOVAL
(2) Remove the front fasci a. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT FASCI A -
REMOVAL)
(3) Di sconnect the el ectri cal connectors. (Fi g. 5)
(4) Di sconnect the rubber si de fl ap push pi n con-
nectors.
(5) Remove the seven bol ts and remove the gri l l e
(6) Di sconnect the headl amp uni ts el ectri cal con-
nectors.
(7) Remove the headl amp uni ts. (Refer to 8 -
HEADLAMP UNI T - REMOVAL)
INSTALLATION
(1) I nstal l the headl amp uni ts. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/HEAD-
LAMP UNI T - I NSTALLATI ON)
(2) Connect the headl amp uni t el ectri cal connec-
tors.
(3) I nstal l the gri l l e openi ng rei nforcement and
i nstal l the seven bol ts.
(4) Connect the rubber si de fl ap and i nstal l the
push pi n connectors.
(5) Connect the el ectri cal connectors. (Fi g. 5)
(6) I nstal l the front fasci a. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT FASCI A - I NSTAL-
LATI ON)
Fig. 3 FUEL FILL DOOR/HOUSING
1 - FUEL FILL DOOR
2 - HOUSING TABS
Fig. 4 GRILLE
1 - GRILLE OPENING REINFORCEMENT
2 - SCREWS (4)
3 - GRILLE CLIPS
FUEL FILL DOOR/HOUSING (Continued)
FRONT WHEELHOUSE
SPLASH SHIELD
REMOVAL
(1) Remove the wheel fl are mol di ng. (Refer to 23 -
BODY/EXTERI OR/FRONT WHEEL OPENI NG
FLARE MOLDI NG - REMOVAL)
(2) Remove the fi ve push pi n fasteners and remove
the spl ash shi el d. (Fi g. 6)
INSTALLATION
(1) I nstal l the spl ash shi el d and i nstal l the fi ve
push pi n fasteners.
(2) I nstal l the wheel fl are mol di ng. (Refer to 23 -
BODY/EXTERI OR/FRONT WHEEL OPENI NG
Fig. 5 GRILLE OPENING REINFORCEMENT
1 - GRILLE OPENING REINFORCEMENT
2 - BOLTS (3)
5 - BOLTS (3)
6 - BOLT (1)
Fig. 6 FRONT WHEELHOUSE SPLASH SHIELD
1 - FENDER
2 - FLARE BRACKET
3 - PUSH PIN FASTENERS (5)
4 - SPLASH SHIELD
5 - FLARE BRACKET
GRILLE OPENING REINFORCEMENT (Continued)
LUGGAGE RACK
REMOVAL
remove the roof rack covers. (Fi g. 8)
(2) Remove the bol ts and remove the roof rack.
(Fi g. 7)
INSTALLATION
(1) I nstal l the roof rack and i nstal l the bol ts.
(2) Ti ghten the bol ts to 8 Nm (75 i n. l bs.).
(3) Snap on the roof rack covers.
REAR WHEELHOUSE SPLASH
SHIELD
REMOVAL
(1) Remove the wheel fl are mol di ngs. (Refer to 23 -
FLARE MOLDI NG - REMOVAL)
(2) Remove the three push pi n fasteners and
remove the spl ash shi el d. (Fi g. 9)
INSTALLATION
(1) I nstal l the spl ash shi el d and i nstal l the three
push pi n fasteners.
(2) I nstal l the wheel fl are mol di ngs. (Refer to 23 -
Fig. 7 LUGGAGE RACK
1 - BOLTS (4)
2 - RACK RAIL
Fig. 8 RACK COVERS
1 - COVER
2 - BOLTS
3 - ROOF PANEL
4 - KNURLED NUT
5 - ROOF RACK
Fig. 9 WHEELHOUSE SPLASH SHIELD
1 - SPLASH SHIELD
2 - PUSH PIN FASTENERS (3)
SIDE VIEW MIRROR
REMOVAL
DOOR - FRONT/TRI M PANEL - REMOVAL)
(2) Di sconnect the el ectri cal connector. (Fi g. 10)
(3) Remove the three nuts and remove the mi rror
assembl y.
INSTALLATION
(1) I nstal l the mi rror assembl y.
(2) I nstal l the three nuts and ti ghten to 7 Nm (65
i n. l bs.).
DOOR - FRONT/TRI M PANEL - I NSTALLATI ON)
FRONT WHEEL OPENING
FLARE MOLDINGS
REMOVAL
(1) Remove the 10 ri vets connecti ng the fl are to
the spl ash shi el d, fl are brackets, fasci a and ai r dam.
(Fi g. 11)
(2) Usi ng a tri m sti ck C-4755 or equi val ent, sepa-
rate the cl i ps attachi ng the mol di ng to the fasci a and
fender.
(3) Remove the fl are mol di ng.
INSTALLATION
(1) Posi ti on fl are mol di ng and seat cl i ps i nto the
fasci a.
(2) Seat the remai ni ng cl i ps i nto the fender.
(3) I nstal l ten new ri vets securi ng the fl are mol d-
i ng to the spl ash shi el d, fl are brackets, fasci a and ai r
dam.
MOLDINGS
REMOVAL
(1) Open the rear door and remove the fi ve ri vets
from the i nsi de surface of the door. (Fi g. 12)
rate the cl i ps attachi ng the mol di ng to the door and
remove the mol di ng.
(3) Remove the 5 ri vets from the rear fl are and
spl ash shi el d.
rate the cl i ps attachi ng the mol di ng to the body and
the rear fasci a and remove the mol di ng.
(5) Remove the two ri vets and remove the fl are
extensi on. (Fi g. 13)
INSTALLATION
(1) I nstal l the fl are extensi on and i nstal l two new
ri vets.
(2) Posi ti on the rear fl are mol di ng and seat the
cl i ps attachi ng i t to the body and the rear fasci a.
(3) I nstal l fi ve new ri vets attachi ng the fl are to the
spl ash shi el d.
Fig. 10 SIDE VIEW MIRROR
1 - MIRROR ASSEMBLY
2 - NUTS (3)
Fig. 11 FRONT WHEEL OPENING FLARE MOLDING
1 - FLARE MOLDING
2 - RIVETS (10)
(4) Posi ti on the door fl are and seat the cl i ps.
(5) I nstal l fi ve new ri vets through the i nsi de sur-
face of the door attachi ng the fl are to the door.
RADIATOR CROSSMEMBER
REMOVAL
(2) Remove the hood l atch. (Refer to 23 - BODY/
HOOD/LATCH - REMOVAL)
(3) Remove the bol t securi ng the washer bottl e to
the crossmember.
(4) Remove the bol ts and remove the hood l atch
support. (Fi g. 14)
(5) Remove the bol ts and remove the crossmember.
INSTALLATION
(1) I nstal l the crossmember and i nstal l the bol ts.
(3) I nstal l the hood l atch support and i nstal l the
bol ts.
(5) I nstal l the hood l atch. (Refer to 23 - BODY/
HOOD/LATCH - I NSTALLATI ON)
(7) I nstal l the bol t securi ng the washer bottl e to
the crossmember and ti ghten to 10 Nm (85 i n. l bs.).
Fig. 12 REAR WHEEL OPENING FLARE MOLDINGS
1 - D-PILLAR
2 - RIVETS (10)
3 - REAR DOOR FLARE MOLDING
4 - REAR FLARE MOLDING
5 - REAR FASCIA
Fig. 13 FLARE EXTENSION
1 - RIVETS (3)
2 - FLARE EXTENSION AND DOOR SILL
Fig. 14 RADIATOR CROSSMEMBER
1 - CROSSMEMBER
2 - BOLTS (2)
3 - BOLTS (4)
4 - BOLTS (2)
5 - HOOD LATCH SUPPORT
REAR WHEEL OPENING FLARE MOLDINGS (Continued)
INSTRUMENT PANEL
TABLE OF CONTENTS
page page
CLUSTER BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 147
GLOVE BOX
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 148
GLOVE BOX LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 148
GLOVE BOX LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 149
INSTRUMENT PANEL ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 151
INSTRUMENT PANEL TOP COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 153
INSTRUMENT PANEL END CAP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 153
INSTRUMENT PANEL DRIVER SIDE BEZELS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 154
INSTRUMENT PANEL CENTER BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 154
BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 154
KNEE BLOCKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 155
CLUSTER BEZEL
REMOVAL
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
(1) Remove the dri ves si de tri m bezel s. (Refer to
PANEL DRI VER SI DE BEZEL - REMOVAL)
(2) Remove the i nstrument panel top cover. (Refer
to 23 - BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL TOP COVER - REMOVAL)
(3) Remove the seven screws and remove the cl us-
ter bezel .
INSTALLATION
(1) I nstal l the cl uster bezel and the seven screws.
(2) I nstal l the i nstrument panel top cover. (Refer
PANEL TOP COVER - I NSTALLATI ON)
(3) I nstal l the dri ves si de tri m bezel s. (Refer to 23
- BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL DRI VER SI DE BEZEL - I NSTALLATI ON)
KJ INSTRUMENT PANEL 23 - 147
GLOVE BOX
REMOVAL
(1) Open the gl ove box.
(2) Squeeze the stop tabs l ocated on the si des of
the box and al l ow the box to open ful l y.
(3) Wi th box i n the ful l down posi ti on sl i de the box
to the ri ght off of the hi nges and remove.
INSTALLATION
(1) Posi ti on the box on and sl i de the box to the l eft
to engage the hi nges.
(2) Cl ose the gl ove box.
GLOVE BOX LATCH
REMOVAL
(1) Remove the gl ove box. (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - REMOVAL)
(2) Remove the ni ne screws and remove the gl ove
box ski n.
(3) Remove the l atch from the l ocators.
INSTALLATION
(1) Posi ti on the l atch onto the l ocators.
(2) I nstal l the gl ove box ski n onto the gl ove box
and i nstal l the ni ne screws.
(3) I nstal l the gl ove box. (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - I NSTALLA-
TI ON)
GLOVE BOX LATCH STRIKER
REMOVAL
23 - 148 INSTRUMENT PANEL KJ
(1) Open the gl ove box.
(2) Remove the two stri ker screws and remove the
l atch stri ker.
INSTALLATION
(1) I nstal l the stri ker and i nstal l the two screws.
(2) Loosen the screws to adjust i f necessary.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
INJURY.
cabl e.
(2) Remove the i nstrument panel top cover. (Refer
(3) Remove the speakers.
(4) Remove the fl oor consol e. (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - REMOVAL)
(5) Remove the radi o. (Refer to 8 - ELECTRI CAL/
AUDI O/RADI O - REMOVAL)
(6) Remove the four nuts and remove the center
support bracket. (Fi g. 6)
(7) Remove the steeri ng col umn. (Refer to 19 -
STEERI NG/COLUMN - REMOVAL)
(8) Remove the dri vers si de cowl tri m cover. (Refer
to 23 - BODY/I NTERI OR/COWL TRI M COVER -
REMOVAL)
(9) Di sconnect the wi re harness connector behi nd
the dri vers si de cowl tri m cover.
(10) Di sconnect the green and l i ght bl ue wi re har-
ness bul k connectors at the juncti on bl ock. (Fi g. 1)
(11) Di sconnect the el ectri cal connector at the
i nner si de of the pedal support bracket. (Fi g. 2)
(12) Remove the two bol ts at the front of the pedal
support bracket. (Fi g. 2)
(13) Remove the two bol ts from the bottom si de of
the pedal support bracket. (Fi g. 2)
Fig. 1 JUNCTION BLOCK CONNECTORS
3 - PEDAL SUPPORT BRACKET
4 - JUNCTION BLOCK
GLOVE BOX LATCH STRIKER (Continued)
(14) Remove the two rol l down bracket bol ts at the
l eft cowl si de panel . (Fi g. 6)
(15) Remove the ground strap bol t and di sconnect
the restrai nt modul e el ectri cal connector. (Fi g. 3)
(16) Remove the gl ove box. (Refer to 23 - BODY/
I NSTRUMENT PANEL/GLOVE BOX - REMOVAL)
(17) Remove the two HVAC mounti ng bol ts behi nd
the center tri m. (Fi g. 3)
(18) Remove the passenger si de tri m bezel . (Refer
to 23 - BODY/I NSTRUMENT PANEL/I P PASSEN-
GER SI DE BEZEL - REMOVAL)
(19) Remove the HVAC mounti ng bol t above the
gl ove box stri ker. (Fi g. 4)
(20) Remove the HVAC bol t at the l ower outsi de
corner of the gl ove box openi ng. (Fi g. 5)
(21) Remove the passenger si de cowl tri m cover.
(Refer to 23 - BODY/I NTERI OR/COWL TRI M
COVER - REMOVAL)
(22) Di sconnect the bl ower resi stor el ectri cal con-
nector. (Fi g. 5)
(23) Remove the two rol l down bracket bol ts at the
ri ght cowl si de panel .
Fig. 2 PEDAL SUPPORT BRACKET
1 - PEDAL SUPPORT BRACKET
2 - BOLTS
3 - BOLTS
Fig. 3 HVAC BOLTS
1 - RESTRAINT MODULE
2 - HVAC BOLTS
3 - RADIO WIRE HARNESS
Fig. 4 HVAC UPPER BOLT
1 - BOLT
2 - GLOVE BOX STRIKER
3 - HVAC UNIT
Fig. 5 HVAC CONNECTIONS
1 - GLOVE BOX STRIKER
2 - BLOWER RESISTOR
3 - VACUUM CHECK VALVE
4 - BOLT
INSTRUMENT PANEL ASSEMBLY (Continued)
(24) Di sconnect the vacuum check val ve and the
vacuum reservoi r. (Fi g. 5)
(25) Di sconnect the bl ower motor el ectri cal connec-
tor.
(26) Remove the four bol ts at the top of the i nstru-
ment panel connecti ng to the cowl front panel .
(27) Rol l the i nstrument panel rearward and
remove the wi re harness from routi ng channel i n the
rear.
(28) Di sconnect the push pi n fastener and posi ti on
asi de the radi o wi re harness. Note the l ocati on of the
harness for i nstal l ati on.
(29) Remove the i nstrument panel .
INSTALLATION
INJURY.
(1) Posi ti on the i nstrument panel i nto the vehi cl e.
(2) Posi ti on the wi re harness i nto the rear routi ng
channel and rol l the i nstrument panel back agai nst
the cowl .
(3) Posi ti on the radi o wi re harness and seat the
push pi n fastener.
NOTE: Position the speaker wires through the
speaker openings.
(4) I nstal l the four bol ts at the top of the i nstru-
ment panel connecti ng to the cowl front panel and
(5) Connect the bl ower motor el ectri cal connector.
(6) Connect the vacuum check val ve and the vac-
uum reservoi r.
(7) Connect the bl ower resi ster el ectri cal connector.
NOTE: Do not push or pull bracket. Tighten at the
rest position.
Fig. 6 INSTRUMENT PANEL ASSEMBLY
1 - TOP BOLTS (4)
2 - CENTER SUPPORT BRACKET
3 - NUTS (4)
4 - ROLL DOWN BOLTS (4)
5 - INSTRUMENT PANEL ASSEMBLY
(8) I nstal l the two rol l down bracket bol ts at the
ri ght cowl si de panel and ti ghten to 54 Nm (40 ft.
l bs.).
(9) I nstal l the HVAC mounti ng bol t at the l ower
outsi de corner of the gl ove box openi ng and ti ghten
to 6 Nm (55 i n. l bs.).
(10) I nstal l the HVAC mounti ng bol t above the
gl ove box stri ker.
(11) I nstal l the passenger si de tri m bezel . (Refer to
PANEL PASSENGER SI DE BEZEL - I NSTALLA-
TI ON)
(12) I nstal l the passenger si de cowl tri m cover.
(Refer to 23 - BODY/I NTERI OR/COWL TRI M
COVER - I NSTALLATI ON)
(13) I nstal l the gl ove box. (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - I NSTALLA-
TI ON)
NOTE: Do not push or pull bracket. Tighten at the
rest position.
(14) I nstal l the two rol l down bracket bol ts at the
dri vers cowl si de panel and ti ghten to 54 Nm (40 ft.
l bs.).
(15) I nstal l the two bol ts at the bottom si de of the
pedal support bracket.
(16) I nstal l the two bol ts at the front of the pedal
support bracket.
(17) Connect the el ectri cal connector at the i nner
si de of the pedal support bracket.
(18) Connect the wi ri ng harness el ectri cal connec-
tors at the juncti on bl ock.
(19) Connect the wi re harness el ectri cal connector
behi nd the dri vers si de cowl tri m cover.
(20) I nstal l the l eft cowl tri m cover. (Refer to 23 -
LATI ON)
(21) I nstal l the steeri ng col umn. (Refer to 19 -
STEERI NG/COLUMN - I NSTALLATI ON)
(22) I nstal l the two HVAC mounti ng bol ts behi nd
the center tri m.
(23) I nstal l the ground strap and bol t and connect
the restrai nt modul e el ectri cal connector.
(24) I nstal l the center support bracket and hol d i t
ti ght agai nst the i nstrument panel .
(25) Ti ghten the l ower nuts to 23 Nm (17 ft. l bs.).
(26) Ti ghten the upper bracket nuts to 23 Nm (17
ft. l bs.).
(27) I nstal l the radi o. (Refer to 8 - ELECTRI CAL/
AUDI O/RADI O - I NSTALLATI ON)
(28) I nstal l the fl oor consol e. (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - I NSTALLATI ON)
(29) I nstal l the speakers.
(30) I nstal l the i nstrument panel top cover. (Refer
(31) Reconnect the battery ground cabl e.
INSTRUMENT PANEL TOP
COVER
REMOVAL
(1) Remove the a-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M AND GRAB HANDLE -
REMOVAL)
rel ease the attachment cl i ps and remove the top
cover. (Fi g. 7)
Fig. 7 INSTRUMENT PANEL COVERS
1 - SIDE COVER
2 - INSTRUMENT PANEL ASSEMBLY
3 - TOP COVER
INSTALLATION
(1) Posi ti on the top cover and seat the cl i ps ful l y.
(2) I nstal l the a-pi l l ar tri m panel s. (Refer to 23 -
BODY/I NTERI OR/A-PI LLAR TRI M AND GRAB
HANDLE - I NSTALLATI ON)
INSTRUMENT PANEL END CAP
REMOVAL
(1) Open the door.
(2) Usi ng the fi nger i ndent, grasp and remove the
si de cover. (Fi g. 7)
INSTALLATION
(1) Posi ti on the si de panel s and seat the cl i ps ful l y.
INSTRUMENT PANEL DRIVER
SIDE BEZELS
REMOVAL
gage the bezel s on ei ther si de of the steeri ng col umn.
(Fi g. 8)
Fig. 8 INSTRUMENT PANEL TRIM BEZELS
2 - DRIVERS SIDE TRIM BEZELS
3 - CENTER TRIM BEZEL
4 - SCREW
5 - PASSENGER SIDE TRIM BEZEL
INSTRUMENT PANEL TOP COVER (Continued)
INSTALLATION
(1) Posi ti on the appropri ate di vers si de bezel s on
ei ther si de of the steeri ng col umn and seat the
attachment cl i ps.
INSTRUMENT PANEL CENTER
BEZEL
REMOVAL
(1) Remove the ashtray and remove the screw.
remove the center bezel from the i nstrument panel
(3) Di sconnect the el ectri cal and vacuum connec-
tors.
INSTALLATION
(1) Connect the el ectri cal and vacuum connectors.
(2) Posi ti on the center bezel and seat the retai ni ng
cl i ps starti ng wi th the l ower cl i ps fi rst.
(3) I nstal l the screw and i nstal l the ash tray.
INSTRUMENT PANEL
PASSENGER SIDE BEZEL
REMOVAL
(1) Remove the two screws.
rel ease the retai ni ng cl i ps and remove the passenger
si de bezel . (Fi g. 8)
INSTALLATION
INSTRUMENT PANEL DRIVER SIDE BEZELS (Continued)
(1) Posi ti on the passenger si de bezel and seat the
(2) I nstal l the two screws.
KNEE BLOCKER
REMOVAL
CAUTION: Do not pry the knee blocker off at the
cover. Failure to follow these instructions may
result in damage to the knee blocker.
(1) At the l abel l ocated on the l ower i nstrument
panel cross member, pl ace a tri m sti ck C-4755 or
equi val ent, approxi matel y 25 mm (1 i n.) up di rectl y
behi nd the l ower edge of the knee bl ocker.
(2) Rel ease the l ower cl i ps and pul l off the knee
bl ocker.
INSTALLATION
(1) Posi ti on the knee bl ocker al i gni ng attachment
cl i ps.
(2) Pressi ng cl ose to the attachment cl i ps, ful l y
seat the l ower and then the upper cl i ps.
INSTRUMENT PANEL PASSENGER SIDE BEZEL (Continued)
INTERIOR
TABLE OF CONTENTS
page page
4WD FLOOR SHIFT BOOT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 156
A-PILLAR TRIM AND GRAB HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 156
COWL TRIM COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 157
DOOR SILL SCUFF PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 157
ASSIST HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 157
B-PILLAR LOWER TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 157
B-PILLAR UPPER TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 158
CARPETS AND FLOOR MATS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 158
SHIFT BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 158
FLOOR CONSOLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 158
FLOOR CONSOLE LID LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 158
HEADLINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 159
QUARTER TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 159
REAR DOOR SCUFF PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 160
SUN VISOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 160
SUN VISOR SUPPORT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 160
REAR VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 161
INSTALLATION - REARVIEW MIRROR
SUPPORT BRACKET . . . . . . . . . . . . . . . . . . 161
4WD FLOOR SHIFT BOOT
REMOVAL
(1) Remove the shi ft l ever and remove the boot
from the l ever. (Refer to 21 - TRANSMI SSI ON/
TRANSAXLE/TRANSFER CASE/SHI FT LEVER -
REMOVAL)
INSTALLATION
(1) I nstal l the shi ft boot onto the shi ft l ever and
i nstal l the l ever. (Refer to 21 - TRANSMI SSI ON/
TRANSAXLE/TRANSFER CASE/SHI FT LEVER -
I NSTALLATI ON)
A-PILLAR TRIM AND GRAB
HANDLE
REMOVAL
(1) Usi ng a smal l pry tool or equi val ent, remove
the grab handl e tri m pl ugs.
(2) Remove the two grab handl e screws.
(3) Remove the grab handl e and a-pi l l ar tri m from
the a-pi l l ar.
INSTALLATION
(1) Snap a-pi l l ar tri m and grab handl e i nto the
a-pi l l ar.
(2) I nstal l the two screws and i nstal l the grab han-
dl e tri m pl ugs.
23 - 156 INTERIOR KJ
COWL TRIM COVER
REMOVAL
(1) Remove the l ower b-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/B-PI LLAR LOWER TRI M -
REMOVAL)
(2) Remove the cowl tri m cover by pul l i ng i t away
from the a-pi l l ar and rel easi ng the cl i ps.
INSTALLATION
(1) I nstal l the cowl tri m cover and seat the retai n-
i ng cl i ps.
(2) I nstal l the l ower b-pi l l ar tri m. (Refer to 23 -
I NSTALLATI ON)
DOOR SILL SCUFF PLATE
REMOVAL
(1) Usi ng a tri m sti ck C-4755 or equi val ent, pry up
the scuff pl ate rel easi ng the retai ni ng cl i ps.
INSTALLATION
(1) Posi ti on the scuff pl ate and seat the retai ni ng
cl i ps.
ASSIST HANDLE
REMOVAL
(1) Usi ng a smal l pry tool or equi val ent, rel ease
the assi st handl e by pryi ng out the cl i ps at ei ther
end. (Fi g. 1)
INSTALLATION
(1) Posi ti on the assi st handl e and seat the retai n-
i ng cl i ps.
B-PILLAR LOWER TRIM
REMOVAL
(1) Usi ng a tri m sti ck C-4755 or equi val ent, pry up
the tri m panel , rel easi ng the retai ni ng cl i ps. (Fi g. 2)
INSTALLATION
(1) Posi ti on the tri m panel and seat the retai ni ng
cl i ps.
B-PILLAR UPPER TRIM
REMOVAL
(1) Remove the l ower b-pi l l ar tri m panel . (Refer to
23 - BODY/I NTERI OR/B-PI LLAR LOWER TRI M -
REMOVAL)
(2) Remove the shoul der bel t turni ng l oop. (Refer
to 8 - ELECTRI CAL/RESTRAI NTS/SEAT BELT &
RETRACTOR - REMOVAL)
rel ease the tri m retai ni ng cl i ps and remove. (Fi g. 2)
Fig. 1 ASSIST HANDLE
1 - HEADLINER
2 - ASSIST HANDLE
3 - RETAINING CLIPS
Fig. 2 B-PILLAR TRIM PANELS
1 - UPPER B-PILLAR TRIM
2 - B-PILLAR
3 - DOOR SILL
4 - LOWER B-PILLAR
KJ INTERIOR 23 - 157
INSTALLATION
(1) Posi ti on the tri m panel and seat the retai ni ng
cl i ps.
(2) I nstal l the seat bel t turni ng l oop. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/SEAT BELT &
RETRACTOR - I NSTALLATI ON)
(3) I nstal l the b-pi l l ar l ower tri m panel . (Refer to
23 - BODY/I NTERI OR/B-PI LLAR LOWER TRI M -
I NSTALLATI ON)
CARPETS AND FLOOR MATS
REMOVAL
Front Carpet
(1) Remove front seats. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - REMOVAL)
(2) Remove the fl oor consol e. (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - REMOVAL)
(3) Remove the rear seats. (Refer to 23 - BODY/
SEATS/SEAT - REAR - REMOVAL)
(4) Remove the cowl tri m panel s. (Refer to 23 -
BODY/I NTERI OR/COWL TRI M COVER -
REMOVAL)
(5) Remove the b-pi l l ar l ower tri m. (Refer to 23 -
REMOVAL)
(6) Remove the jack assembl y.
(7) Remove the carpet.
Rear Cargo Carpet
(1) Remove the ri vets attachi ng the cargo hooks to
the fl oor.
(2) Remove the carpet.
INSTALLATION
Front Carpet
(1) I nstal l the carpet.
(2) I nstal l the jack assembl y.
(3) I nstal l the b-pi l l ar l ower tri m. (Refer to 23 -
I NSTALLATI ON)
(4) I nstal l the cowl tri m panel s. (Refer to 23 -
LATI ON)
(5) I nstal l the rear seats. (Refer to 23 - BODY/
SEATS/SEAT - REAR - I NSTALLATI ON)
(6) I nstal l the fl oor consol e. (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - I NSTALLATI ON)
(7) I nstal l the front seats. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - I NSTALLATI ON)
Rear Cargo Carpet
(1) I nstal l the carpet and sl i de under the tri m pan-
el s.
(2) I nstal l new ri vets securi ng the carpet and
cargo hooks to the fl oor.
SHIFT BEZEL
REMOVAL
(1) Usi ng a tri m sti ck C-4755 or equi val ent, pry
shi ft bezel out of the fl oor consol e.
INSTALLATION
(1) Posi ti on the shi ft bezel and seat the retai ni ng
cl i ps i nto the fl oor consol e.
FLOOR CONSOLE
REMOVAL
(1) Remove the shi ft bezel , i f equi pped. (Refer to
23 - BODY/I NTERI OR/SHI FT BEZEL - REMOVAL)
(2) Set park brake l ever i n the up posi ti on.
(3) Usi ng a tri m sti ck C-4755 or equi val ent, di s-
connect the manual trans shi fter boot, i f equi pped.
(4) Usi ng a tri m sti ck C-4755 or equi val ent, di s-
connect the transfer case shi fter boot, i f equi pped.
(5) Remove the four bol ts. (Fi g. 3)
(6) Li ft the consol e at the back and remove.
INSTALLATION
(1) Posi ti on the front of the consol e and l ower the
rear over the shi fter and brake l evers.
(2) I nstal l the bol ts.
(3) I nstal l the shi ft boots and seat the retai ner
cl i ps.
(4) I nstal l the shi ft bezel . (Refer to 23 - BODY/I N-
TERI OR/SHI FT BEZEL - I NSTALLATI ON)
FLOOR CONSOLE LID LATCH
REMOVAL
(1) Remove the screws and remove the l i d.
(2) Remove the screws attachi ng the l i d cover and
remove the l atch.
INSTALLATION
(1) I nstal l the l atch and the l i d cover.
(2) I nstal l the screws attachi ng the l i d cover.
(3) I nstal l the consol e l i d onto the consol e and
B-PILLAR UPPER TRIM (Continued)
HEADLINER
REMOVAL
(1) Remove the a-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M AND GRAB HANDLE -
REMOVAL)
(2) Remove the vi sors. (Refer to 23 - BODY/I NTE-
RI OR/SUN VI SOR - REMOVAL)
(3) Remove the sun vi sor support. (Refer to 23 -
BODY/I NTERI OR/SUN VI SOR SUPPORT -
REMOVAL)
(4) Remove the overhead consol e. (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - REMOVAL)
(5) Cut rear washer hose at the mark about hal f-
way up the a-pi l l ar.
(6) Remove the upper b-pi l l ar tri m. (Refer to 23 -
REMOVAL)
(7) Remove the assi st handl es. (Refer to 23 -
BODY/I NTERI OR/ASSI ST HANDLE - REMOVAL)
(8) Remove the quarter tri m. (Refer to 23 - BODY/
I NTERI OR/QUARTER TRI M PANEL - REMOVAL)
(9) Di sconnect the el ectri cal connector al ong the
l eft d-pi l l ar and remove the ground wi re.
(10) Remove the dome l i ght i n the rear.
(11) Remove the sunroof openi ng tri m l ace, i f
equi pped. (Refer to 23 - BODY/SUNROOF/OPENI NG
TRI M LACE - REMOVAL)
(12) Remove the rear washer nozzl e.
(13) Remove the headl i ner.
INSTALLATION
(1) I nstal l the headl i ner.
(2) I nstal l the assi st handl es. (Refer to 23 - BODY/
I NTERI OR/ASSI ST HANDLE - I NSTALLATI ON)
(3) I nstal l the vi sors. (Refer to 23 - BODY/I NTERI -
OR/SUN VI SOR - I NSTALLATI ON)
(4) I nstal l the vi sor supports. (Refer to 23 - BODY/
I NTERI OR/SUN VI SOR SUPPORT - I NSTALLA-
TI ON)
(5) I nstal l the overhead consol e. (Refer to 8 -
TI ON)
(6) Connect the rear washer hose, previ ousl y cut,
wi th a hose juncti on.
(7) I nstal l the a-pi l l ar tri m and grab handl es.
(Refer to 23 - BODY/I NTERI OR/A-PI LLAR TRI M -
I NSTALLATI ON)
(8) I nstal l the upper b-pi l l ar tri m. (Refer to 23 -
I NSTALLATI ON)
(9) I nstal l the rear washer nozzl e.
(10) Connect the el ectri cal connector and ground
wi re at the l eft d-pi l l ar.
(11) I nstal l the quarter tri m panel s. (Refer to 23 -
I NSTALLATI ON)
(12) I nstal l the rear dome l i ght.
(13) I nstal l the sunroof openi ng tri m l ace, i f
equi pped. (Refer to 23 - BODY/SUNROOF/OPENI NG
TRI M LACE - I NSTALLATI ON)
QUARTER TRIM PANEL
REMOVAL
remove the rear header tri m.
remove the rear si l l pl ate.
(3) Remove the hook pi n type connector.
(4) Fol d down the rear seat.
(5) Remove the seat bel t anchor and pi vot. (Refer
to 8 - ELECTRI CAL/RESTRAI NTS/SEAT BELT &
(6) Remove the bel t access panel . (Fi g. 4)
(7) Remove the storage cover.
(8) Di sconnect the 12v power suppl y el ectri cal con-
nector, i f equi pped.
INSTALLATION
(1) Posi ti on the 12v power suppl y el ectri cal con-
nector, i f equi pped.
(2) I nstal l the storage cover.
Fig. 3 FLOOR CONSOLE
1 - SHIFT BEZEL
2 - ACCESSORY CUP
3 - BOLTS (4)
4 - FLOOR CONSOLE
FLOOR CONSOLE LID LATCH (Continued)
(3) I nstal l the bel t access panel .
(4) I nstal l the seat bel t anchor and pi vot. (Refer to
8 - ELECTRI CAL/RESTRAI NTS/SEAT BELT &
(5) I nstal l the hook pi n type connector.
(6) Posi ti on the rear si l l pl ate and seat the retai n-
i ng cl i ps.
(7) Posi ti on the rear header tri m and seat the
REAR DOOR SCUFF PLATE
REMOVAL
rel ease the retai ni ng cl i ps and remove the scuff
pl ate.
INSTALLATION
(1) Posi ti on the scuff pl ate and seat the retai ni ng
cl i ps.
SUN VISOR
REMOVAL
(1) Remove the screws at the vi sor pi vot.
(2) Di sconnect the el ectri cal connector and remove
the vi sor.
INSTALLATION
(1) Connect the el ectri cal connector and i nstal l the
vi sor.
(2) I nstal l the screws at the vi sor pi vots.
SUN VISOR SUPPORT
REMOVAL
(1) Usi ng a smal l pry tool or equi val ent, rel ease
the support retai ni ng cl i p by pryi ng out and remove
the support. (Fi g. 5)
INSTALLATION
(1) Posi ti on the vi sor support and seat the retai n-
i ng cl i p.
Fig. 4 QUARTER TRIM PANEL
1 - C-PILLAR
2 - D-PILLAR
3 - BELT ACCESS PANEL
4 - QUARTER TRIM PANEL
Fig. 5 SUN VISOR SUPPORT
1 - HEADLINER
2 - RETAINER CLIP
3 - SUN VISOR SUPPORT
QUARTER TRIM PANEL (Continued)
REAR VIEW MIRROR
REMOVAL
(1) I f equi pped, di sconnect mi rror harness connec-
tor.
(2) Loosen the mi rror base setscrew (Fi g. 6).
(3) Sl i de the mi rror base upward and off the
bracket.
INSTALLATION
INSTALLATION
(1) Posi ti on the mi rror base at the bracket and
sl i de i t downward onto the support bracket (Fi g. 6).
(2) Ti ghten the setscrew 1 Nm (15 i n. l bs.) torque.
(3) I f equi pped, connect mi rror harness connector.
INSTALLATION - REARVIEW MIRROR
SUPPORT BRACKET
(1) Mark the posi ti on for the mi rror bracket on the
outsi de of the wi ndshi el d gl ass wi th a wax penci l .
(2) Cl ean the bracket contact area on the gl ass.
Use a mi l d powdered cl eanser on a cl oth saturated
wi th i sopropyl (rubbi ng) al cohol . Fi nal l y, cl ean the
gl ass wi th a paper towel dampened wi th al cohol .
(3) Sand the surface on the support bracket wi th
fi ne gri t-sandpaper. Wi pe the bracket surface cl ean
wi th a paper towel .
(4) Appl y accel erator to the surface on the bracket
accordi ng to the fol l owi ng i nstructi ons:
(a) Crush the vi al to saturate the fel t appl i cator.
(b) Remove the paper sl eeve.
(c) Appl y accel erator to the contact surface on
the bracket.
(d) Al l ow the accel erator to dry for fi ve mi nutes.
(e) Do not touch the bracket contact surface
after the accel erator has been appl i ed.
(5) Appl y adhesi ve accel erator to the bracket con-
tact surface on the wi ndshi el d gl ass. Al l ow the accel -
erator to dry for one mi nute. Do not touch the gl ass
contact surface after the accel erator has been
appl i ed.
(6) I nstal l the bracket accordi ng to the fol l owi ng
i nstructi ons:
(a) Appl y one drop of adhesi ve at the center of
the bracket contact-surface on the wi ndshi el d
gl ass.
(b) Appl y an even coat of adhesi ve to the contact
surface on the bracket.
(c) Al i gn the bracket wi th the marked posi ti on
on the wi ndshi el d gl ass.
(d) Press and hol d the bracket i n pl ace for at
l east one mi nute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Al l ow the adhesi ve to cure for 8-10 mi nutes.
Remove any excess adhesi ve wi th an al cohol -damp-
ened cl oth.
(8) Al l ow the adhesi ve to cure for an addi ti onal
8-10 mi nutes before i nstal l i ng the mi rror.
Fig. 6 Rear View Mirror
1 - CONNECTOR
2 - SCREW
3 - REAR VIEW MIRROR
4 - SUPPORT BUTTON
5 - WINDSHIELD
PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - PAINT CODES . . . . . . . . . 162
PAINT CODE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 162
BASE COAT/CLEAR COAT FINISH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 162
PAINT TOUCH-UP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 163
FINESSE SANDING/BUFFING & POLISHING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 163
PAINT
SPECIFICATIONS - PAINT CODES
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER
CODE
Black Clear Coat DX8
Bright Cactus Green
Pearl Coat
AFM
Bright Silver Metallic
Clear Coat
WS2
Dark Garnet Red Pearl
Coat
XRV
Flame Red Clear Coat PR4
Patriot Blue Pearl Coat WB7
Salsa Red Pearl Coat WE5
Shale Green Metallic
Clear Coat
XGR
Steel Blue Pearl Coat XBQ
Stone White Clear Coat SW1
Woodland Brown Satin
Glow
YU2
INTERIOR COLORS
INTERIOR COLOR DAIMLERCHRYSLER
CODE
Taupe L5
Dark Slate Gray DV
Dark Slate Gray/Light
Taupe
D2
Taupe/Light Taupe L2
ACCESSORY COLORS
PART COLOR DAIMLERCHRYSLER
CODE
Renegade
Roof
Rack/Light
Bar
Deep Gray ZSP
Sport
Fascia/Wheel
Flare
Dark Neutral
Gray
HS5
PAINT CODE
DESCRIPTION
The pai nt code i s i denti fi ed on the Vehi cl e Safety
Certi fi cati on Label whi ch i s l ocated on the dri vers
door shut face. The col or names provi ded i n the Pai nt
and Tri m Code Descri pti on chart are the col or names
used on most repai r product contai ners.
BASE COAT/CLEAR COAT
FINISH
DESCRIPTION
The ori gi nal equi pment fi ni sh i s a mul ti step pro-
cess that i nvol ves cl eani ng, appl yi ng el ectro de-posi -
ti on (E-coat), anti -chi p pri mer, base coat, and cl ear
coat steps.
On most vehi cl es a two-part pai nt appl i cati on (base
coat/cl ear coat) i s used. Col or pai nt that i s appl i ed to
pri mer i s cal l ed base coat. The cl ear coat protects the
base coat from ul travi ol et l i ght and provi des a dura-
bl e hi gh-gl oss fi ni sh.
23 - 162 PAINT KJ
CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
result.
Do not use harsh alkaline based cleaning solvents
on painted surfaces. Damage to finish or color can
result.
PAINT TOUCH-UP
DESCRIPTION
When a pai nted metal surface has been scratched
or chi pped, i t shoul d be touched-up as soon as possi -
bl e to avoi d corrosi on. For best resul ts, use Mopar
Scratch Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear Top
Coat. Refer to I ntroducti on group of thi s manual for
Body Code Pl ate i nformati on.
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
OPERATION
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th Mopar Tar/Road Oi l
Remover, and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat
of fi l l er/pri mer. Do not overl ap pri mer onto good sur-
face fi ni sh. The appl i cator brush shoul d be wet
enough to puddl e-fi l l the defect wi thout runni ng. Do
not stroke brush appl i cator on body surface. Al l ow
the fi l l er/pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up
pai nt. Do not overl ap touch-up col or onto the ori gi nal
col or coat around the scratch or chi p. Butt the new
col or to the ori gi nal col or, i f possi bl e. Do not stroke
appl i cator brush on body surface. Al l ow touch-up
pai nt to dry hard.
(5) On vehi cl es wi thout cl ear coat, the touch-up
col or can be l i ghtl y fi nesse sanded (1500 gri t) and
pol i shed wi th rubbi ng compound.
(6) On vehi cl es wi th cl ear coat, appl y cl ear top coat
to touch-up pai nt wi th the same techni que as
descri bed i n Step 4. Al l ow cl ear top coat to dry hard.
I f desi red, Step 5 can be performed on cl ear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING/BUFFING &
POLISHING
DESCRIPTION
Mi nor aci d etchi ng, orange peel , or smudgi ng i n
cl ear coat or si ngl e-stage fi ni shes can be reduced
wi th l i ght fi nesse sandi ng, hand buffi ng, and pol i sh-
i ng. If the finish has been finesse sanded in the
past, it cannot be repeated. Finesse sanding
operation should be performed by a trained
automotive paint technician.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat for
durability.
KJ PAINT 23 - 163
BASE COAT/CLEAR COAT FINISH (Continued)
SEATS
TABLE OF CONTENTS
page page
HEADREST
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 164
HEADREST SLEEVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 164
SEAT - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 165
SEAT BACK - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 166
SEAT BACK RECLINER - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 166
SEAT BACK COVER - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 167
SEAT BACK CUSHION - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 167
SEAT CUSHION - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 167
SEAT CUSHION COVER - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 167
SEAT CUSHION SIDE SHIELDS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 167
MANUAL SEAT RISER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 168
SEAT TRACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 168
SEAT - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 168
SEAT BACK - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 168
SEAT BACK COVER - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 169
SEAT BACK CUSHION - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 170
FOLDING REAR SEAT BACK LATCH / LOCK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 170
REAR SEAT BACK LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 171
SEAT BACK FRAME - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 171
SEAT CUSHION - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 171
HEADREST
REMOVAL
(1) Depress head restrai nt rel ease button and l i ft
head restrai nt to ful l up posi ti on.
(2) Usi ng a smal l fl at bl ade, depress tab on ri ght
si de head restrai nt rel ease button and usi ng your
hand, si mul taneousl y press tab on l eft si de head
restrai nt rel ease button and pul l head restrai nt up to
separate from seat back.
INSTALLATION
(1) Posi ti on head restrai nt i n seat back, press tab
on l eft si de head restrai nt rel ease button and push
down head restrai nt to secure.
HEADREST SLEEVE
REMOVAL
(1) Remove the headrest. (Refer to 23 - BODY/
SEATS/HEADREST - REMOVAL)
(2) Remove the headrest sl eeve cover.
(3) Rotate head restrai nt sl eeve 1/4 turn counter-
cl ockwi se to rel ease retai ni ng tab.
(4) Pul l sl eeve from seat back frame.
INSTALLATION
(1) Posi ti on sl eeve i n seat back frame.
(2) Rotate head restrai nt sl eeve 1/4 turn cl ockwi se
to engage retai ni ng tab.
(3) I nstal l the headrest sl eeve cover.
(4) I nstal l the headrest. (Refer to 23 - BODY/
SEATS/HEADREST - I NSTALLATI ON)
23 - 164 SEATS KJ
SEAT - FRONT
REMOVAL
WARNING: DISABLE THE SUPPLEMENTAL
RESTRAINTS SYSTEM BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, DRIVER
AIRBAG, PASSENGER AIRBAG, SEAT BELT TEN-
SIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINTS SYSTEM.
(1) Remove the seat bel t anchor bol t. (Refer to 8 -
(2) Sl i de seat back and remove the front bol ts.
(Fi g. 1)
(3) Sl i de seat to forward posi ti on and remove the
rear bol t/nut.
(4) Di sconnect the el ectri cal connectors and
remove the seat.
INSTALLATION
WARNING: DISABLE THE SUPPLEMENTAL
RESTRAINTS SYSTEM BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, DRIVER
AIRBAG, PASSENGER AIRBAG, SEAT BELT TEN-
SIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE SUPPLEMENTAL RESTRAINTS SYSTEM.
(1) I nstal l the seats and connect the el ectri cal con-
nectors.
(2) Sl i de the seat to the rearward posi ti on and
i nstal l the bol ts.
(3) Ti ghten the outboard bol t to 43 Nm (32 ft. l bs.)
and then ti ghten the i nboard bol t to 43 Nm (32 ft.
l bs.).
Fig. 1 FRONT SEATS
1 - FRONT SEATS
2 - BOLTS
3 - STUDS
5 - NUTS
KJ SEATS 23 - 165
(4) Sl i de the seat to the forward posi ti on and
i nstal l the rear bol t and nut.
(5) Ti ghten the fasteners to 43 Nm (32 ft. l bs.).
(6) I nstal l the seat bel t anchor and bol t. (Refer to
8 - ELECTRI CAL/RESTRAI NTS/SEAT BELT &
SEAT BACK - FRONT
REMOVAL
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - REMOVAL)
(2) Remove the seat cushi on si de shi el ds. (Refer to
23 - BODY/SEATS/SEAT CUSHI ON SI DE SHI ELDS
- REMOVAL)
(3) Di sconnect the l ock out cabl e from both recl i n-
ers. (Fi g. 2)
(4) Remove the bol ts and remove the seat back.
INSTALLATION
(1) I nstal l the seat back and i nstal l the bol ts.
(3) Connect the l ock out cabl e to both recl i ners.
(4) I nstal l the bel t buckl e. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/SEAT BELT BUCKLE - I NSTAL-
LATI ON)
(5) I nstal l the si de shi el ds. (Refer to 23 - BODY/
SEATS/SEAT CUSHI ON SI DE SHI ELDS - I NSTAL-
LATI ON)
(6) I nstal l the seat. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - I NSTALLATI ON)
SEAT BACK RECLINER -
FRONT
REMOVAL
(1) Remove the seat back. (Refer to 23 - BODY/
SEATS/SEAT BACK - FRONT - REMOVAL)
(2) Posi ti on the seat back cover out of the way and
remove the bol ts. (Fi g. 3)
(3) Remove the recl i ners from the seat back frame.
INSTALLATION
(1) I nstal l the recl i ners onto the seat back.
(2) Posi ti on the seat back cover asi de and i nstal l
the recl i ner bol ts.
(4) I nstal l the seat back. (Refer to 23 - BODY/
SEATS/SEAT BACK - FRONT - I NSTALLATI ON)
SEAT BACK COVER - FRONT
REMOVAL
(2) Remove the head rest and remove the tri m
caps. (Refer to 23 - BODY/SEATS/HEADREST -
REMOVAL)
(3) Di sconnect the j-straps.
(4) Remove the two l ower hog ri ngs.
(5) Parti al l y remove the seat back cover and
remove the two upper hog ri ngs.
(6) Remove the seat back cover.
Fig. 2 SEAT BACK RECLINER
1 - LOCK OUT CABLE
2 - BOLTS
3 - RECLINER
4 - SEAT BACK
Fig. 3 SEAT BACK RECLINER
1 - SEAT BACK RECLINER
2 - BOLTS
3 - SEAT BACK
23 - 166 SEATS KJ
SEAT - FRONT (Continued)
INSTALLATION
(1) Parti al l y i nstal l the seat back cover and
repl ace the two top hog ri ngs.
(2) Pul l cover down and repl ace the two l ower hog
ri ngs.
(3) Connect the j-straps.
(4) I nstal l tri m caps and the head rest. (Refer to
23 - BODY/SEATS/HEADREST - I NSTALLATI ON)
SEAT BACK CUSHION - FRONT
REMOVAL
(1) Remove the seat back cover. (Refer to 23 -
BODY/SEATS/SEAT BACK COVER - FRONT -
REMOVAL)
(2) Separate the cushi on from the seat back frame.
INSTALLATION
(1) Posi ti on the cushi on onto the seat back frame.
(2) I nstal l the seat back cover. (Refer to 23 -
BODY/SEATS/SEAT BACK COVER - FRONT -
I NSTALLATI ON)
SEAT CUSHION - FRONT
REMOVAL
(2) Remove the two outer front track bol ts and
remove the track.
INSTALLATION
(1) I nstal l the seat cushi on onto the seat track
assembl y and i nstal l the front two bol ts.
SEAT CUSHION COVER -
FRONT
REMOVAL
(1) Remove the seat cushi on. (Refer to 23 - BODY/
SEATS/SEAT CUSHI ON - FRONT - REMOVAL)
(3) Remove the hog ri ngs and remove the cushi on
cover.
INSTALLATION
(1) Posi ti on the seat cushi on cover and i nstal l new
hog ri ngs.
(3) I nstal l the seat cushi on. (Refer to 23 - BODY/
SEATS/SEAT CUSHI ON - FRONT - I NSTALLA-
TI ON)
SEAT CUSHION SIDE SHIELDS
REMOVAL
(1) Remove the screw and remove the recl i ner han-
dl e.
(2) Remove the screws and remove the seat si de
shi el ds.
INSTALLATION
(1) I nstal l the shi el ds and i nstal l the screws.
(2) I nstal l the recl i ner handl e and i nstal l the
screw.
MANUAL SEAT RISER
REMOVAL
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - REMOVAL)
(2) Remove the bol ts and remove the ri vet from
the rel ease handl e. (Fi g. 4)
(3) Remove the ri ser.
Fig. 4 FRONT SEAT RISER
1 - BOLTS (3)
2 - SEAT CUSHION
3 - SEAT TRACK
4 - SEAT RISER
KJ SEATS 23 - 167
SEAT BACK COVER - FRONT (Continued)
INSTALLATION
(1) I nstal l the seat ri ser and i nstal l the bol ts.
(3) I nstal l a new rel ease handl e ri vet.
(4) I nstal l the seat. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - I NSTALLATI ON)
SEAT TRACK
REMOVAL
(2) Remove the outer ri ser. (Refer to 23 - BODY/
SEATS/SEAT RI SER - REMOVAL)
(3) Remove the front outer bol ts and remove the
tracks.
INSTALLATION
(1) I nstal l the seat track onto the seat cushi on and
i nstal l the front outer bol ts.
(3) I nstal l the seat ri ser. (Refer to 23 - BODY/
SEATS/SEAT RI SER - I NSTALLATI ON)
SEAT - REAR
REMOVAL
(1) Remove the outer seat bel t anchors. (Refer to 8
- ELECTRI CAL/RESTRAI NTS/SEAT BELT &
(2) Remove the i nner seat bel t buckl es. (Refer to 8
- ELECTRI CAL/RESTRAI NTS/SEAT BELT BUCKLE
- REMOVAL)
(3) Remove the center seat bel t anchor. (Refer to 8
- ELECTRI CAL/RESTRAI NTS/SEAT BELT &
(4) Remove the front bol ts and nuts. (Fi g. 5)
(5) Fol d down the seat backs and remove the seat
assembl y through the rear door.
INSTALLATION
(1) I nstal l the seat assembl y and posi ti on over the
studs.
(2) Open the seat back and engage the l atches
onto the l atch stri kers.
(3) I nstal l the rear outboard nuts and ti ghten to
43 Nm (32 ft. l bs.).
(4) I nstal l the outer seat bel t anchors. (Refer to 8 -
(5) I nstal l the i nner seat bel t buckl es. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/SEAT BELT BUCKLE -
I NSTALLATI ON)
(6) I nstal l the center seat bel t anchor. (Refer to 8 -
(7) I nstal l the front outer seat cushi on l eg bol ts
and ti ghten to 35 Nm (26 ft. l bs.)
SEAT BACK - REAR
REMOVAL
(1) Remove the seat assembl y. (Refer to 23 -
BODY/SEATS/SEAT - REAR - REMOVAL)
(2) Remove the front seat cushi on hi nge bol t. (Fi g.
6)
(3) Remove the center seat back hi nge bol ts and
separate the rear seat assembl y. (Fi g. 7)
(4) Rel ease the cl i ps and remove the seat back
hi nge covers.
(5) Li ft the seat cushi on cover and remove the
hi nge bol ts. (Fi g. 8)
(6) Remove the seat back.
INSTALLATION
(1) I nstal l the seat back.
Fig. 5 REAR SEAT ASSEMBLY
1 - SEAT BELT ANCHOR BOLTS
2 - BELT BUCKLES
3 - BELT BUCKLE
4 - SEAT BELT ANCHOR BOLTS
5 - REAR SEAT ASSEMBLY
6 - SEAT BELT ANCHOR
7 - FLOOR PAN
8 - STUDS
9 - CENTER SEAT BELT
10 - FRONT STUDS
11 - NUTS (2)
12 - SEAT BELT ANCHOR
23 - 168 SEATS KJ
MANUAL SEAT RISER (Continued)
(2) I nstal l the seat back hi nge bol t and ti ghten to
8 Nm (71 i n. l bs.).
(3) Posi ti on the seat back hi nge covers and ful l y
seat the cl i ps.
(4) Connect the seat hal ves and i nstal l the center
seat back hi nge bol ts.
(6) I nstal l the front seat cushi on hi nge bol t and
(7) I nstal l the seat assembl y. (Refer to 23 - BODY/
SEATS/SEAT - REAR - I NSTALLATI ON)
SEAT BACK COVER - REAR
REMOVAL
(1) Remove the rear seat back. (Refer to 23 -
BODY/SEATS/SEAT BACK - REAR - REMOVAL)
(2) Remove the screws and remove the center seat
bel t gui de.
(3) Remove the screws and push pi n fasteners and
remove the l atch handl e bezel .
(4) Remove the head rest and remove the gui de
covers. (Refer to 23 - BODY/SEATS/HEADREST -
REMOVAL)
(5) Remove the screws and remove the grocery
hooks.
(6) Remove the push pi n fasteners and remove the
seat back panel .
(8) Remove the seat back cover.
INSTALLATION
(1) I nstal l the seat back cover and connect the
j-straps.
(2) I nstal l the seat back panel and i nstal l the push
pi n fasteners.
(3) I nstal l the grocery hooks and i nstal l the
screws.
(4) I nstal l the head rest gui de covers and i nstal l
the head rest. (Refer to 23 - BODY/SEATS/HEAD-
REST - I NSTALLATI ON)
(5) I nstal l the l atch handl e bezel and i nstal l the
screws and push pi n fasteners.
(6) I nstal l the center seat bel t gui de and screws.
(7) I nstal l the rear seat back. (Refer to 23 - BODY/
SEATS/SEAT BACK - REAR - I NSTALLATI ON)
Fig. 6 CENTER CUSHION HINGE
1 - SEAT CUSHION
2 - BOLT
Fig. 7 CENTER SEAT BACK HINGE
1 - SEAT CUSHION
2 - BOLTS
3 - SEAT BACK HINGE
4 - SEAT CUSHION
Fig. 8 SEAT BACK HINGE
1 - SEAT BACK
2 - BOLT
3 - SEAT BACK HINGE
KJ SEATS 23 - 169
SEAT BACK - REAR (Continued)
SEAT BACK CUSHION - REAR
REMOVAL
(1) Remove the seat back cover. (Refer to 23 -
BODY/SEATS/SEAT BACK COVER - REAR -
REMOVAL)
(2) Separate the cushi on from the seat back frame.
INSTALLATION
(1) Posi ti on the seat back cushi on onto the seat
back frame.
(2) I nstal l the seat back cover. (Refer to 23 -
BODY/SEATS/SEAT BACK COVER - REAR -
I NSTALLATI ON)
FOLDING REAR SEAT BACK
LATCH / LOCK
REMOVAL
(1) Remove the rear seat back cushi on. (Refer to
23 - BODY/SEATS/SEAT BACK CUSHI ON /COVER
- REAR - REMOVAL)
(2) Di sconnect the shoul der bel t rel ease cabl e. (Fi g.
9)
(3) Remove the bol ts and remove the l atch/l ock
INSTALLATION
(1) I nstal l the l atch/l ock assembl y and i nstal l the
bol ts.
(3) Connect the shoul der bel t rel ease cabl e.
(4) I nstal l the rear seat back cushi on. (Refer to 23
- BODY/SEATS/SEAT BACK CUSHI ON / COVER -
REAR - I NSTALLATI ON)
REAR SEAT BACK LATCH
STRIKER
REMOVAL
REMOVAL)
(2) Remove the bol ts and remove the stri ker. (Fi g.
11)
Fig. 9 Seat Back Latch Cable Disengage/Engage
1 - LEVER
2 - PLUNGER
3 - LATCH CABLE FITTING
4 - REAR CENTER RETRACTOR
5 - SUPPORT
Fig. 10 LATCH/LOCK ASSEMBLY
1 - LATCH/LOCK ASSEMBLY
2 - SEAT BELT RETRACTOR
3 - RETRACTOR RELEASE CABLE
4 - BOLTS
5 - REAR SEAT BACK FRAME
23 - 170 SEATS KJ
INSTALLATION
(1) Posi ti on the stri ker and i nstal l the bol ts.
I NSTALLATI ON)
SEAT BACK FRAME - REAR
REMOVAL
(1) Remove the center seat bel t retractor, i f
equi pped. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
SEAT BELT & RETRACTOR - REMOVAL)
(2) Remove the seat back l atch/l ock assembl y.
(Refer to 23 - BODY/SEATS/FOLDI NG REAR SEAT
BACK LATCH / LOCK - REMOVAL)
INSTALLATION
(1) I nstal l the seat back l atch/l ock assembl y. (Refer
to 23 - BODY/SEATS/FOLDI NG REAR SEAT BACK
LATCH / LOCK - I NSTALLATI ON)
(2) I nstal l the center seat bel t retractor, i f
equi pped. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
SEAT BELT & RETRACTOR - I NSTALLATI ON)
SEAT CUSHION - REAR
REMOVAL
SEATS/SEAT BACK - REAR - REMOVAL)
(2) Di sconnect the j-straps and remove the seat
cushi on and cover.
INSTALLATION
(1) Posi ti on the seat cushi on and cushi on cover
onto the seat frame.
SEATS/SEAT BACK - REAR - I NSTALLATI ON)
Fig. 11 REAR SEAT BACK LATCH STRIKER
1 - LATCH STRIKER
2 - BODY SIDE PANEL
3 - STRIKER CLOSE-OUT
4 - BOLTS (3)
KJ SEATS 23 - 171
REAR SEAT BACK LATCH STRIKER (Continued)
STATIONARY GLASS
TABLE OF CONTENTS
page page
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 172
QUARTER WINDOW
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 172
WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS . . . . 173
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 173
DOOR GLASS
REMOVAL
(1) Remove the rear door gl ass run channel . (Refer
to 23 - BODY/DOORS - REAR/GLASS RUN CHAN-
NEL - REMOVAL)
INSTALLATION
(1) I nstal l the rear door gl ass run channel . (Refer
to 23 - BODY/DOORS - REAR/GLASS RUN CHAN-
NEL - I NSTALLATI ON)
QUARTER WINDOW
REMOVAL
(1) Remove the headl i ner as necessary to gai n
access to the gl ass seal from the i nsi de. (Refer to 23 -
BODY/I NTERI OR/HEADLI NER - REMOVAL)
(2) Cut urethane bondi ng from around quarter
wi ndow gl ass usi ng a sui tabl e sharp col d kni fe. A
pneumati c cutti ng devi ce can be used i f avai l abl e.
(3) Separate gl ass from vehi cl e.
INSTALLATION
CAUTION: Open a window before installing glass.
This will avoid pressurizing the passenger compart-
ment. If a door or swing gate flip-up glass is
slammed before urethane is cured, water leaks can
result.
The wi ndow openi ng fence shoul d be cl eaned of ol d
urethane bondi ng materi al .
(1) I nstal l the headl i ner as necessary. (Refer to 23
- BODY/I NTERI OR/HEADLI NER - I NSTALLATI ON)
(2) Cl ean i nsi de of gl ass wi th Mopar Gl ass Cl eaner
and l i nt-free cl oth.
(3) Appl y PVC (vi nyl ) pri mer 25 mm (1 i n.) wi de
around edge of gl ass. Wi pe wi th cl ean/dry l i nt-free
cl oth.
(4) Appl y fence pri mer around edge of fence. Al l ow
at l east ei ghteen mi nutes dryi ng ti me.
(5) Appl y a 10 mm (0.4 i n.) bead of urethane
around wi ndow vi nyl border l ocati on.
(6)
Posi ti on gl ass i nto wi ndow openi ng and l ock cl i ps
i nto pl ace.
23 - 172 STATIONARY GLASS KJ
WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A
SYSTEM. USE GLASS CLEANER, GLASS PREP
SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
AND PINCH WELD (FENCE) PRIMER PROVIDED BY
THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
TURAL INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MAN-
UFACTURERS DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
(1) Remove i nsi de rear vi ew mi rror. (Refer to 23 -
BODY/I NTERI OR/REAR VI EW MI RROR -
REMOVAL)
(2) Remove cowl cover. (Refer to 23 - BODY/EXTE-
RI OR/COWL GRI LLE - REMOVAL)
(3) Remove screws attachi ng wi ndshi el d si de mol d-
i ng to A-pi l l ar.
(4) Remove upper wi ndshi el d mol di ng.
(5) Cut urethane bondi ng from around wi ndshi el d
usi ng a sui tabl e sharp col d kni fe. A pneumati c cut-
ti ng devi ce can be used i f avai l abl e.
(6) Separate wi ndshi el d from vehi cl e.
INSTALLATION
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
CAUTION: Open a window before installing wind-
shield. This will avoid pressurizing the passenger
compartment. If a door or swing gate flip-up glass
is slammed before urethane is cured, water leaks
can result.
The wi ndshi el d fence shoul d be cl eaned of ol d ure-
thane bondi ng materi al . Support spacers shoul d be
cl eaned and properl y i nstal l ed on wel d studs or
repai r screws at bottom of wi ndshi el d openi ng.
(1) Pl ace repl acement wi ndshi el d i nto wi ndshi el d
openi ng. Posi ti on gl ass i n the center of the openi ng
agai nst the support spacers. Mark the gl ass at the
support spacers wi th a grease penci l or maski ng tape
and i nk pen to use as a reference for i nstal l ati on.
Remove repl acement wi ndshi el d from wi ndshi el d
openi ng.
(2) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm
by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced par-
al l el 75 cm (2.5 ft.) apart.
(3) Cl ean i nsi de of wi ndshi el d wi th Mopar Gl ass
Cl eaner and l i nt-free cl oth.
(4) Appl y cl ear gl ass pri mer 25 mm (1 i n.) wi de
around edge of wi ndshi el d. Wi pe wi th cl ean/dry l i nt-
free cl oth.
(5) Appl y bl ack-out pri mer 15 mm (.75 i n.) wi de on
top and si des of wi ndshi el d and 25 mm (1 i n.) on bot-
tom of wi ndshi el d. Al l ow at l east three mi nutes dry-
i ng ti me.
(6) Posi ti on wi ndshi el d spacers on l ower fence
above support spacers at the edge of the wi ndshi el d
openi ng.
(7) Al i gn the dot on the upper mol di ng to the ti ck
mark i n the center of the gl ass and i nstal l upper
mol di ng onto wi ndshi el d.
(8) Appl y a 10 mm (0.4 i n.) bead of urethane
around peri meter of wi ndshi el d al ong the i nsi de of
the mol di ngs. Appl y two beads al ong the bottom
edge.
KJ STATIONARY GLASS 23 - 173
(9) Appl y fence pri mer around the peri meter of the
wi ndshi el d openi ng fence. Al l ow at l east 18 mi nutes
dryi ng ti me.
(10) Wi th ai d of a hel per, posi ti on wi ndshi el d over
wi ndshi el d openi ng. Al i gn reference marks at bottom
of wi ndshi el d to support spacers.
(11) Sl owl y l ower wi ndshi el d gl ass to wi ndshi el d
openi ng fence. Gui de top mol di ng i nto proper posi ti on
i f necessary. Push wi ndshi el d i nward to fence spacers
at bottom and unti l top mol di ng i s fl ush to roof l i ne.
(12) Cl ean excess urethane from exteri or wi th
Mopar Super Cl ean or equi val ent.
(13) I nstal l wi ndshi el d si de mol di ngs. (Refer to 23
- BODY/WEATHERSTRI P/SEALS/WI NDSHI ELD
A-PI LLAR WEATHERSTRI P - I NSTALLATI ON)
(14) I nstal l cowl gri l l e. (Refer to 23 - BODY/EXTE-
RI OR/COWL GRI LLE - I NSTALLATI ON)
(15) I nstal l i nsi de rear vi ew mi rror. (Refer to 23 -
BODY/I NTERI OR/REAR VI EW MI RROR - I NSTAL-
LATI ON)
(16) After urethane has cured, water test wi nd-
shi el d to veri fy repai r.
23 - 174 STATIONARY GLASS KJ
WINDSHIELD (Continued)
SUNROOF
TABLE OF CONTENTS
page page
SUNROOF
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 175
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 176
DIAGNOSTIC PROCEDURES . . . . . . . . . . . 176
GLASS PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 178
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT . . 178
GLASS PANEL SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 178
SUNSHADE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 179
GUIDE ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 179
WIND DEFLECTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 180
OPENING TRIM LACE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 180
DRAIN TUBE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 181
MODULE ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 181
DRIVE MOTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 182
CONTROL MODULE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 183
CONTROL SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 184
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 184
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 184
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 184
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sunroof features a power sl i di ng gl ass panel
and a sunshade whi ch can be manual l y posi ti oned
anywhere al ong i ts travel , rearward of gl ass panel
front edge.
The sunroof i s el ectri cal l y operated from two
swi tches l ocated on the wi ndshi el d header, rearward
of the map l amp. To operate the sunroof the i gni ti on
swi tch must be i n ei ther the Accessory or On/Run
posi ti on. One swi tch (vent) i s a push button type and
opens the sunroof to the vent posi ti on onl y. The other
swi tch (open/cl ose) i s a rocker type for openi ng and
cl osi ng the sunroof. Pressi ng and rel easi ng the open
button once the sunroof wi l l express open and the
wi nd defl ector wi l l rai se. I f the button i s pressed a
second ti me the sunroof wi l l stop i n that posi ti on.
Pressi ng and hol di ng the cl ose button wi l l cl ose the
sunroof. I f the cl ose button i s rel eased the sunroof
wi l l stop i n that posi ti on.
KJ SUNROOF 23 - 175
SUNROOF OPERATION INSTRUCTIONS
SWITCH INPUTS
OPEN CLOSE VENT
FULL VENT
Push and hold switch until
glass stops in flush closed
position glass will then
express open
position.
No action
VENT RANGE
glass passes through
flush closed position.
Glass will then open
position.
glass stops in full vent
position.
FLUSH
1. Press switch for less
than 0.65 seconds for
express to comfort stop.
No action Press and hold switch.
Glass will travel through
flush closed to full vent.
Glass will stop when
switch is released or when
fully vented.
2. Press switch for more
than 0.65 seconds and
glass will stop when
switch is released
FULL OPEN
Press switch for less than
0.65 seconds for express
to full open.
Press and hold switch
until glass stops in flush
closed position or
anywhere in between.
Press and hold switch.
Glass will travel through
flush closed to full vent.
Glass will stop when
switch is released.
DIAGNOSIS
The sl i di ng gl ass panel i s desi gned to seal water
entry wi th a snug fi t between the roof and the seal .
The fi t can be checked by i nserti ng a pi ece of paper
between the roof and the seal . The pi ece of paper
shoul d have some resi stance when pul l ed out when
the gl ass panel i s i n the cl osed posi ti on. The sunroof
housi ng wi l l drai n off a mi ni mum amount of water.
Excessi ve wi nd noi se coul d resul t i f the gap cl ear-
ances are exceeded. The sunroof gl ass panel may
need to be adjusted. Refer to Sunroof Gl ass Panel
Adjustment for proper procedures.
Adequate drai nage i s provi ded by a drai n trough i n
the sunroof housi ng whi ch enci rcl es the sl i di ng gl ass
panel and l eads to drai n hoses. I f a wet headl i ner or
other water l eak compl ai nts are encountered, before
performi ng any adjustments, fi rst ensure that the
drai nage system i s not pl ugged or di sconnected. Use
a pi nt contai ner to pour water i nto the sunroof hous-
i ng drai n trough. I f water fl ow i s restri cted, use com-
pressed ai r to bl ow out any materi al pl uggi ng the
drai n system. Retest system agai n.
To further check for a di sconnected drai n hose:
(1) Remove A-pi l l ar tri m, sun vi sors, and map
l amps/mi ni consol e.
(2) Remove sunroof openi ng tri m l ace. Refer to
Sunroof Openi ng Tri m Lace.
(3) Lower headl i ner as necessary to gai n access to
sunroof housi ng drai n tubes. (Refer to 23 - BODY/I N-
TERI OR/HEADLI NER - REMOVAL)
(4) Repai r as necessary.
DIAGNOSTIC PROCEDURES
Before begi nni ng sunroof di agnosti cs veri fy that al l
other power accessori es are i n proper operati ng condi -
ti on. Refer to Sunroof Di agnosti c Chart for possi bl e
causes. I f not, a common el ectri cal probl em may exi st.
Refer to Wi ri ng Di agrams, i n thi s publ i cati on for ci rcui t,
spl i ce and component descri pti ons. Check the condi ti on
of the ci rcui t protecti on (20 amp ci rcui t breaker i n cav-
i ty 19 of the Juncti on Bl ock). I nspect al l wi ri ng connec-
tor pi ns for proper engagement and conti nui ty. Check
for battery vol tage at the power sunroof control l er, refer
to Wi ri ng Di agrams, for ci rcui t i nformati on. I f battery
vol tage of more than 10 vol ts i s detected at the control -
l er, proceed wi th the fol l owi ng tests (the control l er wi l l
not operate at l ess than 10 vol ts).
23 - 176 SUNROOF KJ
SUNROOF (Continued)
Before begi nni ng di agnosi s for wi nd noi se or water
l eaks, veri fy that the probl em was not caused by
rel easi ng the control swi tch before the sunroof was
ful l y cl osed. The sunroof modul e has a water-man-
agement system. I f however, the sunroof gl ass i s i n a
parti al cl osed posi ti on, hi gh pressure water may be
forced beyond the water management system bound-
ari es and onto the headl i ni ng.
SUNROOF DIAGNOSIS CHART
SYMPTOM POSSIBLE CAUSE
Sunroof motor inoperative. Faulty control switch.
Faulty circuit ground between sunroof electronics module,
control switch, and body harness.
Faulty power circuit between sunroof electronics module,
control switch, and body harness.
Faulty drive motor.
Faulty electronics module.
Faulty drive motor electrical connector.
Audible whine when switch is depressed,
sunroof does not operate.
Faulty drive motor.
Binding cable.
Audible clicking or ratcheting when switch is
pressed, sunroof does not operate.
Broken or worn drive cable.
Worn drive motor gear.
Mechanisms not synchronized.
Sunroof vents and opens, but does not close. Binding cable.
Faulty circuit.
Faulty control switch.
Faulty electronic module.
Faulty drive motor.
Sunroof vents, but does not open. Binding cable or mechanism.
Faulty circuit.
Faulty switch.
Faulty electronic module.
Sunroof does not vent Binding cable or mechanism.
Faulty circuit.
Faulty control switch.
Faulty sunroof electronic module.
Sunroof water leak. Drain tubes clogged or kinked or disconnected from the
sunroof.
Glass panel improperly adjusted.
Faulty glass panel seal.
Gurgling sound from sunroof Low spot in drain hose routing, allowing water to stand.
Wind noise from sunroof. Front of glass panel too high or rear too low.
Wind deflector not deploying.
Glass not centered in opening.
Faulty glass panel seal.
Rattles from open sunroof while driving Loose or broken attaching hardware.
Worn or broken mechanism.
KJ SUNROOF 23 - 177
SUNROOF (Continued)
GLASS PANEL
REMOVAL
(1) Sl i de sunshade rearward to the open posi ti on.
(2) Move the gl ass panel to the cl osed posi ti on.
(3) Remove the four gl ass panel screws (Fi g. 1).
(4) Li ft off gl ass panel and remove from vehi cl e.
INSTALLATION
(1) Posi ti on gl ass panel on to mechani sm l i ft arm.
(2) Start the four attachi ng screws.
(3) Center gl ass i n openi ng by runni ng a busi ness
card around the gl ass.
(4) Adjust gl ass panel . (Refer to 23 - BODY/SUN-
ROOF/GLASS PANEL - ADJUSTMENTS)
ADJ USTMENTS
SUNROOF GLASS PANEL ADJUSTMENT
(1) Move the sunshade rearward to the open posi -
ti on.
(2) Move the sunroof gl ass panel to the ful l y cl osed
posi ti on.
(3) Adjust the gl ass one corner at a ti me.
(a) Loosen four gl ass screws (Fi g. 2).
(b) Li ft gl ass assembl y and al i gn the top of the
gl ass panel to the top of the roof panel .
(c) Ti ghten screw to 3.5 Nm (31 i n. l bs.).
(d) Repeat steps a. and b. for each corner of the
gl ass panel .
(e) When properl y adjusted, the front of the
gl ass panel i s 1.75 mm (0.07 i n.) to 2.75 mm (0.11
i n.) l ower than the roof surface and the rear edge
of the gl ass panel i s 1.75mm (0.07 i n.) to .75 mm
(0.03 i n.) l ower than the roof surface.
NOTE: Glass assembly seal is 2.5mm (0.1 in) higher
than the glass panel. Measure at 300mm (11.8 in)
outboard of the centerline of the vehicle.
(4) Veri fy sunroof operati on and al i gnment. Check
fi t and re-adjust as necessary.
GLASS PANEL SEAL
REMOVAL
(1) Remove sunroof gl ass panel . (Refer to 23 -
BODY/SUNROOF/GLASS PANEL - REMOVAL)
(2) Pl ace gl ass panel on cl ean work area wi th the
top si de up. Support the gl ass assembl y from under-
si de to avoi d bendi ng or otherwi se damagi ng the
mounti ng tabs.
(3) Grasp the seal and pul l seal away from the
gl ass panel . The seal i s a one pi ece seal .
INSTALLATION
NOTE: Always position seal seam on center of the
passenger side of glass panel.
(1) Pl ace seal i nto posi ti on.
(2) I nstal l seal on gl ass. Usi ng care worki ng the
seal around the gl ass, bei ng careful not to over
stretch the seal whi l e i nstal l i ng.
(3) I nstal l the gl ass panel . (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - I NSTALLATI ON)
Fig. 1 GLASS PANEL
1 - SCREWS
2 - GLASS PANEL
3 - MODULE ASSEMBLY
Fig. 2 GLASS PANEL
1 - SCREWS
2 - GLASS PANEL
3 - MODULE ASSEMBLY
23 - 178 SUNROOF KJ
SUNSHADE
REMOVAL
(1) Remove gl ass assembl y from the sunroof
assembl y. (Refer to 23 - BODY/SUNROOF/GLASS
PANEL - REMOVAL)
(2) Remove two screws from trough assembl y (Fi g.
3).
(3) Remove trough assembl y.
(4) Sl i de the sunshade forward to di sengage the
gui de feet from the tracks through the cutouts at the
front of the tracks.
CAUTION: Use care not to crease the sunshade
when removing or installing.
INSTALLATION
(1) Pl ace sunshade i nto posi ti on, through the cut-
outs at the front of the tracks and sl i de the sunshade
back.
(2) Pl ace trough assembl y i nto posi ti on on sunroof
modul e and i nstal l the screws.
GUIDE ASSEMBLY
REMOVAL
(1) Remove the gl ass panel . (Refer to 23 - BODY/
SUNROOF/GLASS PANEL - REMOVAL)
(2) Pl ace sunroof i nto the vent posi ti on.
(3) Remove two screws from trough assembl y (Fi g.
3).
(4) Remove trough assembl y.
(5) Di sconnect the gui de l i nk (Fi g. 4).
(6) Sl i de trough gui de forward and di sengage the
sl i ders through the notches i n the gui de channel s
(Fi g. 5).
INSTALLATION
(1) I nstal l the trough gui de and engage the sl i ders
i nto the gui de channel s through the notches.
(2) Connect the gui de l i nk.
(3) I nstal l the trough and i nstal l the two screws.
Fig. 3 GUIDE ASSEMBLY TROUGH
1 - TROUGH
2 - TROUGH GUIDE
3 - SCREW
Fig. 4 TROUGH GUIDES
1 - TROUGH GUIDE
2 - GUIDE LINK
KJ SUNROOF 23 - 179
WIND DEFLECTOR
REMOVAL
(1) Open sunroof gl ass panel to the ful l open posi -
ti on.
(2) Remove screws attachi ng wi nd defl ector straps
to front crossmember (Fi g. 6).
(3) Rotate wi nd defl ector back about 110 and sl i de
backwards to di sengage from the spri ng hook.
INSTALLATION
(1) Pl ace wi nd defl ector i n posi ti on 110 to roof.
(2) Push arms down and forward to engage spri ng
hooks.
(3) Rotate wi nd defl ector forward i nto correct posi -
ti on. Depress wi nd defl ector down onto front cross-
member to check spri ng functi on.
(4) I nstal l fasteners attachi ng wi nd defl ector
straps to front crossmember.
(5) Test sunroof operati on.
OPENING TRIM LACE
REMOVAL
(1) Remove l ace by starti ng at the joi nt center of
the openi ng on dri vers si de.
(2) Pul l one end of the l ace away from the head-
l i ner unti l the enti re l ace i s removed.
INSTALLATION
(1) Pl ace end of tri m l ace i nto posi ti on starti ng at
center of the openi ng on dri vers si de.
(2) Push l ace i nto posi ti on.
(3) Ensure that the corner radi i i s ful l y engage.
(4) Once tri m l ace i s attached to sunroof modul e
begi n tucki ng the headl i ne under the l i p on the tri m
l ace worki ng al l the way around the openi ng.
DRAIN TUBE
REMOVAL
FRONT DRAIN TUBES
(1) Move gl ass panel to the ful l y cl osed posi ti on.
(2) Remove sunroof openi ng tri m l ace.
(3) Remove the headl i ner. (Refer to 23 - BODY/I N-
TERI OR/HEADLI NER - REMOVAL)
(4) Di sconnect the drai n hose from the sunroof
housi ng (Fi g. 7).
(5) Drai n any l i qui d from hose connecti on, i f nec-
essary.
(6) Remove the i nstrument panel top panel . (Refer
(7) Di sconnect the grommet, attachment cl i ps and
remove the drai n tube.
REAR DRAIN TUBES
(3) Remove headl i ner.
Fig. 5 TROUGH GUIDE REMOVAL
1 - TROUGH GUIDE
2 - NOTCH
3 - SLIDER
Fig. 6 SUNSHADE
1 - WIND DEFLECTOR
2 - SCREW
3 - SPRING
23 - 180 SUNROOF KJ
GUIDE ASSEMBLY (Continued)
(4) Di sconnect the drai n hose from the sunroof
housi ng (Fi g. 8).
(5) Drai n any l i qui d from hose connecti on, i f nec-
essary.
(6) Di sconnect the grommet, attachment cl i ps and
remove the drai n tube.
INSTALLATION
FRONT DRAIN TUBES
(1) Connect the drai n hose to the sunroof housi ng
and test drai nage.
(2) Connect the body grommet and attachment
cl i ps.
(3) I nstal l the i nstrument panel top panel . (Refer
(4) I nstal l the headl i ner. (Refer to 23 - BODY/I N-
TERI OR/HEADLI NER - I NSTALLATI ON)
(5) I nstal l sunroof openi ng tri m l ace. (Refer to 23 -
BODY/SUNROOF/OPENI NG TRI M LACE - I NSTAL-
LATI ON)
REAR DRAIN TUBES
(1) Connect the drai n hose to the sunroof housi ng
and test drai nage.
(2) Connect the body grommet and attachment
cl i ps.
(3) I nstal l the headl i ner.
(4) I nstal l sunroof openi ng tri m l ace.
MODULE ASSEMBLY
REMOVAL
cabl e.
(4) Remove headl i ner. (Refer to 23 - BODY/I NTE-
RI OR/HEADLI NER - REMOVAL)
(5) Di sconnect wi re harness push i n fasteners and
el ectri cal connector. (Fi g. 9)
(6) Di sconnect the drai n tubes from sunroof hous-
i ng.
(7) Loosen fasteners attachi ng sunroof modul e
assembl y.
(8) Wi th the ai d of a hel per, remove fasteners
attachi ng sunroof modul e assembl y to roof panel
(Fi g. 10).
INSTALLATION
(1) Wi th the Gl ass panel i n the ful l y cl osed posi -
ti on.
(2) Rai se rear end of sunroof modul e assembl y and
gui de i nto posi ti on and start fasteners.
(3) Ti ghten the fasteners to 9 Nm (80 i n. l bs.).
(4) Connect the drai n tubes.
Fig. 7 FRONT DRAIN TUBE
1 - TUBE
2 - CLIPS
3 - GROMMET
Fig. 8 REAR DRAIN TUBE
1 - GROMMET
2 - TUBE
3 - CLIPS
KJ SUNROOF 23 - 181
DRAIN TUBE (Continued)
(5) Connect wi re harness.
(6) I nstal l the headl i ner. (Refer to 23 - BODY/I N-
TERI OR/HEADLI NER - I NSTALLATI ON)
(7) I nstal l the openi ng tri m l ace. (Refer to 23 -
BODY/SUNROOF/OPENI NG TRI M LACE - I NSTAL-
LATI ON)
(9) Test sunroof operati on, adjust as necessary.
(Refer to 23 - BODY/SUNROOF/GLASS PANEL -
ADJUSTMENTS)
DRIVE MOTOR
REMOVAL
(1) Remove headl i ner. (Refer to 23 - BODY/I NTE-
RI OR/HEADLI NER - REMOVAL)
(2) Cut wi re retai ni ng tape bei ng careful not to cut
wi res.
(3) Di sconnect the el ectri cal connector (Fi g. 11).
(4) Remove three motor assembl y attachi ng screws
from bottom si de of motor assembl y and remove
motor assembl y from the motor bracket.
INSTALLATION
(1) Pl ace motor i nto posi ti on and i nstal l screws
attachi ng motor to bracket.
NOTE: Hold electronics module to motor bracket
when inserting motor shaft to avoid disengaging
drive cables.
(3) Tape wi res to dri ve cabl es to prevent rattl es.
Fig. 9 WIRE HARNESS
1 - CLIPS
3 - WIRE HARNESS
Fig. 10 MODULE ASSEMBLY
1 - U-NUTS
2 - DRIVE MOTOR
3 - BOLTS
4 - GLASS OPENING
5 - MODULE ASSEMBLY
Fig. 11 DRIVE MOTOR ASSEMBLY
1 - CONTROL MODULE
2 - SCREWS
3 - DRIVE MOTOR
4 - SCREW
23 - 182 SUNROOF KJ
MODULE ASSEMBLY (Continued)
(4) Test sunroof operati on, adjust as necessary.
(5) I nstal l headl i ner. (Refer to 23 - BODY/I NTERI -
OR/HEADLI NER - I NSTALLATI ON)
CONTROL MODULE
REMOVAL
(1) Remove the modul e assembl y. (Refer to 23 -
BODY/SUNROOF/MODULE ASSEMBLY -
REMOVAL)
(2) Remove three motor assembl y retai ni ng screws
from bottom si de of motor, and remove motor assem-
bl y (Fi g. 11).
(3) From top si de of modul e assembl y, remove one
attachi ng screw from el ectroni cs modul e. (Fi g. 12)
(4) Remove ol d ti mi ng modul e.
INSTALLATION
(1) Check gl ass assembl y posi ti on. Adjust to ful l
cl osed posi ti on. I nsert pi n i nto hol es i n l i ft arm
assembl y to check posi ti on (Fi g. 13).
(2) Set new el ectroni c modul e i n posi ti on on top
si de of motor mounti ng bracket engagi ng dri ve cabl es
wi th pi ni on gear i n el ectroni cs modul e.
(3) I nstal l one screw to attach el ectroni cs modul e
to motor bracket. Ti ghten screw to 3 Nm (27 i n. l bs.)
torque.
(4) I nstal l motor assembl y to motor bracket and
el ectroni cs modul e wi th three screws. Ti ghten screw
to 1.75 Nm (15.5 i n. l bs.) torque.
(5) Remove the new modul es ti mi ng pi n and di s-
card. (Fi g. 14)
(6) Connect el ectri cal connector to modul e assem-
bl y wi re harness. Secure any l oose wi res.
(7) I nstal l modul e assembl y. (Refer to 23 - BODY/
SUNROOF/MODULE ASSEMBLY - I NSTALLA-
TI ON)
(8) Test operati on, adjust as necessary. (Refer to 23
- BODY/SUNROOF/GLASS PANEL - ADJUST-
MENTS)
(9) I nstal l openi ng tri m l ace. (Refer to 23 - BODY/
SUNROOF/OPENI NG TRI M LACE - I NSTALLA-
TI ON)
Fig. 12 CONTROL MODULE
1 - MOTOR BRACKET
2 - CABLES
3 - SCREW
4 - CONTROL MODULE
Fig. 13 LIFT ARM POSITIONING
1 - GLASS BRACKET
2 - LIFT ARM
3 - ALIGNMENT PIN
Fig. 14 MODULE TIMING PIN
1 - CONTROL MODULE
2 - TIMING PIN
KJ SUNROOF 23 - 183
DRIVE MOTOR (Continued)
CONTROL SWITCH
DESCRIPTION
Vehi cl es equi pped wi th a power sunroof uti l i ze an
sunroof control swi tch. On thi s model , the sunroof
control swi tch i s l ocated i n the overhead consol e, i n
between the two readi ng l amps. The swi tch i s
mounted i n the overhead consol e wi th four pl asti c
retai ni ng tabs, mol ded i nto the swi tch housi ng.
Thi s swi tch i ncorporates four sel ecti ons of opera-
ti on open, auto open, cl ose and vent. The i ndi vi dual
swi tches i n the sunroof control swi tch uni t cannot be
repai red. I f one swi tch i s damaged or faul ty, the
enti re sunroof control swi tch uni t must be repl aced.
OPERATION
Wi th the operati on of the sunroof control swi tch,
vol tage i s di rected to the sunroof motor, through the
swi tch contacts or control modul e. I f the control
swi tch i s depressed and hel d depressed the vol tage
si gnal i s control l ed manual l y through the swi tch con-
tacts, so when the swi tch i s rel eased the sunroof
stops.
on the operati on of the sunroof swi tch and system.
The fol l owi ng test wi l l determi ne i f the sunroof
control swi tch i s operati ng properl y.
SOLE - REMOVAL).
(2) Remove the sunroof control swi tch from the
overhead consol e (Refer to 23 - BODY/SUNROOF/
CONTROL SWI TCH - REMOVAL).
(3) Usi ng an ohmmeter, test the swi tch termi nal s
for proper conti nui ty usi ng the tabl e bel ow. I f any of
the termi nal s do not show proper conti nui ty, repl ace
the sunroof control swi tch.
SWITCH POSITION
(DEPRESSED)
CONTINUITY BETWEEN
TERMINALS
VENT (V) 3, 4
OPEN (AUTO) 1, 4
CLOSE 2, 4
REMOVAL
cabl e.
SOLE - REMOVAL).
(3) Di sconnect the sunroof control swi tch el ectri cal
connector. Depress the connector retai ni ng tab and
pul l the connector strai ght out.
(4) To remove the swi tch from the overhead con-
sol e, push on the back of the swi tch unti l i t comes
free from the overhead consol e.
INSTALLATION
(1) I nstal l the swi tch i n the overhead consol e
assembl y. Be certai n the swi tch i s securel y snapped
i n pl ace.
(2) Connect the sunroof control swi tch el ectri cal
connector. Be certai n the swi tch connector i s securel y
snapped i n pl ace.
(3) I nstal l the overhead consol e (Refer to 8 -
TI ON).
23 - 184 SUNROOF KJ
WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
A-PILLAR SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 185
COWL WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 185
DOOR PRIMARY WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 185
DOOR LOWER WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 186
FRONT DOOR OUTER BELT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 186
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 186
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 186
REAR DOOR OUTER BELT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 186
SIDE RAIL WEATHERSTRIP/RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 186
RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 187
COWL/PLENUM SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 187
COWL/PLENUM WINDOW BAFFLE SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 187
A-PILLAR SEAL
REMOVAL
(1) Open the doors and peal the seal away from
the a-pi l l ar/wi ndshi el d and the si de rai l weather
stri p fl anges.
INSTALLATION
(1) Posi ti on the a-pi l l ar seal over the wi ndshi el d/a-
pi l l ar and the si de rai l weatherstri p fl anges and seat
ful l y.
COWL WEATHERSTRIP
REMOVAL
(1) Open the hood and peal the cowl seal from the
cowl panel and cowl fl ange.
INSTALLATION
(1) Posi ti on the weatherstri p over the cowl fl ange
and the cowl gri l l e and seat ful l y.
DOOR PRIMARY
WEATHERSTRIP
REMOVAL
(1) Remove the l ower b-pi l l ar tri m. (Refer to 23 -
REMOVAL)
(2) Peal seal off of the door openi ng fl ange.
INSTALLATION
(1) Posi ti on the seal to the bottom of the door
openi ng, wi th bul b faci ng outboard, starti ng the
i nstal l ati on at the center of the l ower fl ange. Press
the seal onto the si l l fl ange and work around the
peri meter of the door openi ng unti l ful l y seated.
Work i n one di recti on, smoothi ng the seal to avoi d
puckers or wri nkl es.
(2) I nstal l the l ower b-pi l l ar tri m. (Refer to 23 -
I NSTALLATI ON)
(3) When i nstal l i ng a new weatherstri p on the
front door openi ng, remove the tear stri p starti ng at
the spl i ce and movi ng around the front of the door to
the back of the openi ng.
KJ WEATHERSTRIP/SEALS 23 - 185
(4) When i nstal l i ng a new weatherstri p on the rear
door openi ng, remove the tear stri p starti ng at the
spl i ce and movi ng around the back of the door to the
front of the openi ng.
DOOR LOWER WEATHERSTRIP
REMOVAL
(1) Careful l y di sengage the push pi n fasteners and
remove the seal .
INSTALLATION
(1) Posi ti on the seal and seat the push pi n fasten-
ers.
FRONT DOOR OUTER BELT
MOLDING
REMOVAL
(1) Lower the wi ndow.
(2) Pul l the outer bel t mol di ng off of the door
fl ange starti ng at the rear and movi ng forward.
INSTALLATION
(1) Press the bel t mol di ng onto the outer door wi n-
dow fl ange starti ng at the rear and worki ng forward.
SWING GATE BELTLINE
WEATHERSTRIP
REMOVAL
(1) Remove the swi ng gate tri m panel . (Refer to 23
- BODY/SWI NG GATE/TRI M PANEL - REMOVAL)
(2) Pul l seal away from the corner tabs and
remove from the swi ng gate fl ange.
INSTALLATION
(1) I nstal l the seal over the swi ng gate fl ange and
seat the corner tabs.
(2) I nstal l the swi ng gate tri m panel . (Refer to 23 -
BODY/SWI NG GATE/TRI M PANEL - I NSTALLA-
TI ON)
SWING GATE OPENING
WEATHERSTRIP
REMOVAL
(1) Open the swi ng gate and peal seal off of the
gate openi ng fl ange.
INSTALLATION
(1) Posi ti on the seal to the bottom of the gate
openi ng starti ng the i nstal l ati on at the center of the
fl ange. Press the seal onto the si l l fl ange and work
around the peri meter of the door openi ng unti l ful l y
seated. Work i n one di recti on, smoothi ng the seal to
avoi d puckers or wri nkl es.
REAR DOOR OUTER BELT
MOLDING
REMOVAL
(1) Lower the wi ndow.
(2) Pul l the outer bel t mol di ng off of the door
fl ange starti ng at the rear and movi ng forward.
INSTALLATION
(1) Press the bel t mol di ng onto the outer door wi n-
dow fl ange starti ng at the front and worki ng back.
SIDE RAIL WEATHERSTRIP/
RETAINER
REMOVAL
(1) Remove the wi ndshi el d weatherstri p retai ner.
(Refer to 23 - BODY/WEATHERSTRI P/SEALS/
WI NDSHI ELD A-PI LLAR WEATHERSTRI P/RE-
TAI NER - REMOVAL)
(2) Remove the two screws.
rel ease the push i n fasteners and remove the weath-
erstri p.
INSTALLATION
(1) Posi ti on the weatherstri p and seat the push i n
fasteners.
(2) I nstal l the two screws.
(3) I nstal l the wi ndshi el d weatherstri p. (Refer to
23 - BODY/WEATHERSTRI P/SEALS/WI NDSHI ELD
A-PI LLAR WEATHERSTRI P/RETAI NER - I NSTAL-
LATI ON)
WINDSHIELD A-PILLAR
WEATHERSTRIP/RETAINER
REMOVAL
(1) Open the doors and peal the a-pi l l ar seal away
from the a-pi l l ar/wi ndshi el d and the si de rai l
weather stri p fl anges.
(2) Remove the seven screws and remove the
weatherstri p.
23 - 186 WEATHERSTRIP/SEALS KJ
DOOR PRIMARY WEATHERSTRIP (Continued)
INSTALLATION
(1) Posi ti on the weatherstri p and i nstal l the seven
screws.
(2) Posi ti on the a-pi l l ar seal over the wi ndshi el d/a-
pi l l ar and the si de rai l weatherstri p fl anges and seat
ful l y.
COWL/PLENUM SEAL
REMOVAL
(1) Remove the cowl gri l l e. (Refer to 23 - BODY/
EXTERI OR/COWL GRI LLE - REMOVAL)
(2) Remove the seal from the pl enum fl ange above
the ai r i nl et duct.
INSTALLATION
NOTE: Seal should not be touching the plenum baf-
fle flange seal.
(1) Posi ti on the seal on the pl enum fl ange and seat
ful l y.
(2) I nstal l the cowl gri l l e. (Refer to 23 - BODY/EX-
TERI OR/COWL GRI LLE - I NSTALLATI ON)
COWL/PLENUM WINDOW
BAFFLE SEAL
REMOVAL
(1) Remove the cowl gri l l e. (Refer to 23 - BODY/
EXTERI OR/COWL GRI LLE - REMOVAL)
(2) Remove the seal from the wi ndow bel ow the
cowl /pl enum seal .
INSTALLATION
(1) Posi ti on the seal agai nst the upper fl ange of
the i nner pl enum wi ndow bel ow the cowl /pl enum seal
and seat ful l y.
(2) I nstal l the cowl gri l l e. (Refer to 23 - BODY/EX-
TERI OR/COWL GRI LLE - I NSTALLATI ON)
KJ WEATHERSTRIP/SEALS 23 - 187
WINDSHIELD A-PILLAR WEATHERSTRIP/RETAINER (Continued)
HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 1
REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT. . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION - REFRIGERANT SYSTEM
SERVICE PORT. . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - A/C
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - DIODE
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
A/C APPLICATION TABLE . . . . . . . . . . . . . . . . 9
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 10
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
CONDITIONER
Al l vehi cl es are equi pped wi th a common HVAC
housi ng assembl y (Fi g. 1). The system combi nes ai r
condi ti oni ng, heati ng, and venti l ati ng capabi l i ti es i n
a si ngl e uni t housi ng mounted under the i nstrument
panel . On heater-onl y systems, the evaporator coi l i s
omi tted from the housi ng.
REQUIREMENTS
To mai ntai n the performance l evel of the HVAC
system, the engi ne cool i ng system must be properl y
mai ntai ned. The use of a bug screen i s not recom-
mended. Any obstructi ons i n front of the radi ator or
condenser wi l l reduce the performance of the ai r con-
di ti oni ng and engi ne cool i ng systems.
The engi ne cool i ng system i ncl udes the heater core
and the heater hoses. Refer to Engi ne Cool i ng for
more i nformati on before the openi ng of, or attempt-
i ng any servi ce to the engi ne cool i ng system.
Fig. 1 Blend Door
1 - DEFROSTER DOOR
2- HEATER CORE
3- BLEND DOORS
4- BLOWER MOTOR HOUSING
5- EVAPORATOR (A/C ONLY)
6- LOWER HVAC CASE ASSEMBLY
KJ HEATING & AIR CONDITIONING 24 - 1
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT
The two refri gerant system servi ce ports are used
to charge, recover/recycl e, evacuate, and test the ai r
condi ti oni ng refri gerant system. Uni que servi ce port
coupl er si zes are used on the R-134a system, to
ensure that the refri gerant system i s not acci dental l y
contami nated by the use of the wrong refri gerant
(R-12), or refri gerant system servi ce equi pment.
OPERATION
OPERATION - HEATER AND AIR CONDITIONER
The heater and opti onal ai r condi ti oner are bl end-
ai r type systems. I n a bl end-ai r system, a bl end door
control s the amount of uncondi ti oned ai r (or cool ed
ai r from the evaporator on model s wi th ai r condi ti on-
i ng) that i s al l owed to fl ow through, or around, the
heater core. A temperature control knob on the A/C
Heater control panel determi nes the di scharge ai r
temperature by control l i ng an el ectri c actuator,
whi ch moves the bl end door. Thi s al l ows an al most
i mmedi ate control of the output ai r temperature of
the system.
The mode control knob on the heater-onl y or A/C
Heater control panel i s used to di rect the condi ti oned
ai r to the sel ected system outl ets. Both mode control
swi tches use engi ne vacuum to control the mode
doors, whi ch are operated by vacuum actuators.
On al l vehi cl es, the outsi de ai r i ntake can be shut
off by sel ecti ng the Reci rcul ati on Mode wi th the
mode control knob. Thi s wi l l operate a vacuum actu-
ated reci rcul ati on door that cl oses off the outsi de
fresh ai r i ntake and reci rcul ates the ai r that i s
al ready i nsi de the vehi cl e.
The opti onal ai r condi ti oner for al l model s i s
desi gned for the use of non-CFC, R-134a refri gerant.
The ai r condi ti oni ng system has an evaporator to cool
and dehumi di fy the i ncomi ng ai r pri or to bl endi ng i t
wi th the heated ai r. Thi s ai r condi ti oni ng system
uses a fi xed ori fi ce tube i n the l i qui d l i ne near the
condenser outl et tube to meter refri gerant fl ow to the
evaporator coi l . To mai ntai n mi ni mum evaporator
temperature and prevent evaporator freezi ng, the
A/C l ow pressure swi tch on the accumul ator cycl es
the compressor cl utch.
OPERATION - REFRIGERANT SYSTEM SERVICE
PORT
The hi gh pressure servi ce port i s l ocated on the
refri gerant l i ne, near the di scharge port of the com-
pressor. The l ow pressure servi ce port i s l ocated on
the l i qui d l i ne at the si de of the engi ne compartment,
near the condensor.
Each of the servi ce ports has a threaded pl asti c
protecti ve cap i nstal l ed over i t from the factory. After
servi ci ng the refri gerant system, al ways rei nstal l
both of the servi ce port caps.
PERFORMANCE
The ai r condi ti oni ng system i s desi gned to provi de
the passenger compartment wi th l ow temperature
and l ow humi di ty ai r. The evaporator, l ocated i n the
HVAC housi ng on the dash panel bel ow the i nstru-
ment panel , i s cool ed to temperatures near the freez-
i ng poi nt. As warm damp ai r passes through the
cool ed evaporator, the ai r transfers i ts heat to the
refri gerant i n the evaporator and the moi sture i n the
ai r condenses on the evaporator fi ns. Duri ng peri ods
of hi gh heat and humi di ty, an ai r condi ti oni ng sys-
tem wi l l be more effecti ve i n the Reci rcul ati on Mode.
Wi th the system i n the Reci rcul ati on Mode, onl y ai r
from the passenger compartment passes through the
evaporator. As the passenger compartment ai r dehu-
mi di fi es, the ai r condi ti oni ng system performance
l evel s i mprove.
Humi di ty has an i mportant beari ng on the temper-
ature of the ai r del i vered to the i nteri or of the vehi -
cl e. I t i s i mportant to understand the effect that
humi di ty has on the performance of the ai r condi ti on-
i ng system. When humi di ty i s hi gh, the evaporator
has to perform a doubl e duty. I t must l ower the ai r
temperature, and i t must l ower the temperature of
the moi sture i n the ai r that condenses on the evapo-
rator fi ns. Condensi ng the moi sture i n the ai r trans-
fers heat energy i nto the evaporator fi ns and tubi ng.
Thi s reduces the amount of heat the evaporator can
absorb from the ai r. Hi gh humi di ty greatl y reduces
the abi l i ty of the evaporator to l ower the temperature
of the ai r.
However, evaporator capaci ty used to reduce the
amount of moi sture i n the ai r i s not wasted. Remov-
i ng some of the moi sture out of the ai r enteri ng the
vehi cl e adds to the comfort of the passengers.
Al though, an owner may expect too much from the
ai r condi ti oni ng system on humi d days. A perfor-
mance test i s the best way to determi ne whether the
system i s performi ng up to standard. Thi s test al so
provi des val uabl e cl ues as to the possi bl e cause of
troubl e wi th the ai r condi ti oni ng system.
Before proceedi ng, (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - WARNI NG) and
(Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
PLUMBI NG - CAUTI ON). The ai r temperature i n
the test room and i n the vehi cl e must be a mi ni mum
of 21 C (70 F) for thi s test.
24 - 2 HEATING & AIR CONDITIONING KJ
HEATING & AIR CONDITIONING (Continued)
(1) Connect a tachometer a mani fol d gauge set or
A/C recycl i ng/chargi ng stati on.
(2) Set the A/C Heater mode control swi tch knob i n
the Reci rcul ati on Mode posi ti on, the temperature
control knob i n the ful l cool posi ti on, and the bl ower
motor swi tch knob i n the hi ghest speed posi ti on.
(3) Start the engi ne and hol d the i dl e at 1,000 rpm
wi th the compressor cl utch engaged.
(4) The engi ne shoul d be at operati ng temperature.
The doors and wi ndows must be cl osed.
(5) I nsert a thermometer i n the dri ver si de center
A/C (panel ) outl et. Operate the engi ne for fi ve mi n-
utes.
(6) The compressor cl utch may cycl e, dependi ng
upon the ambi ent temperature and humi di ty. I f the
cl utch cycl es, unpl ug the a/c l ow pressure swi tch wi re
harness connector. (Fi g. 2). Pl ace a jumper wi re
across the termi nal s of the a/c l ow pressure swi tch
wi re harness connector.
(7) Wi th the compressor cl utch engaged, record the
di scharge ai r temperature and the compressor di s-
charge pressure.
(8) Compare the di scharge ai r temperature to the
Performance Temperature and Pressure chart. I f the
di scharge ai r temperature i s hi gh, (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
DI AGNOSI S AND TESTI NG - REFRI GERANT SYS-
TEM LEAKS) and (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - SPECI FI CATI ONS -
CHARGE CAPACI TY).
Performance Temperature and Pressure
Ambient Air
Temperature
21C
(70F)
27C
(80F)
32C
(90F)
38C
(100F)
43C
(110F)
Air Temperature at
Center Panel Outlet
7C
(45F)
7C
(45F)
13C
(55F)
13C
(55F)
18C
(64F)
Compressor Inlet
Pressure at Service
Port (low Side)
138 to 207 kPa
(20 to 30 psi)
172 to 241
kPa
(25 to 35 psi)
207 to 276
kPa
(30 to 40 psi)
241 to 310
kPa
(35 to 45 psi)
276 to 345 kPa
(40 to 50 psi)
Condensor Out
Pressuree at Service
POrt (High Side)
1034 to 1724
kPa
(150 to 250
psi)
1379 to 2068
kPa
(200 to 300
psi)
1724 to 2413
kPa
(250 to 350
psi)
1999 to 2689
kPa
(290 to 390
psi)
2413 to 2965
kPa
(350 to 430 psi)
(9) Compare the compressor di scharge pressure to
the Performance Temperature and Pressure chart. I f
the compressor di scharge pressure i s hi gh, see the
Pressure Di agnosi s chart.
Fig. 2 A/C LOW PRESSURE SWITCH - TYPICAL
1 - A/C LOW PRESSURE SWITCH
2 - ACCUMULATOR
Pressure Diagnosis
Rapid compressor clutch
cycling (ten or more cycles
per minute).
1. Low refrigerant system
charge.
1. See Plumbing/Diagnosis and Testing -
Refrigerant System Leaks in this group. Test the
refrigerant system for leaks. Repair, evacuate and
charge the refrigerant system, if required.
Equal pressures, but the
compressor clutch does not
engage.
1. No refrigerant in the
refrigerant system.
2. Faulty fuse. 2. Check the fuses in the Power Distribution
Center and the junction block. Repair the shorted
circuit or component and replace the fuses, if
required.
3. Faulty a/c compressor
clutch coil.
3. See A/C Compressor/Diagnosis and Testing -
Compressor Clutch Coil in this group. Test the
compressor clutch coil and replace, if required.
4. Faulty a/c compressor
clutch relay.
4. See A/C Compressor Clutch Relay/Diagnosis
and Testing - Compressor Clutch Relay in this
group. Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
5. Improperly installed or
faulty a/c low pressure
switch.
5. See A/C Low Pressure Switch/Diagnosis and
Testing in this group. Test the a/c low pressure
switch and tighten or replace, if required.
6. Faulty a/c high pressure
switch.
6. See A/C High Pressure Switch/Diagnosis and
Testing in this group. Test the a/c high pressure
switch and replace, if required.
7. Faulty Powertrain Control
Module (PCM).
7. (Refer to Appropriate Diagnostic Information).
Test the PCM and replace, if required.
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.
1. Excessive refrigerant oil in
system.
1. See Refrigerant Oil/Standard Procedure -
Refrigerant Oil Level in this group. Recover the
refrigerant from the refrigerant system and
inspect the refrigerant oil content. Restore the
refrigerant oil to the proper level, if required.
2. Blend door inoperative or
sealing improperly.
2. See Blend Door in this group. Inspect the
blend door for proper operation and sealing and
correct, if required.
3. Blend door actuator faulty
or inoperative.
3. Perform blend door actuator diagnosis, replace
if faulty.
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.
1. Low refrigerant system
charge.
2. Refrigerant flow through
the accumulator is restricted.
2. See Accumulator in this group. Replace the
restricted accumulator, if required.
3. Refrigerant flow through
the evaporator coil is
restricted.
3. See A/C Evaporator in this group. Replace the
restricted evaporator coil, if required.
Pressure Diagnosis
4. Faulty compressor. 4. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.
1. Condenser air flow
restricted.
1. Check the condenser for damaged fins, foreign
objects obstructing air flow through the condenser
fins, and missing or improperly installed air seals.
Refer to Cooling for more information on air
seals. Clean, repair, or replace components as
required.
2. Inoperative cooling fan. 2. Refer to Cooling for more information. Test the
cooling fan and replace, if required.
3. Refrigerant system
overcharged.
3. See Plumbing/Standard Procedure -
Refrigerant System Charge in this group. Recover
the refrigerant from the refrigerant system.
Charge the refrigerant system to the proper level,
if required.
4. Air in the refrigerant
system.
5. Engine overheating. 5. Refer to Cooling for more information. Test the
cooling system and repair, if required.
The low side pressure is too
high, and the high side
pressure is too low.
1. Accessory drive belt
slipping.
1. Refer to Cooling for more information. Inspect
the accessory drive belt condition and tension.
Tighten or replace the accessory drive belt, if
required.
2. Fixed orifice tube not
installed.
2. See A/C Orifice Tube in this group. Replace
the liquid line, if required.
3. Faulty compressor. 3. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is too
low, and the high side
pressure is too high.
1. Restricted refrigerant flow
through the refrigerant lines.
1. See Liquid, Suction, and Discharge Line in this
group. Inspect the refrigerant lines for kinks, tight
bends or improper routing. Correct the routing or
replace the refrigerant line, if required.
through the fixed orifice tube.
2. See A/C Orifice Tube in this group. Replace
the liquid line, if required.
through the condenser.
3. See A/C Condenser in this group. Replace the
restricted condenser, if required.
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE
Before performi ng the fol l owi ng tests, refer to Cool -
i ng for the procedures to check the radi ator cool ant
l evel , serpenti ne dri ve bel t tensi on, radi ator ai r fl ow
and the radi ator fan operati on. Al so be certai n that
the accessory vacuum suppl y l i ne i s connected at the
engi ne i ntake mani fol d.
MAXIMUM HEATER OUTPUT
Engi ne cool ant i s del i vered to the heater core
through two heater hoses. Wi th the engi ne i dl i ng at
normal operati ng temperature, set the temperature
control knob i n the ful l hot posi ti on, the mode control
swi tch knob i n the fl oor heat posi ti on, and the bl ower
motor swi tch knob i n the hi ghest speed posi ti on.
Usi ng a test thermometer, check the temperature of
the ai r bei ng di scharged at the HVAC housi ng fl oor
outl ets. Compare the test thermometer readi ng to the
Temperature Reference chart.
Temperature Reference
Ambient Air Temperature
15.5C
(60F)
21.1C
(70F)
26.6C
(80F)
32.2C
(90F)
Minimum Air Temperature at
Floor Outlet
52.2C
(126F)
56.1C
(133F)
59.4C
(139F)
62.2C
(144F)
I f the fl oor outl et ai r temperature i s too l ow, refer
to Cool i ng to check the engi ne cool ant temperature
speci fi cati ons. Both of the heater hoses shoul d be hot
to the touch. The cool ant return heater hose shoul d
be sl i ghtl y cool er than the cool ant suppl y heater
hose. I f the return hose i s much cool er than the sup-
pl y hose, l ocate and repai r the engi ne cool ant fl ow
obstructi on i n the cool i ng system. Refer to Cool i ng
for the procedures.
OBSTRUCTED COOLANT FLOW Possi bl e l oca-
ti ons or causes of obstructed cool ant fl ow:
Pi nched or ki nked heater hoses.
I mproper heater hose routi ng.
Pl ugged heater hoses or suppl y and return ports
at the cool i ng system connecti ons.
A pl ugged heater core.
I f proper cool ant fl ow through the cool i ng system i s
veri fi ed, and heater outl et ai r temperature i s sti l l
l ow, a mechani cal probl em may exi st.
MECHANI CAL PROBLEMS Possi bl e l ocati ons or
causes of i nsuffi ci ent heat:
An obstructed cowl ai r i ntake.
Obstructed heater system outl ets.
A bl end door not functi oni ng properl y.
TEMPERATURE CONTROL
I f the heater outl et ai r temperature cannot be
adjusted wi th the temperature control knob on the
A/C Heater control panel , the fol l owi ng coul d requi re
servi ce:
The A/C Heater control .
The bl end door actuator.
The bl end door.
I mproper engi ne cool ant temperature.
DIAGNOSIS AND TESTING - VACUUM SYSTEM
Vacuum control i s used to operate the mode doors
i n the heater-onl y and a/c heater housi ngs. Testi ng of
the heater-onl y and A/C Heater mode control swi tch
operati on wi l l determi ne i f the vacuum, el ectri cal ,
and mechani cal control s are functi oni ng. However, i t
i s possi bl e that a vacuum control system that oper-
ates perfectl y at engi ne i dl e (hi gh engi ne vacuum)
may not functi on properl y at hi gh engi ne speeds or
l oads (l ow engi ne vacuum). Thi s can be caused by
l eaks i n the vacuum system, or a faul ty vacuum
check val ve.
A vacuum system test wi l l hel p to i denti fy the
source of poor vacuum system performance or vac-
uum system l eaks. Before starti ng thi s test, stop the
engi ne and make certai n that the probl em i s not a
di sconnected vacuum suppl y tube at the engi ne
i ntake mani fol d vacuum tap or at the vacuum reser-
voi r.
Use an adjustabl e vacuum test set (Speci al Tool
C-3707-B) and a sui tabl e vacuum pump to test the
HVAC vacuum control system. Wi th a fi nger pl aced
over the end of the vacuum test hose probe (Fi g. 3),
adjust the bl eed val ve on the test set gauge to obtai n
a vacuum of exactl y 27 kPa (8 i n. Hg.). Rel ease and
bl ock the end of the probe several ti mes to veri fy that
the vacuum readi ng returns to the exact 27 kPa (8
i n. Hg.) setti ng. Otherwi se, a fal se readi ng wi l l be
obtai ned duri ng testi ng.
VACUUM CHECK VALVE
(1) Remove the vacuum check val ve. The val ve i s
l ocated i n the vacuum suppl y tube (bl ack) at the
HVAC system vacuum tee.
(2) Connect the test set vacuum suppl y hose to the
A/C Heater Control si de of the val ve. When con-
nected to thi s si de of the check val ve, no vacuum
shoul d pass and the test set gauge shoul d return to
the 27 kPa (8 i n. Hg.) setti ng. I f OK, go to Step 3. I f
not OK, repl ace the faul ty val ve.
(3) Connect the test set vacuum suppl y hose to the
engi ne vacuum si de of the val ve. When connected to
thi s si de of the check val ve, vacuum shoul d fl ow
through the val ve wi thout restri cti on. I f not OK,
repl ace the faul ty val ve.
A/C HEATER CONTROLS
(1) Connect the test set vacuum probe to the
HVAC vacuum suppl y (bl ack) tube at the tee i n the
engi ne compartment. Posi ti on the test set gauge so
that i t can be vi ewed from the passenger compart-
ment.
(2) Pl ace the A/C Heater Mode Control swi tch
knob i n each mode posi ti on, one posi ti on at a ti me,
and pause after each sel ecti on. The test set gauge
shoul d return to the 27 kPa (8 i n. Hg.) setti ng
shortl y after each sel ecti on i s made. I f not OK, a
component or vacuum l i ne i n the vacuum ci rcui t of
the sel ected mode has a l eak. See the procedure i n
Locati ng Vacuum Leaks.
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will ruin the
vacuum valve in the switch. A drop of clean water
in the connector plug holes will help the connector
slide onto the switch ports.
LOCATING VACUUM LEAKS
INJURY.
(1) Di sconnect the vacuum harness connector from
the back of the HVAC control head(Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/CONTROLS/A/C
HEATER CONTROL - REMOVAL).
(2) Connect the test set vacuum hose probe to each
port i n the HVAC housi ng hal f of the vacuum har-
ness connector, one port at a ti me, and pause after
each connecti on. The test set gauge shoul d return to
the 27 kPa (8 i n. Hg.) setti ng shortl y after each con-
necti on i s made. I f OK, repl ace the faul ty A/C Heater
Control . I f not OK, go to Step 3.
(3) Determi ne the vacuum l i ne col or of the vacuum
ci rcui t that i s l eaki ng. To determi ne the vacuum l i ne
col ors, refer to the Vacuum Ci rcui ts chart (Fi g. 4).
(4) Di sconnect and pl ug the vacuum l i ne from the
component (fi tti ng, actuator, val ve, swi tch, or reser-
voi r) on the other end of the l eaki ng ci rcui t. I nstru-
ment panel di sassembl y or removal may be necessary
to gai n access to some components. See the appropri -
ate servi ce procedures.
Fig. 3 ADJUST VACUUM TEST BLEED VALVE
1 - VACUUM PUMP TOOL C-4289
2 - VACUUM TEST SET C-3707
3 - BLEED VALVE
4 - PROBE
Fig. 4
(5) Connect the test set hose or probe to the open
end of the l eaki ng ci rcui t. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each connecti on i s made. I f OK, repl ace the faul ty
di sconnected component. I f not OK, go to Step 6.
(6) To l ocate a l eak i n a vacuum l i ne, l eave one end
of the l i ne pl ugged and connect the test set hose or
probe to the other end of the l i ne. Run your fi ngers
sl owl y al ong the l i ne whi l e watchi ng the test set gauge.
The vacuum readi ng wi l l fl uctuate when your fi ngers
contact the source of the l eak. To repai r the vacuum
l i ne, cut out the l eaki ng secti on of the l i ne. Then, i nsert
the l oose ends of the l i ne i nto a sui tabl e l ength of 3 mi l -
l i meter (0.125 i nch) i nsi de di ameter rubber hose.
STANDARD PROCEDURE - DIODE
REPLACEMENT
(1) Di sconnect the battery negati ve cabl e and i so-
l ate i t.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 5).
(4) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(5) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary refer to the
appropri ate wi ri ng di agram for current fl ow.
type sol der onl y. Do not use acid core solder.
(7) Tape the di ode to the harness usi ng el ectri cal
tape maki ng, sure the di ode i s compl etel y seal ed
from the el ements.
(8) Re-connect the battery negati ve cabl e, and test
affected systems.
SPECIFICATIONS
A/C APPLICATION TABLE
Item Description Notes
Vehicle KJ- Liberty
System R134a w/ fixed
orifice tube
Compressor Sanden PXF-18 SP-10 PAG oil
Freezeup
Control
A/C low
pressure switch
accumulator
mounted
Low psi Control opens < 25 psi
- resets > 43
psi
High psi Control switch - opens
> 450-490 psi -
resets <
270-330 psi
discharge line
Control Head manual type
Mode Door vacuum
Blend Door electric
Recirculation
Door
vacuum
Blower Motor hardwired to
control head
resistor block
Cooling Fan viscous for
cooling, single
speed electric
for A/C
Clutch Electro-
mechanical
Control relay PCM
Draw 2 - 3.7 amps @
12V
0.5V @ 70F
Gap 0.016 - 0.031
DRB III
Reads TPS, RPM, A/C
switch test
Actuators clutch and fan
relay
Fig. 5 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
SPECIFICATIONS
A/C COMPRESSOR CLUTCH PLATE NUT 14.4 10.5 127.4
A/C COMPRESOR LINE MANIFOLD FASTENER 28 (6) 21 (4) 250 (50)
A/C COMPRESSOR TO MOUNTING BRACKET
BOLTS - 3.7L and 2.4L
27 20 239
A/C COMPRESSOR TO MOUNTING BRACKET
BOLTS - 2.5L DIESEL
33 25 292
ACCUMULATOR RETAINING BAND 5 3.7 44
BLEND DOOR ACTUATOR SCREWS 2.4 (.34) 1.8 (.25) 21 (3)
HVAC HOUSING SCREWS 2.4 (.34) 1.8 (.25) 21 (3)
HVAC HOUSING TO DASH PANEL NUTS 6.2 4.6 55
SUCTION LINE TO ACCUMULATOR FITTING 9 6.6 80
CONTROLS
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH
DESCRIPTION - 3.7L and 2.4L . . . . . . . . . . . . . 12
OPERATION - 3.7L and 2.4L . . . . . . . . . . . . . . . 12
COMPRESSOR CLUTCH COIL . . . . . . . . . . . 12
STANDARD PROCEDURE - A/C
COMPRESSOR CLUTCH BREAK-IN . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
A/C HEATER CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
A/C HIGH PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - A/C HIGH
PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
A/C LOW PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - A/C LOW
PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
BLEND DOOR ACTUATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
BLOWER MOTOR RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - BLOWER
MOTOR RELAY . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
BLOWER MOTOR RESISTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MOTOR RESISTOR . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
BLOWER MOTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MOTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
MODE DOOR ACTUATOR
REMOVAL
REMOVAL - PANEL DOOR ACTUATOR . . . . . 24
REMOVAL - FLOOR - DEFROST DOOR
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION
INSTALLATION - PANEL DOOR ACTUATOR . 25
INSTALLATION - FLOOR - DEFROST DOOR
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RECIRCULATION DOOR ACTUATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
VACUUM CHECK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
KJ CONTROLS 24 - 11
DESCRIPTION - 3. 7L and 2. 4L
The compressor cl utch assembl y consi sts of a sta-
ti onary el ectromagneti c coi l , a rotor beari ng and
rotor assembl y, and a cl utch pl ate (Fi g. 1). The el ec-
tromagneti c coi l uni t and the rotor beari ng and rotor
assembl y are each retai ned on the nose of the com-
pressor front housi ng wi th snap ri ngs. The cl utch
pl ate i s keyed to the compressor shaft and secured
wi th a nut. These components provi de the means to
engage and di sengage the compressor from the
engi ne serpenti ne accessory dri ve bel t.
OPERATION - 3. 7L and 2. 4L
When the cl utch coi l i s energi zed, i t magneti cal l y
draws the cl utch i nto contact wi th the rotor and
dri ves the compressor shaft. When the coi l i s not
energi zed, the rotor freewheel s on the cl utch rotor
beari ng, whi ch i s part of the rotor. The compressor
cl utch and coi l are the onl y servi ced parts on the
compressor.
The compressor cl utch engagement i s control l ed by
several components: the A/C Heater mode control
swi tch, the A/C l ow pressure swi tch, the A/C hi gh
pressure swi tch, the compressor cl utch rel ay, and the
Powertrai n Control Modul e (PCM). The PCM may
del ay compressor cl utch engagement for up to thi rty
seconds. Refer to El ectroni c Control Modul es for
more i nformati on on the PCM control s.
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH COIL
Appropri ate Wi ri ng I nformati on). The battery must
be ful l y-charged before performi ng the fol l owi ng
tests. Refer to Battery for more i nformati on.
(1) Connect an ammeter (0 to 10 ampere scal e) i n
seri es wi th the cl utch coi l termi nal . Use a vol tmeter
(0 to 20 vol t scal e) wi th cl i p-type l eads for measuri ng
the vol tage across the battery and the compressor
cl utch coi l .
(2) Wi th the A/C Heater mode control swi tch i n
any A/C mode, and the bl ower motor swi tch i n the
l owest speed posi ti on, start the engi ne and run i t at
normal i dl e.
(3) The compressor cl utch coi l vol tage shoul d read
wi thi n 0.2 vol ts of the battery vol tage. I f there i s
vol tage at the cl utch coi l , but the readi ng i s not
wi thi n 0.2 vol ts of the battery vol tage, test the cl utch
coi l feed ci rcui t for excessi ve vol tage drop and repai r
as requi red. I f there i s no vol tage readi ng at the
cl utch coi l , use a DRB I I I scan tool and (Refer to
Appropri ate Di agnosti c I nformati on) for testi ng of the
compressor cl utch ci rcui t and PCM control . The fol -
l owi ng components must be checked and repai red as
requi red before you can compl ete testi ng of the cl utch
coi l :
Fuses i n the juncti on bl ock and the Power Di s-
tri buti on Center (PDC)
A/C heater mode control swi tch
Compressor cl utch rel ay
A/C hi gh pressure swi tch
A/C l ow pressure swi tch
Powertrai n Control Modul e (PCM).
(4) The compressor cl utch coi l i s acceptabl e i f the
current draw measured at the cl utch coi l i s 2.0 to 3.9
amperes wi th the el ectri cal system vol tage at 11.5 to
12.5 vol ts. Thi s shoul d onl y be checked wi th the work
area temperature at 21 C (70 F). I f system vol tage
i s more than 12.5 vol ts, add el ectri cal l oads by turn-
i ng on el ectri cal accessori es unti l the system vol tage
drops bel ow 12.5 vol ts.
(a) I f the cl utch coi l current readi ng i s four
amperes or more, the coi l i s shorted and shoul d be
repl aced.
(b) I f the cl utch coi l current readi ng i s zero, the
coi l i s open and shoul d be repl aced.
STANDARD PROCEDURE - A/C COMPRESSOR
CLUTCH BREAK-IN
After a new compressor cl utch has been i nstal l ed,
cycl e the compressor cl utch approxi matel y twenty
ti mes (fi ve seconds on, then fi ve seconds off). Duri ng
thi s procedure, set the A/C Heater control to the
Reci rcul ati on Mode, the bl ower motor swi tch i n the
hi ghest speed posi ti on, and the engi ne speed at 1500
Fig. 1 COMPRESSOR CLUTCH - TYPICAL
1 - CLUTCH PLATE
2 - NOT USED ON KJ
3 - ROTOR
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
24 - 12 CONTROLS KJ
to 2000 rpm. Thi s procedure (burni shi ng) wi l l seat
the opposi ng fri cti on surfaces and provi de a hi gher
compressor cl utch torque capabi l i ty.
REMOVAL
The refri gerant system can remai n ful l y-charged
duri ng compressor cl utch, rotor, or coi l repl acement.
The compressor cl utch can be servi ced i n the vehi cl e.
cabl e.
(2) Remove the serpenti ne dri ve bel t(Refer to 7 -
REMOVAL).
(3) Unpl ug the compressor cl utch coi l wi re harness
connector.
(4) Remove the four bol ts that secure the compres-
sor to the mounti ng bracket.
(5) Remove the compressor from the mounti ng
bracket. Support the compressor i n the engi ne com-
partment whi l e servi ci ng the cl utch.
(6) I nsert the two pi ns of the spanner wrench
(Speci al Tool C-4489 or equi val ent) i nto the hol es of
the cl utch pl ate. Hol d the cl utch pl ate stati onary and
remove the hex nut (Fi g. 2).
(7) Remove the cl utch pl ate.
(8) Remove the compressor cl utch shi ms.
(9) Remove the external front housi ng snap ri ng
wi th snap ri ng pl i ers (Fi g. 3).
(10) I nstal l the l i p of the rotor pul l er (Speci al Tool
C-6141-1 or equi val ent) i nto the snap ri ng groove
exposed i n the previ ous step, and i nstal l the shaft
protector (Speci al Tool C-6141-2 or equi val ent) (Fi g.
4).
Fig. 2 CLUTCH NUT REMOVE
1 - CLUTCH PLATE
2 - SPANNER
Fig. 3 EXTERNAL SNAP RING REMOVE
1 - PULLEY
Fig. 4 SHAFT PROTECTOR AND PULLER
1 - PULLER JAW
2 - SHAFT PROTECTOR
KJ CONTROLS 24 - 13
A/C COMPRESSOR CLUTCH (Continued)
(11) I nstal l the pul l er through-bol ts (Speci al Tool
C-6461 or equi val ent) through the pul l er fl ange and
i nto the jaws of the rotor pul l er and ti ghten (Fi g. 5).
Turn the pul l er center bol t cl ockwi se unti l the rotor
i s free.
CAUTION: DO NOT APPLY FORCE TO THE END OF
THE COMPRESSOR SHAFT.
(12) Remove the screw and retai ner from the
cl utch coi l l ead wi re harness on the compressor front
housi ng (Fi g. 6).
(13) Remove the snap ri ng from the compressor
hub and remove the cl utch fi el d coi l (Fi g. 7). Sl i de
the cl utch fi el d coi l off of the compressor hub.
INSPECTION
Exami ne the fri cti on surfaces of the cl utch rotor
and the cl utch pl ate for wear. The rotor and cl utch
pl ate shoul d be repl aced i f there i s excessi ve wear or
scori ng.
I f the fri cti on surfaces are oi l y, i nspect the shaft
and nose area of the compressor for oi l . Remove the
fel t from the front cover. I f the fel t i s saturated wi th
oi l , the shaft seal i s l eaki ng and the compressor must
be repl aced.
Check the rotor beari ng for roughness or excessi ve
l eakage of grease. Repl ace the rotor and cl utch pl ate,
i f requi red.
INSTALLATION
(1) I nstal l the cl utch fi el d coi l and snap ri ng.
(2) I nstal l the screw and retai ner on the cl utch coi l
l ead wi re harness on the compressor front housi ng.
Ti ghten screw to 2.2 Nm (20 i n. l bs.).
(3) Al i gn the rotor assembl y squarel y on the front
compressor housi ng hub.
(4) I nstal l the rotor beari ng assembl y wi th the
i nstal l er (Speci al Tool C-6871 or equi val ent) (Fi g. 8).
Thread the i nstal l er on the shaft, then turn the nut
unti l the rotor assembl y i s seated.
(5) I nstal l the external front housi ng snap ri ng
wi th snap ri ng pl i ers. The bevel si de of the snap ri ng
must be faci ng outward. Press the snap ri ng to make
sure i t i s properl y seated i n the groove.
Fig. 5 INSTALL PULLER PLATE
1 - PULLER JAW
2 - PULLER
Fig. 6 CLUTCH COIL LEAD WIRE HARNESS
1 - COIL
2 - COIL WIRE
3 - RETAINER SCREW
Fig. 7 CLUTCH FIELD COIL SNAP RING REMOVE
1 - COIL
24 - 14 CONTROLS KJ
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(6) I nstal l the ori gi nal cl utch shi ms on the com-
pressor shaft.
(7) I nstal l the cl utch pl ate. I nstal l the shaft hex
nut and ti ghten to 1520 Nm (1115 ft. l bs.).
(8) Check the cl utch ai r gap wi th a feel er gauge
(Fi g. 9). I f the ai r gap does not meet the speci fi cati on,
add or subtract shi ms as requi red. The ai r gap spec-
i fi cati on i s 0.41 to 0.79 mi l l i meter (0.016 to 0.031
i nch).
NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install-
ing a new clutch onto a compressor that previously
did not have a clutch, use a 1.0, 0.50, and 0.13 mil-
limeter (0.040, 0.020, and 0.005 inch) shims from the
new clutch hardware package that is provided with
the new clutch.
(9) To compl ete the procedure, (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C
COMPRESSOR - I NSTALLATI ON).
RELAY
DESCRIPTION
The compressor cl utch rel ay i s a I nternati onal
Standards Organi zati on (I SO) mi cro-rel ay. The termi -
nal desi gnati ons and functi ons are the same as a con-
venti onal I SO rel ay. However, the mi cro-rel ay
termi nal ori entati on (footpri nt) i s di fferent, the cur-
rent capaci ty i s l ower, and the rel ay case di mensi ons
are smal l er than those of the conventi onal I SO rel ay.
The compressor cl utch rel ay i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
ment. Refer to the PDC l abel for rel ay i denti fi cati on
and l ocati on.
OPERATION
The compressor cl utch rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the compres-
sor cl utch coi l when the Powertrai n Control Modul e
(PCM) grounds the coi l si de of the rel ay. The PCM
responds to i nputs from the A/C Heater mode control
swi tch, the A/C l ow pressure swi tch, and the A/C
hi gh pressure swi tch. (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/CONTROLS/A/C COMPRESSOR
CLUTCH RELAY - DI AGNOSI S AND TESTI NG)
The compressor cl utch rel ay cannot be repai red
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH RELAY
RELAY TEST
The compressor cl utch rel ay (Fi g. 10) i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
PDC l abel for rel ay i denti fi cati on and l ocati on.
Remove the rel ay from the PDC to perform the fol -
l owi ng tests:
Fig. 8 CLUTCH PULLEY INSTALL
1 - ROTOR BEARING ASSEMBLY
2 - INSTALLER
Fig. 9 CHECK CLUTCH AIR GAP
1 - FEELER GAUGE
KJ CONTROLS 24 - 15
and 30. I f OK, see Rel ay Ci rcui t Test. I f not OK,
repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
connected to fused battery feed. There shoul d be bat-
tery vol tage at the cavi ty for rel ay termi nal 30 at al l
ci rcui t to the fuse i n the PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s not
used i n thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to the compressor cl utch coi l . There shoul d
be conti nui ty between thi s cavi ty and the A/C com-
pressor cl utch rel ay output ci rcui t cavi ty of the com-
pressor cl utch coi l wi re harness connector. I f OK, go
to Step 4. I f not OK, repai r the open ci rcui t as
requi red.
(4) The rel ay coi l battery termi nal (86) i s con-
nected to the fused i gni ti on swi tch output (run/start)
ci rcui t. There shoul d be battery vol tage at the cavi ty
for rel ay termi nal 86 wi th the i gni ti on swi tch i n the
On posi ti on. I f OK, go to Step 5. I f not OK, repai r the
open ci rcui t to the fuse i n the juncti on bl ock as
requi red.
(5) The coi l ground termi nal cavi ty (85) i s swi tched
to ground through the Powertrai n Control Modul e
(PCM). There shoul d be conti nui ty between thi s cav-
i ty and the A/C compressor cl utch rel ay control ci r-
cui t cavi ty of the PCM wi re harness connector C
(gray) at al l ti mes. I f not OK, repai r the open ci rcui t
as requi red.
REMOVAL
cabl e.
Center (PDC).
(3) Refer to the l abel on the PDC for compressor
cl utch rel ay i denti fi cati on and l ocati on.
(4) Unpl ug the compressor cl utch rel ay from the
PDC.
INSTALLATION
(1) I nstal l the compressor cl utch rel ay by al i gni ng
the rel ay termi nal s wi th the cavi ti es i n the PDC and
pushi ng the rel ay fi rml y i nto pl ace.
(2) I nstal l the PDC cover.
A/C HEATER CONTROL
DESCRIPTION
Both the heater-onl y and A/C heater systems use a
combi nati on of mechani cal , el ectri cal , and vacuum
control s. These control s provi de the vehi cl e operator
wi th a number of setti ng opti ons to hel p control the
cl i mate and comfort wi thi n the vehi cl e. Refer to the
owners manual i n the vehi cl e gl ove box for more
i nformati on on the features, use, and suggested oper-
ati on of these control s.
The heater-onl y or A/C heater control panel i s
l ocated to the ri ght of the i nstrument cl uster on the
i nstrument panel . The control panel contai ns a rota-
ry-type temperature control knob, a rotary-type mode
control swi tch knob, and a rotary-type bl ower motor
speed swi tch knob. The control al so has a push but-
ton to acti vate the rear wi ndow defogger.
The heater-onl y or A/C heater control panel cannot
be repai red. I f faul ty or damaged, the enti re uni t
must be repl aced. The i l l umi nati on l amps are avai l -
abl e for servi ce repl acement.
Fig. 10 COMPRESSOR CLUTCH RELAY
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
24 - 16 CONTROLS KJ
A/C COMPRESSOR CLUTCH RELAY (Continued)
REMOVAL
INJURY.
cabl e.
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL CENTER BEZEL - REMOVAL).
(3) Rel ease the vacuum harness from the A/C
Heater control .
(4) Remove the four screws that secure the A/C
Heater control to the i nstrument panel (Fi g. 11).
(5) Pul l the A/C Heater control assembl y away
from the i nstrument panel far enough to access the
connecti ons on the back of the control .
(6) Unpl ug the wi re harness connectors from the
back of the A/C Heater control (Fi g. 12).
INSTALLATION
(1) Pl ug the two wi re harness connectors and one
vacuum connector i nto the back of the A/C Heater
control .
(2) Posi ti on the A/C Heater control i n the i nstru-
ment panel bezel and secure i t wi th four screws.
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL CENTER BEZEL - I NSTALLA-
TI ON).
A/C HIGH PRESSURE SWITCH
DESCRIPTION
The A/C hi gh pressure swi tch control s both A/C
compressor cl utch engagement/di sengagement, and
Fig. 11 A/C HEATER CONTROL
1 - REAR WINDOW DEFOGGER SWITCH
2 - BLOWER SPEED CONTROL
4 - TEMPERATURE SELECT CONTROL
Fig. 12 A/C HEATER CONTROL HEAD (Rear View)
1 - A/C HEATER CONTROL HEAD
3 - REAR WINDOW DEFOGGER SWITCH AND TEMPERATURE
BLEND DOOR- CONNECTOR B (12 PIN)
6 - BLOWER SPEED CONTROL- CONNECTOR A (7 PIN)
7 - MOUNTING SCREWS (4)
KJ CONTROLS 24 - 17
A/C HEATER CONTROL (Continued)
el ectri c cool i ng fan operati ons. The swi tch i s l ocated
on the di scharge l i ne near the compressor. The
swi tch i s screwed onto a fi tti ng that contai ns a
Schrader-type val ve, whi ch al l ows the swi tch to be
servi ced wi thout di schargi ng the refri gerant system.
The di scharge l i ne fi tti ng i s equi pped wi th an O-ri ng
to seal the swi tch connecti on.
OPERATION
The A/C hi gh pressure swi tch i s connected i n seri es
el ectri cal l y wi th the A/C l ow pressure swi tch between
ground and the Powertrai n Control Modul e (PCM).
The swi tch contacts open and cl ose causi ng the PCM
to turn the compressor cl utch on and off. Thi s pre-
vents compressor operati on when the di scharge l i ne
pressure approaches hi gh l evel s, and al so reduces
el ectri cal surgi ng from compressor cl utch engage-
ment.
The A/C hi gh pressure swi tch control s the el ectri c
cool i ng fan operati on by moni tori ng refri gerant l i ne
pressures. When the di scharge l i ne pressure ri ses
above 1900 to 2200 kPa (280 to 320 psi ) the fan wi l l
turn on. The cool i ng fan wi l l turn off when the di s-
charge l i ne pressure drops to 1600 kPa (235 psi ).
The A/C hi gh pressure swi tch control s the A/C
cl utch operati on by di sengagi ng the cl utch when the
di scharge l i ne pressure ri ses above 3100 to 3375 kPa
(450 to 490 psi ). The swi tch contacts wi l l cl ose and
al l ow A/C cl utch engagement when the di scharge l i ne
pressure drops to 1860 to 2275 kPa (270 to 330 psi ).
The A/C hi gh pressure swi tch i s a factory-cal i -
brated uni t. The swi tch cannot be adjusted or
repl aced.
DIAGNOSIS AND TESTING - A/C HIGH
PRESSURE SWITCH
Before performi ng di agnosi s of the A/C hi gh pres-
sure swi tch, veri fy that the refri gerant system has
the correct refri gerant charge. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - STAN-
DARD PROCEDURE - REFRI GERANT SYSTEM
CHARGE)
cabl e.
(2) Unpl ug the A/C hi gh pressure swi tch wi re har-
ness connector from the swi tch on the refri gerant
system fi tti ng.
(3) On the four termi nal A/C hi gh pressure swi tch,
check for conti nui ty between termi nal s C and D. On
the two termi nal A/C hi gh pressure swi tch, check for
conti nui ty between both termi nal s of the swi tch.
There shoul d be conti nui ty. I f OK, test and repai r the
A/C swi tch sense ci rcui t as requi red. I f not OK,
repl ace the faul ty swi tch.
REMOVAL
cabl e.
A/C hi gh pressure swi tch, whi ch i s mounted to a fi t-
ti ng on the non-fl exi bl e secti on of the di scharge l i ne
nearest the compressor.
(3) Unscrew the A/C hi gh pressure swi tch from the
di scharge l i ne fi tti ng.
(4) Remove the A/C hi gh pressure swi tch from the
vehi cl e.
(5) Remove the O-ri ng seal from the di scharge l i ne
fi tti ng and di scard.
INSTALLATION
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the di scharge l i ne fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e(Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG - SPECI FI CATI ONS). (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/RE-
FRI GERANT OI L - DESCRI PTI ON)
(2) I nstal l and ti ghten the a/c hi gh pressure swi tch
on the di scharge l i ne fi tti ng. The swi tch shoul d be
hand-ti ghtened onto the di scharge l i ne fi tti ng.
(3) Pl ug the wi re harness connector i nto the a/c
hi gh pressure swi tch.
A/C LOW PRESSURE SWITCH
DESCRIPTION
The a/c l ow pressure swi tch i s l ocated on the top of
the accumul ator. The swi tch i s screwed onto an accu-
mul ator fi tti ng that contai ns a Schrader-type val ve,
whi ch al l ows the swi tch to be servi ced wi thout di s-
chargi ng the refri gerant system. The accumul ator fi t-
ti ng i s equi pped wi th an O-ri ng to seal the swi tch
connecti on.
OPERATION
The a/c l ow pressure swi tch i s connected i n seri es
el ectri cal l y wi th the a/c hi gh pressure swi tch,
between ground and the Powertrai n Control Modul e
(PCM). The swi tch contacts open and cl ose causi ng
the PCM to turn the a/c compressor cl utch on and
off. Thi s regul ates the refri gerant system pressure
and control s evaporator temperature. Control l i ng the
evaporator temperature prevents condensate water
24 - 18 CONTROLS KJ
A/C HIGH PRESSURE SWITCH (Continued)
on the evaporator fi ns from freezi ng and obstructi ng
ai r condi ti oni ng system ai r fl ow.
The a/c l ow pressure swi tch contacts are open
when the sucti on pressure i s approxi matel y 141 kPa
(20.5 psi ) or l ower. The swi tch contacts wi l l cl ose
when the sucti on pressure ri ses to approxi matel y 234
to 262 kPa (34 to 38 psi ) or above. Lower ambi ent
temperatures, bel ow approxi matel y -1 C (30 F), wi l l
al so cause the swi tch contacts to open. Thi s i s due to
the pressure/temperature rel ati onshi p of the refri ger-
ant i n the system.
The a/c l ow pressure swi tch i s a factory-cal i brated
uni t. I t cannot be adjusted or repai red and, i f faul ty
or damaged, i t must be repl aced.
DIAGNOSIS AND TESTING - A/C LOW
PRESSURE SWITCH
Before performi ng di agnosi s of the a/c l ow pressure
swi tch, be certai n that the swi tch i s properl y
i nstal l ed on the accumul ator fi tti ng. I f the swi tch i s
too l oose i t may not open the Schrader-type val ve i n
the accumul ator fi tti ng, whi ch wi l l prevent the
swi tch from correctl y moni tori ng the refri gerant sys-
tem pressure. Remember that l ower ambi ent temper-
atures, bel ow about -1 C (30 F), duri ng col d
weather wi l l open the swi tch contacts and prevent
compressor operati on due to the pressure/tempera-
ture rel ati onshi p of the refri gerant.
Al so veri fy that the refri gerant system has the cor-
rect refri gerant charge. (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG - DI AGNOSI S AND TESTI NG
- A/C PERFORMANCE) and (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG - SPECI FI CA-
TI ONS).
cabl e.
(2) Unpl ug the a/c l ow pressure swi tch wi re har-
ness connector from the swi tch on the accumul ator
fi tti ng.
(3) I nstal l a jumper wi re between the two cavi ti es
of the a/c l ow pressure swi tch wi re harness connector.
(4) Connect a mani fol d gauge set to the refri gerant
system servi ce ports. (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - STANDARD PRO-
CEDURE - REFRI GERANT SYSTEM SERVI CE
EQUI PMENT) and (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG - DESCRI PTI ON - REFRI GERANT
SYSTEM SERVI CE PORT)
(6) Pl ace the A/C Heater mode control swi tch knob
i n any A/C posi ti on and start the engi ne.
(7) Check for conti nui ty between the two termi nal s
of the a/c l ow pressure swi tch. There shoul d be con-
ti nui ty wi th a sucti on pressure readi ng of 262 kPa
(38 psi ) or above, and no conti nui ty wi th a sucti on
pressure readi ng of 141 kPa (20.5 psi ) or bel ow. I f
OK, test and repai r the A/C swi tch sense ci rcui t as
requi red. I f not OK, repl ace the faul ty swi tch.
REMOVAL
cabl e.
(2) Unpl ug the wi re harness connector from the a/c
l ow pressure swi tch on the top of the accumul ator
(Fi g. 13).
(3) Unscrew the a/c l ow pressure swi tch from the
fi tti ng on the top of the accumul ator.
(4) Remove the O-ri ng seal from the accumul ator
fi tti ng and di scard.
INSTALLATION
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the accumul ator fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e. (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG/REFRI GERANT
OI L - DESCRI PTI ON)
Fig. 13 A/C LOW PRESSURE SWITCH
1 - WIRING HARNESS CONNECTOR
3 - A/C LINE TO EVAPORATOR
4 - ACCUMULATOR MOUNTING BRACKET
5 - ACCUMULATOR
6 - A/C LOW PRESSURE LINE
KJ CONTROLS 24 - 19
A/C LOW PRESSURE SWITCH (Continued)
(2) I nstal l and ti ghten the a/c l ow pressure swi tch
on the accumul ator fi tti ng. The swi tch shoul d be
hand-ti ghtened onto the accumul ator fi tti ng.
(3) Pl ug the wi re harness connector i nto the a/c
l ow pressure swi tch.
BLEND DOOR ACTUATOR
REMOVAL
INJURY.
cabl e.
(2) Remove A/C housi ng from vehi cl e(Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
HVAC HOUSI NG - REMOVAL).
(3) Remove the screws that secure the bl end door
actuator to the top of the HVAC housi ng. (Fi g. 14).
(4) Remove the bl end door actuator.
INSTALLATION
(1) I nstal l the bl end door actuator i n pl ace.
(2) I nstal l and ti ghten the screws that secure the
bl end door actuator to the housi ng. Ti ghten the
mounti ng screws to 2.4 (.34) Nm (21 (3) i n. l bs.).
(3) I nstal l the HVAC housi ng i nto the vehi cl e(Re-
fer to 24 - HEATI NG & AI R CONDI TI ONI NG/DI S-
TRI BUTI ON/HVAC HOUSI NG - I NSTALLATI ON).
(4) I nstal l the bl end door actuator el ectri cal con-
nector from the wi ri ng harness through the gl ove
box.
BLOWER MOTOR RELAY
DESCRIPTION
The bl ower motor rel ay i s a I nternati onal Stan-
dards Organi zati on (I SO)-type rel ay. The rel ay i s a
el ectromechani cal devi ce that swi tches battery cur-
rent from a fuse i n the Power Di stri buti on Center
(PDC) di rectl y to the bl ower motor. The rel ay i s ener-
gi zed when the rel ay coi l i s provi ded a vol tage si gnal
by the i gni ti on swi tch. (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/CONTROLS/BLOWER
MOTOR RELAY - DI AGNOSI S AND TESTI NG)
OPERATION
The bl ower motor rel ay i s i nstal l ed i n a wi re har-
ness connector that i s secured to the passenger si de
outboard end of the HVAC housi ng i n the passenger
compartment, next to the HVAC wi re harness con-
nector.
The bl ower motor rel ay cannot be repai red and, i f
Fig. 14 HEATER CORE REMOVAL/INSTALLATION
1 - HEATER CORE
2- MOUNTING SCREW HOLE
3- INLET AND OUTLET TUBES
4- VACUUM HARNESS
5- ACTUATOR SCREWS (3)
6- ELECTRIC BLEND DOOR ACTUATOR
8- HEATER CORE RETAINER TABS (4)
24 - 20 CONTROLS KJ
A/C LOW PRESSURE SWITCH (Continued)
DIAGNOSIS AND TESTING - BLOWER MOTOR
RELAY
INJURY.
RELAY TEST
The bl ower motor rel ay (Fi g. 15) i s l ocated i n the
PDC whi ch i s l ocated under the hood.. Remove the
rel ay from the PDC to perform the fol l owi ng tests:
and 30. I f OK, see the Rel ay Ci rcui t Test. I f not OK,
repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
connected to fused battery feed di rectl y from a fuse
i n the Power Di stri buti on Center (PDC), and shoul d
be hot at al l ti mes. Check for battery vol tage at the
connector cavi ty for rel ay termi nal 30. I f OK, go to
Step 2. I f not OK, repai r the open ci rcui t to the PDC
fuse as requi red.
(2) The rel ay normal l y cl osed termi nal cavi ty (87A)
i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to the bl ower motor. When the rel ay i s
energi zed, termi nal 87 i s connected to termi nal 30
and provi des ful l battery current to the bl ower motor
feed ci rcui t. There shoul d be conti nui ty between the
connector cavi ty for termi nal 87 and the bl ower
motor at al l ti mes. I f OK, go to Step 4. I f not OK,
repai r the open ci rcui t to the bl ower motor as
requi red.
(4) The coi l battery termi nal cavi ty (86) i s con-
nected to the i gni ti on swi tch. When the i gni ti on
swi tch i s pl aced i n the On posi ti on, fused i gni ti on
swi tch output i s di rected from a fuse i n the juncti on
bl ock to the rel ay el ectromagneti c coi l to energi ze the
rel ay. There shoul d be battery vol tage at the connec-
tor cavi ty for rel ay termi nal 86 wi th the i gni ti on
swi tch i n the On posi ti on. I f OK, go to Step 5. I f not
OK, repai r the open ci rcui t to the juncti on bl ock fuse
as requi red.
(5) The coi l ground termi nal cavi ty (85) i s con-
nected to ground. Thi s termi nal suppl i es the ground
for the rel ay el ectromagnet coi l . There shoul d be con-
ti nui ty between the connector cavi ty for rel ay termi -
nal 85 and a good ground at al l ti mes. I f not OK,
repai r the open ci rcui t as requi red.
REMOVAL
INJURY.
Fig. 15 BLOWER MOTOR RELAY
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
KJ CONTROLS 24 - 21
BLOWER MOTOR RELAY (Continued)
cabl e.
(2) Unpl ug the bl ower motor rel ay from the PDC
l ocated under the hood.
(3) Remove the bl ower motor rel ay.
INSTALLATION
(1) I nstal l the bl ower motor rel ay by al i gni ng the
rel ay termi nal s wi th the cavi ti es i n the PDC and
pushi ng the rel ay fi rml y i nto pl ace.
BLOWER MOTOR RESISTOR
DESCRIPTION
The bl ower motor resi stor i s mounted to the rear
si de of the HVAC housi ng on the passenger si de of
the vehi cl e.
OPERATION
The resi stor i s a credi t card resi stor that uti l i zes
resi stor ci rcui t tracers to reduce current fl ow to the
bl ower. The bl ower motor swi tch di rects the ground
path through the correct resi stor ci rcui t to obtai n the
sel ected speed.
The bl ower motor resi stor cannot be repai red and,
i f faul ty or damaged, i t must be repl aced.
RESISTOR
INJURY.
cabl e.
(2) Open the gl ove box door and reach i n and
unpl ug the wi re harness connector from the bl ower
motor resi stor.
(3) Check for conti nui ty between each of the
bl ower motor swi tch i nput termi nal s of the resi stor
and the resi stor output termi nal . I n each case there
shoul d be conti nui ty. I f OK, repai r the wi re harness
ci rcui ts between the bl ower motor swi tch and the
bl ower motor resi stor or bl ower motor rel ay as
requi red. I f not OK, repl ace the faul ty bl ower motor
resi stor.
REMOVAL
INJURY.
cabl e.
(2) Open the gl ove box door to gai n access to the
bl ower motor resi stor.
(3) Pul l out the l ock on the bl ower motor resi stor
wi re harness connector to unl ock the connector l atch.
(4) Depress the l atch on the bl ower motor resi stor
wi re harness connector and unpl ug the connector
from the resi stor.
(5) Remove the two screws that secure the resi stor
to the HVAC housi ng.
(6) Remove the resi stor from the HVAC housi ng.
INSTALLATION
(1) I nstal l the new resi stor i n the HVAC housi ng.
(2) I nstal l the two screws that secure the resi stor
to the HVAC housi ng and ti ghten to 2.2 Nm (20 i n.
l bs.).
(3) Pl ug i n the bl ower motor harness connector.
(4) Push i n the l ock on the bl ower motor resi stor
harness connector.
(5) Cl ose the gl ove box door.
24 - 22 CONTROLS KJ
BLOWER MOTOR RELAY (Continued)
BLOWER MOTOR SWITCH
DESCRIPTION
The heater-onl y or A/C Heater bl ower motor i s con-
trol l ed by a four posi ti on rotary-type bl ower motor
swi tch, mounted i n the A/C Heater control panel . The
swi tch al l ows the sel ecti on of one of four bl ower
motor speeds, but can onl y be turned off by sel ecti ng
the Off posi ti on wi th the heater-onl y or A/C Heater
mode control swi tch knob.
OPERATION
The bl ower motor swi tch di rects the bl ower motor
ground path through the mode control swi tch to the
bl ower motor resi stor, or di rectl y to ground, as
requi red to achi eve the sel ected bl ower motor speed.
The bl ower motor swi tch cannot be repai red and, i f
faul ty or damaged, the enti re heater-onl y or A/C
Heater control uni t must be repl aced.
SWITCH
INJURY.
(1) Check for battery vol tage at the fuse i n the
Power Di stri buti on Center (PDC). I f OK, go to Step
Remove the A/C Heater control from the i nstrument
panel . Check for conti nui ty between the ground ci r-
cui t cavi ty of the A/C Heater control wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to ground as requi red.
(3) Wi th the A/C Heater control wi re harness con-
nector unpl ugged, pl ace the A/C Heater mode control
swi tch knob i n any posi ti on except the Off posi ti on.
Check for conti nui ty between the ground ci rcui t ter-
mi nal and each of the bl ower motor dri ver ci rcui t ter-
mi nal s of the A/C Heater control as you move the
bl ower motor swi tch knob to each of the four speed
posi ti ons. There shoul d be conti nui ty at each dri ver
ci rcui t termi nal i n onl y one bl ower motor swi tch
speed posi ti on. I f OK, test and repai r the bl ower
dri ver ci rcui ts between the A/C Heater control con-
nector and the bl ower motor resi stor as requi red. I f
not OK, repl ace the faul ty A/C Heater control uni t.
REMOVAL
INJURY.
The bl ower motor swi tch cannot be repai red and, i f
faul ty or damaged, the enti re heater-onl y or A/C
Heater control uni t must be repl aced. (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/CONTROLS/A/C
HEATER CONTROL - REMOVAL)
INSTALLATION
INJURY.
(1) The bl ower motor swi tch cannot be repai red
and, i f faul ty or damaged the enti re heater-onl y or
A/C heater control uni t must be repl aced(Refer to 24
- HEATI NG & AI R CONDI TI ONI NG/CONTROLS/
A/C HEATER CONTROL - I NSTALLATI ON).
KJ CONTROLS 24 - 23
MODE DOOR ACTUATOR
REMOVAL
REMOVAL - PANEL DOOR ACTUATOR
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO MIN-
UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD RESULT
IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.
(2) Remove the i nstrument panel assembl y from
the vehi cl e(Refer to 23 - BODY/I NSTRUMENT
PANEL - REMOVAL).
(3) Unpl ug the vacuum harness connector from the
defrost door actuator (Fi g. 16).
(4) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the HVAC
housi ng actuator mount. Gentl y pry the actuator
l atch whi l e pul l i ng fi rml y outwards on the actuator
to remove the actuator from the mount.
(5) Rotate and ti l t the vacuum actuator as
requi red to di sengage the hol e on the end of the
actuator l i nk from the hooked pi n on the end of the
defrost door l ever.
(6) Remove the defrost door vacuum actuator from
the vehi cl e.
ACTUATOR
INJURY.
cabl e.
PANEL - REMOVAL).
fl oor door actuator (Fi g. 17).
housi ng actuator mount. Gentl y pry the actuator
l atch whi l e pul l i ng fi rml y outwards on the actuator
to remove the actuator from the mount. (Fi g. 18)
(5) Rotate and ti l t the vacuum actuator as
requi red to di sengage the hol e on the end of the
actuator l i nk from the hooked pi n on the end of the
fl oor door l ever.
(6) Remove the fl oor door vacuum actuator from
the vehi cl e.
Fig. 16 HVAC DOOR VACUUM ACTUATORS
1 - VACUUM LINE AND CONNECTOR
2 - PANEL DOOR ACTUATOR
4 - FLOOR-DEFROST DOOR ACTUATOR
5 - HVAC ASSEMBLY
24 - 24 CONTROLS KJ
INSTALLATION
INSTALLATION - PANEL DOOR ACTUATOR
(1) I nstal l the defrost door vacuum actuator by
snappi ng i t i nto pl ace, engage the hol e on the end of
the actuator l i nk wi th the hooked pi n on the end of
the panel /demi st door l ever.
(2) Pl ug i n the vacuum harness connector to the
defrost door actuator.
(3) I nstal l the i nstrument panel assembl y i n the
vehi cl e(Refer to 23 - BODY/I NSTRUMENT PANEL/
I NSTRUMENT PANEL ASSEMBLY - I NSTALLA-
TI ON).
INSTALLATION - FLOOR - DEFROST DOOR
ACTUATOR
(1) Engage the hol e on the end of the actuator
l i nk to the hooked pi n. I nstal l the fl oor-defrost door
vacuum actuator to the HVAC assembl y. on the end
of the fl oor door l ever.
(2) I nstal l the fl oor door vacuum actuator to the
HVAC assembl y.
(3) I nstal l the i nstrument panel assembl y i nto the
vehi cl e(Refer to 23 - BODY/I NSTRUMENT PANEL/
I NSTRUMENT PANEL ASSEMBLY - I NSTALLA-
TI ON).
Fig. 17 HVAC DOOR VACUUM ACTUATORS
2 - PANEL DOOR ACTUATOR
4 - FLOOR-DEFROST DOOR ACTUATOR
5 - HVAC ASSEMBLY
Fig. 18 VACUUM ACTUATOR REMOVE/INSTALL -
TYPICAL
1 - ACTUATOR MOUNT LATCH HOLE
2 - TRIM STICK
3 - ACTUATOR LATCH
KJ CONTROLS 24 - 25
MODE DOOR ACTUATOR (Continued)
RECIRCULATION DOOR
ACTUATOR
REMOVAL
INJURY.
cabl e.
reci rcul ati on door actuator (Fi g. 19).
housi ng actuator mount (Fi g. 20).
(4) Gentl y pry the actuator l atch whi l e pul l i ng
fi rml y outwards on the actuator to remove the actua-
tor from the mount (Fi g. 21).
(5) Di sengage the hol e on the end of the actuator
l i nk from the hooked pi n on the end of the reci rcul a-
ti on door l ever.
(6) Remove the reci rcul ati on door vacuum actuator
from the vehi cl e.
INSTALLATION
(1) I nstal l the reci rcul ati on door vacuum actuator
by sl i ppi ng the arm on to the hol e on the end of the
actuator l i nk wi th the hooked pi n on the end of the
panel /demi st door l ever.
(2) Snap the actuator back i nto i ts mount.
(3) Pl ug i n the vacuum harness connector to the
reci rcul ati on door actuator.
Fig. 19 RECIRCULATION DOOR ASSEMBLY
1- INSTRUMENT PANEL ELECTRICAL HARNESS MOUNTING
TABS
2- MOUNTING TAB
3- RECIRCULATION DOOR
4- MOUNTING TAB
5- RECIRCULATION DOOR ASSEMBLY
6- RECIRCULATION DOOR LEVER
Fig. 20 VACUUM ACTUATOR REMOVE/INSTALL -
TYPICAL
1 - ACTUATOR MOUNT LATCH HOLE
2 - TRIM STICK
3 - ACTUATOR LATCH
24 - 26 CONTROLS KJ
Fig. 21 HVAC CASE ASSEMBLY
1 - BLOWER MOTOR AND CAGE
2 - RECIRCULATION DOOR ACTUATOR LINKAGE
3 - RECIRCULATION DOOR VACUUM ACTUATOR
4 - CASE RETAINER SCREW
5 - BLEND DOOR ACTUATOR MOUNTING SCREWS
6 - ELECTRIC BLEND DOOR ACTUATOR
7 - ELECTRICAL CONNECTOR FOR BLEND DOOR ACTUATOR
8 - HEATER CORE RETAINER TABS (4) AND SCREWS (2)
9 - HEATER CORE
10 - HVAC CASE RETAINER CLIP
11 - HEATER CORE INPUT AND OUTPUT CONNECTIONS
12 - EVAPORATOR CONNECTION FLANGE
13 - HVAC CASE RETAINER SCREWS
14 - HVAC HOUSING
KJ CONTROLS 24 - 27
RECIRCULATION DOOR ACTUATOR (Continued)
VACUUM CHECK VALVE
DESCRIPTION
A vacuum check val ve i s i nstal l ed i n the accessory
vacuum suppl y l i ne i n the engi ne compartment, near
the vacuum tap on the engi ne i ntake mani fol d, and
at the HVAC uni t takeout. The vacuum check val ve
i s desi gned to al l ow vacuum to fl ow i n onl y one di rec-
ti on through the accessory vacuum suppl y ci rcui ts.
OPERATION
The use of a vacuum check val ve hel ps to mai ntai n
the system vacuum needed to retai n the sel ected A/C
Heater mode setti ngs. The check val ve wi l l prevent
the engi ne from bl eedi ng down system vacuum
through the i ntake mani fol d duri ng extended heavy
engi ne l oad (l ow engi ne vacuum) operati on.
The vacuum check val ve cannot be repai red and, i f
REMOVAL
(1) Unpl ug the HVAC vacuum suppl y l i ne connec-
tor at the vacuum check val ve. The check val ve i s
l ocated behi nd the gl ove box on the passengers si de
of the vehi cl e (Fi g. 22).
(2) Note the ori entati on of the check val ve i n the
vacuum suppl y l i ne for correct rei nstal l ati on.
(3) Unpl ug the vacuum check val ve from the vac-
uum suppl y l i ne fi tti ngs.
INSTALLATION
(1) Pl ug i n the vacuum check val ve at the vacuum
suppl y l i ne fi tti ngs maki ng sure of proper ori enta-
ti on.
(2) Pl ug i n the vacuum check val ve at the HVAC
vacuum suppl y l i ne connector.
Fig. 22 RECIRCULATION ACTUATOR AND CHECK
VALVE
1 - RECIRCULATION ACTUATOR
2 - VACUUM LINE TO RESEVOIR
3 - HVAC HOUSING
4 - VACUUM CHECK VALVE
24 - 28 CONTROLS KJ
DISTRIBUTION
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION - DEMISTER OUTLETS . . . . . . . 29
REMOVAL - PANEL OUTLET BARRELS . . . . . . 29
INSTALLATION - PANEL OUTLET BARRELS . . . 29
BLOWER MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
FLOOR CONSOLE DUCT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
FLOOR DUCT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
DEFROST - DEMISTER DUCT
REMOVAL - DEFROST DUCT/DEMISTER
ADAPTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION - DEFROST/DEMISTER DUCT . 32
HVAC HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 34
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
BLEND DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
MODE DOOR
REMOVAL
REMOVAL - DEFROST DOOR . . . . . . . . . . . . 35
REMOVAL - FLOOR - DEFROST DOOR . . . . 36
INSTALLATION
INSTALLATION - PANEL DOOR . . . . . . . . . . . 36
INSTALLATION - FLOOR - DEFROST DOO . . 37
RECIRC DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
AIR OUTLETS
DESCRIPTION - DEMISTER OUTLETS
The si de wi ndow demi ster outl ets are i ntegral to
the i nstrument panel end caps(Refer to 23 - BODY/
I NSTRUMENT PANEL/I NSTRUMENT PANEL END
CAP - REMOVAL) and (Refer to 23 - BODY/I NSTRU-
MENT PANEL/I NSTRUMENT PANEL END CAP -
REMOVAL).
REMOVAL - PANEL OUTLET BARRELS
(1) Use a tri m sti ck or another sui tabl e wi de fl at-
bl aded tool to gentl y pry the panel outl et barrel s out
of the panel outl et housi ng (Fi g. 1). The barrel i s
retai ned by a l i ght snap fi t.
INSTALLATION - PANEL OUTLET BARRELS
To i nstal l , posi ti on the barrel i n the panel outl et
housi ng and press fi rml y unti l the barrel snaps i nto
pl ace.
Fig. 1 DASH PANEL OUTLETS
1 - CENTER OUTLETS
2 - SIDE WINDOW DEMISTER OUTLETS
3 - SIDE OUTLETS
4 - WIRING FOR HVAC CONTROL ASSEMBLY
5 - WINDSHIELD DEFROSTER OUTLET
KJ DISTRIBUTION 24 - 29
BLOWER MOTOR
DESCRIPTION
The bl ower motor and bl ower wheel are l ocated i n
the passenger si de end of the HVAC housi ng, bel ow
the gl ove box. The bl ower motor control s the vel oci ty
of ai r fl owi ng through the HVAC housi ng by spi nni ng
a squi rrel cage-type bl ower wheel wi thi n the housi ng
at the sel ected speed. The bl ower motor and wheel
can be removed from the housi ng i nsi de the vehi cl e
wi thout removi ng the dash or HVAC housi ng assem-
bl y.
OPERATION
The bl ower motor wi l l onl y operate when the i gni -
ti on swi tch i s i n the On posi ti on, and the A/C Heater
mode control swi tch knob i s i n any posi ti on, except
Off. The bl ower motor recei ves a fused battery feed
through the bl ower motor rel ay whenever the i gni -
ti on swi tch i s i n the On posi ti on. The bl ower motor
battery feed ci rcui t i s protected by a fuse i n the
Power Di stri buti on Center (PDC). Bl ower motor
speed i s control l ed by regul ati ng the ground path
through the A/C Heater control bl ower motor swi tch
and the bl ower motor resi stor.
The bl ower motor and bl ower motor wheel cannot
be repai red and, i f faul ty or damaged, they must be
repl aced. The bl ower motor and bl ower wheel are ser-
vi ced onl y as a uni t.
INJURY.
Appropri ate Wi ri ng I nformati on). Possi bl e causes of
an i noperati ve bl ower motor i ncl ude:
Faul ty fuse
Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connectors
Faul ty bl ower motor resi stor
Faul ty bl ower motor rel ay
Faul ty bl ower motor swi tch
Faul ty A/C Heater mode control swi tch
Faul ty bl ower motor.
Possi bl e causes of the bl ower motor not operati ng
i n al l speeds i ncl ude:
Faul ty bl ower motor swi tch
Faul ty bl ower motor resi stor
Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connectors.
VIBRATION
Possi bl e causes of bl ower motor vi brati on i ncl ude:
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower wheel out of bal ance or bent
Bl ower motor faul ty.
NOISE
To veri fy that the bl ower i s the source of the noi se,
unpl ug the bl ower motor wi re harness connector and
operate the HVAC system. I f the noi se goes away,
possi bl e causes i ncl ude:
Forei gn materi al i n the HVAC housi ng
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower motor faul ty.
REMOVAL
INJURY.
24 - 30 DISTRIBUTION KJ
The bl ower motor i s l ocated on the passenger si de
of the vehi cl e under the dash
cabl e.
(2) Unpl ug the bl ower motor wi re harness connec-
tor (Fi g. 2).
(3) Rel ease the l ocki ng tab that secures the bl ower
motor and wheel assembl y to the HVAC housi ng.
(4) Rotate and ti l t the bl ower motor uni t as needed
for cl earance to remove the bl ower motor and wheel
from the HVAC housi ng.
INSTALLATION
(1) Al i gn and i nstal l the bl ower motor and wheel
assembl y i nto the HVAC housi ng.
(2) Rotate the bl ower assembl y unti l the l ocki ng
tab secures the bl ower motor and wheel assembl y to
the HVAC housi ng.
(3) Pl ug i n the bl ower motor wi re harness connec-
tor.
FLOOR CONSOLE DUCT
REMOVAL
cabl e.
(2) Remove the fl oor consol e from the sl ed (Fi g. 3).
Refer to Fl oor Consol e for the procedures(Refer to 23
- BODY/I NTERI OR/FLOOR CONSOLE - REMOV-
AL).
(3) Li ft the rear of the consol e duct out of the con-
sol e rear mounti ng bracket on the sl ed and sl i de the
duct rearward to di sengage i t from the fl oor duct and
adapter.
(4) Remove the consol e rear duct from the vehi cl e.
INSTALLATION
(1) Push the consol e duct forward i n pl ace on the
HVAC fl oor duct.
(2) Al i gn the rear tab of the consol e duct wi th the
hol e on the sl ed bracket.
(3) I nsert the push pi n i n the hol e on the sl ed.
(4) I nstal l the fl oor consol e on the fl oor panel
transmi ssi on tunnel (Refer to 23 - BODY/I NTERI OR/
FLOOR CONSOLE - I NSTALLATI ON).
Fig. 2 HVAC BLOWER MOTOR
1 - HVAC HOUSING
2 - BLOWER MOTOR
3 - RETAINER-LOCKING TAB
4 - BLOWER MOTOR ELECTRICAL CONNECTOR
Fig. 3 CONSOLE DUCT REMOVE/INSTALL
1 - REAR DUCT ASSEMBLY
2 - REAR DUCT RETAINER SCREW
3 - REAR DUCT MOUNTING FLANGE
4 - TRANSMISSION SHIFT LEVER ASSEMBLY
5 - FRONT TO REAR DUCT CONNECTING POINT
BLOWER MOTOR (Continued)
FLOOR DUCT
REMOVAL
INJURY.
(1) Remove the i nstrument panel from the vehi -
cl e(Refer to 23 - BODY/I NSTRUMENT PANEL -
REMOVAL).
(2) Remove the three screws that secure the fl oor
duct to the HVAC housi ng.
(3) Remove the fl oor duct from the HVAC housi ng.
INSTALLATION
(1) I nstal l the fl oor duct on the HVAC housi ng.
(2) I nstal l the three screws that secure the fl oor
duct to the HVAC housi ng. Ti ghten the mounti ng
screws to 2.2 Nm (20 i n. l bs.).
(3) I nstal l the i nstrument panel i n the vehi cl e(Re-
fer to 23 - BODY/I NSTRUMENT PANEL - I NSTAL-
LATI ON).
DEFROST - DEMISTER DUCT
REMOVAL - DEFROST DUCT/DEMISTER
ADAPTOR
INJURY.
PANEL - REMOVAL).
(2) Remove the three screws that secure the
defrost duct/demi ster adapter to the i nstrument
panel (Fi g. 4).
(3) Remove the defrost duct/demi ster duct from the
i nstrument panel .
INSTALLATION - DEFROST/DEMISTER DUCT
(1) I nstal l the defrost/demi ster duct i n the i nstru-
ment panel .
(2) I nstal l the three screws that secure the defrost/
demi ster duct to the i nstrument panel .
(3) Ti ghten the mounti ng screws to 2.2 Nm (20 i n.
l bs.).
(4) I nstal l the i nstrument panel assembl y i n the
vehi cl e(Refer to 23 - BODY/I NSTRUMENT PANEL -
I NSTALLATI ON).
Fig. 4 DEFROST/DEMISTER DUCT
2 - DEFROST DUCT/ DEMISTER ADAPTOR
3 - SCREW
HVAC HOUSING
REMOVAL
INJURY.
cabl e.
(2) Remove the i nstrument panel from the vehi -
cl e(Refer to 23 - BODY/I NSTRUMENT PANEL -
REMOVAL).
(3) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 6. I f the vehi cl e i s equi pped wi th
ai r condi ti oni ng, recover the refri gerant from the
refri gerant system. (Refer to 24 - HEATI NG & AI R
CEDURE - REFRI GERANT RECOVERY)
(4) Di sconnect the l i qui d l i ne refri gerant l i ne fi t-
ti ng from the evaporator i nl et tube (Fi g. 5). (Refer to
24 - HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG
- STANDARD PROCEDURE - A/C LI NE COU-
PLERS)
(5) Di sconnect the accumul ator i nl et tube refri ger-
ant l i ne fi tti ng from the evaporator outl et tube.
PLUMBI NG - STANDARD PROCEDURE - A/C LI NE
COUPLERS) I nstal l pl ugs i n, or tape over al l of the
opened refri gerant l i ne fi tti ngs.
(6) Drai n the engi ne cool i ng system(Refer to 7 -
COOLI NG - STANDARD PROCEDURE).
Fig. 5 HVAC CASE ASSEMBLY
1 - BLOWER MOTOR AND CAGE
2 - RECIRCULATION DOOR ACTUATOR LINKAGE
3 - RECIRCULATION DOOR VACUUM ACTUATOR
4 - CASE RETAINER SCREW
5 - BLEND DOOR ACTUATOR MOUNTING SCREWS
6 - ELECTRIC BLEND DOOR ACTUATOR
7 - ELECTRICAL CONNECTOR FOR BLEND DOOR ACTUATOR
8 - HEATER CORE RETAINER TABS (4) AND SCREWS (2)
9 - HEATER CORE
10 - HVAC CASE RETAINER CLIP
11 - HEATER CORE INPUT AND OUTPUT CONNECTIONS
12 - EVAPORATOR CONNECTION FLANGE
13 - HVAC CASE RETAINER SCREWS
14 - HVAC HOUSING
(7) Di sconnect the heater hoses from the heater
core tubes. I nstal l pl ugs i n, or tape over the opened
heater core tubes.
(8) Unpl ug the HVAC system vacuum suppl y l i ne
connector from the engi ne si de harness.
(9) Remove the nuts from the HVAC housi ng
mounti ng studs.
(10) Remove the HVAC housi ng from i nsi de the
vehi cl e taki ng care not to al l ow any remai ni ng cool -
ant to drai n on the vehi cl es i nteri or.
DISASSEMBLY
(1) Remove the HVAC housi ng from the vehi cl e
and pl ace i t on the workbench. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/HVAC
HOUSI NG - REMOVAL)
(2) Unpl ug the vacuum harness connectors from
the mode and reci rcul ati on door actuators and the
reci rcul ati on door actuator.
(3) Di sengage the vacuum harness from any rout-
i ng cl i ps l ocated on the l ower hal f of the HVAC hous-
i ng.
(4) Remove the bl ower motor and bl ower wheel
uni t from the HVAC housi ng. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/
BLOWER MOTOR - REMOVAL)
(5) Pop out the grommet onl the vacuum suppl y
l i ne and sl i de hol e i n housi ng.
(6) Careful l y remove the foam seal s from the
heater core and evaporator coi l tube mounti ng fl ange
of the HVAC housi ng. I f the ei ther seal i s deformed
or damaged i t must be repl aced.
(7) Use a screwdri ver to pry off the four snap cl i ps
that hel p secure the upper and l ower HVAC housi ng
hal ves together.
(8) Remove the screws that secure the upper and
l ower HVAC housi ng hal ves together.
(9) Careful l y separate the upper HVAC housi ng
from the l ower hal f.
ASSEMBLY
(1) Assembl e the upper HVAC housi ng hal f to the
l ower hal f. Duri ng assembl y, be certai n of the fol l ow-
i ng.
(a) That each of the mode door pi vot shaft ends
and the two temperature bl end door shafts are
properl y engaged i n there pi vot hol es.
(b) That the bl ower motor venturi ri ng i s prop-
erl y i ndexed and i nstal l ed.
(c) I f the uni t i s equi pped wi th ai r condi ti oni ng,
that the evaporator coi l tube rubber seal i s prop-
erl y posi ti oned i n the grooves i n both the upper
and l ower HVAC housi ng hal ves.
(2) I nstal l the screws and four snap cl i ps that
secure the upper and l ower HVAC housi ng hal ves to
each other. Ti ghten the screws to 2.2 Nm (20 i n.
l bs.).
(3) I nstal l the bl ower motor and wheel uni t i n the
HVAC housi ng. (Refer to 24 - HEATI NG & AI R CON-
DI TI ONI NG/DI STRI BUTI ON/BLOWER MOTOR -
I NSTALLATI ON)
(4) I nstal l the foam seal s on the fl anges around
the heater core and evaporator coi l tube mounti ng
fl ange of the HVAC housi ng.
(5) I nsert the vacuum suppl y l i ne and connector
through the foam seal on the heater core and evapo-
rator coi l tube mounti ng fl ange of the HVAC housi ng.
Check that the vacuum grommet i s securel y seated
i nto the housi ng hol e fl ange.
(6) Engage the vacuum harness to the routi ng
cl i ps and pl ug i n the vacuum harness connector at
the fl oor door actuator and, i f the uni t i s so equi pped,
at the reci rcul ati on ai r door actuator.
INSTALLATION
WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR
CONDITIONING, REVIEW THE WARNINGS AND
CAUTIONS IN PLUMBING BEFORE PERFORMING
THE FOLLOWING OPERATION. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - WARNING)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION -
REFRIGERANT HOSES/LINES/TUBES PRECAU-
TIONS)
(1) Posi ti on the HVAC housi ng to the dash panel .
Be certai n that the evaporator condensate drai n tube
and the housi ng mounti ng studs are i nserted i nto
thei r correct mounti ng hol es.
(2) I nstal l and ti ghten the nuts onto the HVAC
housi ng mounti ng studs. Ti ghten the nuts to 6.2 Nm
(55 i n.l bs.).
(3) Connect the HVAC system vacuum suppl y l i ne
connector.
(4) Unpl ug or remove the tape from the heater
core tubes. Connect the heater hoses to the heater
core tubes and fi l l the engi ne cool i ng system(Refer to
7 - COOLI NG/ENGI NE - STANDARD PROCE-
DURE).
(5) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 10.
(6) Unpl ug or remove the tape from the l i qui d l i ne
and the evaporator i nl et tube fi tti ngs. Connect the
l i qui d l i ne coupl er to the evaporator i nl et tube. (Refer
to 24 - HEATI NG & AI R CONDI TI ONI NG/PLUMB-
I NG - STANDARD PROCEDURE - A/C LI NE COU-
PLERS)
(7) Evacuate the refri gerant system. (Refer to 24 -
HVAC HOUSING (Continued)
STANDARD PROCEDURE - REFRI GERANT SYS-
TEM EVACUATE)
(8) Charge the refri gerant system. (Refer to 24 -
TEM CHARGE)
(9) I nstal l the i nstrument panel i n the vehi cl e(Re-
fer to 23 - BODY/I NSTRUMENT PANEL - I NSTAL-
LATI ON).
(11) Start the engi ne and check for proper opera-
ti on of the heati ng and ai r condi ti oni ng systems.
BLEND DOOR
REMOVAL
INJURY.
(1) Remove and di sassembl e the HVAC housi ng.
DI STRI BUTI ON/HVAC HOUSI NG - REMOVAL)
DI STRI BUTI ON/HVAC HOUSI NG - DI SASSEMBLY)
(2) Li ft the bl end door pi vot shaft out of the pi vot
hol e i n the bottom of the l ower hal f of the HVAC
housi ng (Fi g. 6).
INSTALLATION
(1) Pl ace the bl end door pi vot shaft i n of the pi vot
hol e i n the bottom of the l ower hal f of the HVAC
housi ng.
(2) Assembl e the HVAC housi ng. (Refer to 24 -
HVAC HOUSI NG - ASSEMBLY)
(3) I nstal l the HVAC housi ng i n the vehi cl e. (Refer
to 24 - HEATI NG & AI R CONDI TI ONI NG/DI STRI -
BUTI ON/HVAC HOUSI NG - I NSTALLATI ON)
MODE DOOR
REMOVAL
REMOVAL - DEFROST DOOR
INJURY.
Fig. 6 Blend Door
1 - DEFROSTER DOOR
2- HEATER CORE
3- BLEND DOORS
HVAC HOUSING (Continued)
WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION).
(2) I nsert a screwdri ver i nto the l atch hol e (Fi g. 7)
of the panel door pi vot shaft to rel ease the l atch of
the panel door l ever, and pul l the l ever out of the
pi vot shaft from the outsi de of the upper hal f of the
HVAC housi ng.
(3) Remove the defrost door from the HVAC hous-
i ng.
INJURY.
WARNING: (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - CAU-
TION).
(2) Remove the fl oor door vacuum actuator from
the l ower HVAC housi ng. (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/CONTROLS/MODE DOOR
ACTUATOR - REMOVAL - FLOOR DOOR ACTUA-
TOR)
(3) I nsert a screwdri ver i nto the l atch hol e (Fi g. 8)
of the fl oor door pi vot shaft to rel ease the l atch of the
fl oor door l ever, and pul l the l ever out of the pi vot
shaft from the outsi de of the l ower hal f of the HVAC
housi ng.
(4) Reach i nsi de the l ower hal f of the HVAC hous-
i ng and careful l y fl ex the fl oor door (Fi g. 9) enough
so that the door pi vot cl ears the pi vot hol e i n the
housi ng.
(5) Remove the fl oor door from the HVAC housi ng.
INSTALLATION
INSTALLATION - PANEL DOOR
(1) I nstal l the panel door i n the HVAC housi ng.
(2) Snap the panel door pi vot shaft over the l atch
of the panel door l ever.
(3) Attach the demi st door and l ever to the upper
HVAC housi ng. (Refer to 24 - HEATI NG & AI R CON-
Fig. 7 PANEL DOOR REMOVE/INSTALL
1 - DOOR PIVOT SHAFT
2 - LATCH HOLE
3 - CRANK ARM LATCH
4 - FLAT BLADE PRY TOOL
Fig. 8 FLOOR DOOR REMOVE/INSTALL (typical)
1 - DOOR PIVOT SHAFT
2 - LATCH HOLE
3 - CRANK ARM LATCH
4 - FLAT BLADE PRY TOOL
MODE DOOR (Continued)
DI TI ONI NG/DI STRI BUTI ON/MODE DOOR -
I NSTALLATI ON - PANEL/DEMI ST DOOR)
INSTALLATION - FLOOR - DEFROST DOO
(1) I nstal l the fl oor-defrost door i n the HVAC hous-
i ng by pl aci ng the door i n the l ower housi ng.
(3) I nstal l the fl oor door vacuum actuator i n the
l ower HVAC housi ng. (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/CONTROLS/MODE DOOR
ACTUATOR - I NSTALLATI ON - FLOOR DOOR
ACTUATOR)
RECIRC DOOR
REMOVAL
A reci rcul ati on door and vacuum actuator are used
onl y on model s wi th the opti onal ai r condi ti oni ng sys-
tem.
INJURY.
CAUTIONS IN PLUMBING BEFORE PERFORMING
THE FOLLOWING OPERATION. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - WARNING)
PLUMBING - CAUTION)
(1) Remove the HVAC housi ng and di sassembl e.
(2) Remove the four screws to remove the reci rcu-
l ati on door assembl y. (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/CONTROLS/RECI RCULATI ON
DOOR ACTUATOR - REMOVAL)
(3) I nsert a screwdri ver i nto the l atch hol e of the
panel door pi vot shaft to rel ease the l atch of the
panel door l ever and pul l the l ever out of the pi vot
shaft from the outsi de of the upper hal f of the HVAC
housi ng.
INSTALLATION
(1) Gui de the reci rcul ati on door l ever through the
ai r i ntake gri l l e of the HVAC housi ng whi l e i nstal l i ng
the door i n the housi ng.
(4) I nstal l the reci rcul ati on door vacuum actuator
on the l ower HVAC housi ng. (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/CONTROLS/RECI RCULA-
TI ON DOOR ACTUATOR - I NSTALLATI ON)
Fig. 9 FLOOR DOOR (typical)
1 - LOWER HVAC HOUSING
2 - PIVOT SHAFT
3 - CRANK ARM
4 - FLOOR DOOR
MODE DOOR (Continued)
PLUMBING
TABLE OF CONTENTS
page page
PLUMBING
DESCRIPTION - REFRIGERANT LINE . . . . . . . 38
WARNING
SERVICE WARNINGS . . . . . . . . . . . . . . . . . . 39
CAUTION
SERVICE CAUTIONS . . . . . . . . . . . . . . . . . . 39
CAUTION - REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS . . . . . . . . . . . . . . . . . 40
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT . . . . . . . . . . 40
RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SYSTEM EVACUATE . . . . . . . . . . . . . . . . . . . 41
SYSTEM CHARGE. . . . . . . . . . . . . . . . . . . . . 41
SPECIFICATIONS - CHARGE CAPACITY . . . . . 42
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 42
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION - HIGH PRESSURE RELIEF
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
COMPRESSOR NOISE . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
A/C CONDENSER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
A/C DISCHARGE LINE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
A/C LIQUID LINE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
A/C SUCTION LINE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
A/C EVAPORATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
A/C ORIFICE TUBE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
ACCUMULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 51
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
HEATER CORE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53
REFRIGERANT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
REFRIGERANT OIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
PLUMBING
DESCRIPTION - REFRIGERANT LINE
The refri gerant l i nes and hoses are used to carry
the refri gerant between the vari ous ai r condi ti oni ng
system components. A barri er hose desi gn wi th a
nyl on tube, whi ch i s sandwi ched between rubber l ay-
ers, i s used for the R-134a ai r condi ti oni ng system on
thi s vehi cl e. Thi s nyl on tube hel ps to further contai n
the R-134a refri gerant, whi ch has a smal l er mol ecu-
l ar structure than R-12 refri gerant. The ends of the
refri gerant hoses are made from l i ghtwei ght al umi -
num or steel , and commonl y use braze-l ess fi tti ngs.
Any ki nks or sharp bends i n the refri gerant pl umb-
i ng wi l l reduce the capaci ty of the enti re ai r condi -
ti oni ng system. Ki nks and sharp bends reduce the
fl ow of refri gerant i n the system. A good rul e for the
fl exi bl e hose refri gerant l i nes i s to keep the radi us of
al l bends at l east ten ti mes the di ameter of the hose.
24 - 38 PLUMBING KJ
I n addi ti on, the fl exi bl e hose refri gerant l i nes shoul d
be routed so they are at l east 80 mi l l i meters (3
i nches) from an exhaust mani fol d.
WARNING
SERVICE WARNINGS
WARNING: THE AIR CONDITIONING SYSTEM CON-
TAINS REFRIGERANT UNDER HIGH PRESSURE.
SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER SERVICE PROCEDURES. REPAIRS
SHOULD ONLY BE PERFORMED BY QUALIFIED SER-
VICE PERSONNEL.
AVOID BREATHING THE REFRIGERANT AND REFRIG-
ERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRI-
TATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE
PROTECTION WHEN SERVICING THE AIR CONDITION-
ING REFRIGERANT SYSTEM. SERIOUS EYE INJURY
CAN RESULT FROM DIRECT CONTACT WITH THE
REFRIGERANT. IF EYE CONTACT OCCURS, SEEK
MEDICAL ATTENTION IMMEDIATELY.
DO NOT EXPOSE THE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC LEAK
DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VEN-
TILATE THE WORK AREA BEFORE RESUMING SER-
VICE. LARGE AMOUNTS OF REFRIGERANT
RELEASED IN A CLOSED WORK AREA WILL DIS-
PLACE THE OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGERANT
AT AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT
COMES IN CONTACT WITH THE REFRIGERANT WILL
FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE
OBJECTS FROM DIRECT CONTACT WITH THE
REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHICLE
REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED AIR.
SOME MIXTURES OF AIR AND R-134a HAVE BEEN
SHOWN TO BE COMBUSTIBLE AT ELEVATED PRES-
SURES. THESE MIXTURES ARE POTENTIALLY DAN-
GEROUS, AND MAY RESULT IN FIRE OR EXPLOSION
CAUSING INJURY OR PROPERTY DAMAGE.
CAUTION
SERVICE CAUTIONS
CAUTION: Liquid refrigerant is corrosive to metal sur-
faces. Follow the operating instructions supplied with
the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a. Damage to the system will result.
R-12 refrigerant oil must not be mixed with R-134a
refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the R-134a
system. Damage to the system will result.
Do not overcharge the refrigerant system. This will
cause excessive compressor head pressure and can
cause noise and system failure.
Recover the refrigerant before opening any fitting or
connection. Open the fittings with caution, even after
the system has been discharged. Never open or
loosen a connection before recovering the refrigerant.
Do not remove the secondary retention clip from any
spring-lock coupler connection while the refrigerant
system is under pressure. Recover the refrigerant
before removing the secondary retention clip. Open
the fittings with caution, even after the system has
been discharged. Never open or loosen a connection
before recovering the refrigerant.
The refrigerant system must always be evacuated
before charging.
Do not open the refrigerant system or uncap a
replacement component until you are ready to service
the system. This will prevent contamination in the sys-
tem.
Before disconnecting a component, clean the outside
of the fittings thoroughly to prevent contamination
from entering the refrigerant system.
Immediately after disconnecting a component from the
refrigerant system, seal the open fittings with a cap or
plug.
Before connecting an open refrigerant fitting, always
install a new seal or gasket. Coat the fitting and seal
with clean refrigerant oil before connecting.
Do not remove the sealing caps from a replacement
component until it is to be installed.
When installing a refrigerant line, avoid sharp bends
that may restrict refrigerant flow. Position the refriger-
ant lines away from exhaust system components or
any sharp edges, which may damage the line.
Tighten refrigerant fittings only to the specified torque.
The aluminum fittings used in the refrigerant system
will not tolerate overtightening.
When disconnecting a refrigerant fitting, use a wrench
on both halves of the fitting. This will prevent twisting
of the refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace the
cap on the oil container immediately after using. Store
refrigerant oil only in a clean, airtight, and moisture-
free container.
Keep service tools and the work area clean. Contami-
nation of the refrigerant system through careless work
habits must be avoided.
KJ PLUMBING 24 - 39
PLUMBING (Continued)
CAUTION - REFRIGERANT HOSES/LINES/
TUBES PRECAUTIONS
Ki nks or sharp bends i n the refri gerant pl umbi ng wi l l
reduce the capaci ty of the enti re system. Hi gh pressures
are produced i n the system when i t i s operati ng.
Extreme care must be exerci sed to make sure that al l
refri gerant system connecti ons are pressure ti ght.
A good rul e for the fl exi bl e hose refri gerant l i nes i s
to keep the radi us of al l bends at l east ten ti mes the
di ameter of the hose. Sharp bends wi l l reduce the
fl ow of refri gerant. The fl exi bl e hose l i nes shoul d be
routed so they are at l east 80 mi l l i meters (3 i nches)
from the exhaust mani fol d. I t i s a good practi ce to
i nspect al l fl exi bl e refri gerant system hose l i nes at
l east once a year to make sure they are i n good con-
di ti on and properl y routed.
There are two types of refri gerant fi tti ngs:
Al l fi tti ngs wi th O-ri ngs need to be coated wi th
refri gerant oi l before i nstal l ati on. Use onl y O-ri ngs that
are the correct si ze and approved for use wi th R-134a
refri gerant. Fai l ure to do so may resul t i n a l eak.
Uni fi ed pl umbi ng connecti ons wi th gaskets can-
not be servi ced wi th O-ri ngs. The gaskets are not
reusabl e and new gaskets do not requi re l ubri cati on
before i nstal l i ng.
Usi ng the proper tool s when maki ng a refri gerant
pl umbi ng connecti on i s very i mportant. I mproper
tool s or i mproper use of the tool s can damage the
refri gerant fi tti ngs. Al ways use two wrenches when
l ooseni ng or ti ghteni ng tube fi tti ngs. Use one wrench
to hol d one si de of the connecti on stati onary, whi l e
l ooseni ng or ti ghteni ng the other si de of the connec-
ti on wi th a second wrench.
The refri gerant must be recovered compl etel y from
the system before openi ng any fi tti ng or connecti on.
Open the fi tti ngs wi th cauti on, even after the refri g-
erant has been recovered. I f any pressure i s noti ced
as a fi tti ng i s l oosened, ti ghten the fi tti ng and
recover the refri gerant from the system agai n.
Do not di scharge refri gerant i nto the atmosphere.
Use an R-134a refri gerant recovery/recycl i ng devi ce
that meets SAE Standard J2210.
The refri gerant system wi l l remai n chemi cal l y sta-
bl e as l ong as pure, moi sture-free R-134a refri gerant
and refri gerant oi l i s used. Di rt, moi sture, or ai r can
upset thi s chemi cal stabi l i ty. Operati onal troubl es or
seri ous damage can occur i f forei gn materi al i s
present i n the refri gerant system.
When i t i s necessary to open the refri gerant sys-
tem, have everythi ng needed to servi ce the system
ready. The refri gerant system shoul d not be l eft open
to the atmosphere any l onger than necessary. Cap or
pl ug al l l i nes and fi tti ngs as soon as they are opened
to prevent the entrance of di rt and moi sture. Al l l i nes
and components i n parts stock shoul d be capped or
seal ed unti l they are to be i nstal l ed.
Al l tool s, i ncl udi ng the refri gerant recycl i ng equi p-
ment, the mani fol d gauge set, and test hoses shoul d
be kept cl ean and dry. Al l tool s and equi pment must
be desi gned for R-134a refri gerant.
STANDARD PROCEDURE
SYSTEM SERVICE EQUIPMENT
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
When servi ci ng the ai r condi ti oni ng system, a
R-134a refri gerant recovery/recycl i ng/chargi ng sta-
ti on that meets SAE Standard J2210 must be used.
Contact an automoti ve servi ce equi pment suppl i er for
refri gerant recovery/recycl i ng/chargi ng equi pment.
Refer to the operati ng i nstructi ons suppl i ed by the
equi pment manufacturer for proper care and use of
thi s equi pment.
A mani fol d gauge set may be needed wi th some
recovery/recycl i ng/chargi ng equi pment (Fi g. 1). The
servi ce hoses on the gauge set bei ng used shoul d
have manual (turn wheel ), or automati c back-fl ow
val ves at the servi ce port connector ends. Thi s wi l l
prevent refri gerant from bei ng rel eased i nto the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
LOW PRESSURE GAUGE HOSE The l ow pressure
hose (Bl ue wi th Bl ack stri pe) attaches to the sucti on
servi ce port. Thi s port i s l ocated on the sucti on l i ne
between the accumul ator outl et and the compressor.
HI GH PRESSURE GAUGE HOSE The hi gh pres-
sure hose (Red wi th Bl ack stri pe) attaches to the di s-
charge servi ce port. Thi s port i s l ocated on the
di scharge l i ne between the compressor and the con-
denser i nl et.
RECOVERY/RECYCLI NG/EVACUATI ON/CHARG-
I NG HOSE The center mani fol d hose (Yel l ow, or
Whi te, wi th Bl ack stri pe) i s used to recover, evacu-
ate, and charge the refri gerant system. When the l ow
or hi gh pressure val ves on the mani fol d gauge set
are opened, the refri gerant i n the system wi l l escape
through thi s hose.
24 - 40 PLUMBING KJ
RECOVERY
A R-134a refri gerant recovery/recycl i ng/chargi ng
stati on that meets SAE Standard J2210 must be
used to recover the refri gerant from an R-134a refri g-
erant system. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for the proper
care and use of thi s equi pment.
SYSTEM EVACUATE
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be charged. I f moi sture and ai r enters the system
and becomes mi xed wi th the refri gerant, the com-
pressor head pressure wi l l ri se above acceptabl e
operati ng l evel s. Thi s wi l l reduce the performance of
the ai r condi ti oner and damage the compressor.
Evacuati ng the refri gerant system wi l l remove the
ai r and boi l the moi sture out of the system at near
room temperature. To evacuate the refri gerant sys-
tem, use the fol l owi ng procedure:
(1) Connect a R-134a refri gerant recovery/recy-
cl i ng/chargi ng stati on that meets SAE Standard
J2210 and a mani fol d gauge set to the refri gerant
system of the vehi cl e.
(2) Open the l ow and hi gh si de val ves and start
the chargi ng stati on vacuum pump. When the suc-
ti on gauge reads 88 kPa (26 i n. Hg.) vacuum or
greater, cl ose al l of the val ves and turn off the vac-
uum pump.
(a) I f the refri gerant system fai l s to reach the
speci fi ed vacuum, the system has a l eak that must
be corrected. (Refer to 24 - HEATI NG & AI R CON-
DI TI ONI NG/PLUMBI NG - DI AGNOSI S AND
TESTI NG - REFRI GERANT SYSTEM LEAKS)
(b) I f the refri gerant system mai ntai ns the spec-
i fi ed vacuum for fi ve mi nutes, restart the vacuum
pump, open the sucti on and di scharge val ves and
evacuate the system for an addi ti onal ten mi nutes.
(3) Cl ose al l of the val ves, and turn off the charg-
i ng stati on vacuum pump.
(4) The refri gerant system i s now ready to be
charged wi th R-134a refri gerant. (Refer to 24 -
TEM CHARGE)
SYSTEM CHARGE
After the refri gerant system has been tested for
l eaks and evacuated, a refri gerant charge can be
i njected i nto the system. (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG - SPECI FI CA-
TI ONS - CHARGE CAPACI TY)
A R-134a refri gerant recovery/recycl i ng/chargi ng
stati on that meets SAE Standard J2210 must be
Fig. 1 MANIFOLD GAUGE SET - TYPICAL
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/ BLACK
STRIPE)
4 - HIGH PRESSURE HOSE (RED W/ BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/ BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
KJ PLUMBING 24 - 41
used to charge the refri gerant system wi th R-134a
refri gerant. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for proper care
and use of thi s equi pment.
SPECIFICATIONS - CHARGE CAPACITY
The R-134a refri gerant system charge capaci ty for
thi s vehi cl e i s 0.737 ki l ograms (1.63 pounds).
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION
The ai r condi ti oni ng system uses a Sanden
PXF-18, reci procati ng swash pl ate-type compressor
on al l model s. Thi s compressor has a fi xed di spl ace-
ment of 180 cubi c centi meters (10.984 cubi c i nches),
and has both the sucti on and di scharge ports l ocated
on the cyl i nder head. A l abel i denti fyi ng the use of
R-134a refri gerant i s l ocated on the compressor.
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE
A hi gh pressure rel i ef val ve i s l ocated on the com-
pressor cyl i nder head, whi ch i s on the rear of the
compressor. Thi s mechani cal val ve i s desi gned to
vent refri gerant from the system to protect agai nst
damage to the compressor and other system compo-
nents, caused by condenser ai r fl ow restri cti on or an
overcharge of refri gerant.
OPERATION
OPERATION
The compressor i s dri ven by the engi ne through an
el ectri c cl utch, dri ve rotor and bel t arrangement. The
compressor i s l ubri cated by refri gerant oi l that i s ci r-
cul ated throughout the refri gerant system wi th the
refri gerant.
The compressor draws i n l ow-pressure refri gerant
vapor from the evaporator through i ts sucti on port. I t
then compresses the refri gerant i nto a hi gh-pressure,
hi gh-temperature refri gerant vapor, whi ch i s then
pumped to the condenser through the compressor di s-
charge port.
The compressor cannot be repai red. I f faul ty or
damaged, the enti re compressor assembl y must be
repl aced. The compressor cl utch, pul l ey and cl utch
coi l are avai l abl e for servi ce.
OPERATION - HIGH PRESSURE RELIEF VALVE
The hi gh pressure rel i ef val ve vents the system
when a di scharge pressure of 3445 to 4135 kPa (500
to 600 psi ) or above i s reached. The val ve cl oses
when a mi ni mum di scharge pressure of 2756 kPa
(400 psi ) i s reached.
The hi gh pressure rel i ef val ve vents onl y enough
refri gerant to reduce the system pressure, and then
re-seats i tsel f. The majori ty of the refri gerant i s con-
served i n the system. I f the val ve vents refri gerant, i t
does not mean that the val ve i s faul ty.
The hi gh pressure rel i ef val ve i s a factory-cal i -
brated uni t. The val ve cannot be adjusted or
repai red, and must not be removed or otherwi se di s-
turbed. The val ve i s onl y servi ced as a part of the
compressor assembl y.
DIAGNOSIS AND TESTING - A/C COMPRESSOR
NOISE
When i nvesti gati ng an ai r condi ti oni ng rel ated
noi se, you must fi rst know the condi ti ons under
whi ch the noi se occurs. These condi ti ons i ncl ude:
weather, vehi cl e speed, transmi ssi on i n gear or neu-
tral , engi ne speed, engi ne temperature, and any
other speci al condi ti ons. Noi ses that devel op duri ng
ai r condi ti oni ng operati on can often be mi sl eadi ng.
For exampl e: What sounds l i ke a fai l ed front beari ng
or connecti ng rod, may be caused by l oose bol ts, nuts,
mounti ng brackets, or a l oose compressor cl utch
assembl y.
Dri ve bel ts are speed sensi ti ve. At di fferent engi ne
speeds and dependi ng upon bel t tensi on, bel ts can
devel op noi ses that are mi staken for a compressor
noi se. I mproper bel t tensi on can cause a mi sl eadi ng
noi se when the compressor cl utch i s engaged, whi ch
may not occur when the compressor cl utch i s di sen-
gaged. Check the serpenti ne dri ve bel t condi ti on and
tensi on as descri bed i n Cool i ng before begi nni ng thi s
procedure.
(1) Sel ect a qui et area for testi ng. Dupl i cate the
compl ai nt condi ti ons as much as possi bl e. Swi tch the
compressor on and off several ti mes to cl earl y i den-
ti fy the compressor noi se. Li sten to the compressor
whi l e the cl utch i s engaged and di sengaged. Probe
the compressor wi th an engi ne stethoscope or a l ong
screwdri ver wi th the handl e hel d to your ear to bet-
ter l ocal i ze the source of the noi se.
(2) Loosen al l of the compressor mounti ng hard-
ware and reti ghten. Ti ghten the compressor cl utch
mounti ng nut. Be certai n that the cl utch coi l i s
mounted securel y to the compressor, and that the
cl utch pl ate and rotor are properl y al i gned and have
the correct ai r gap. (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/CONTROLS/A/C COMPRESSOR
CLUTCH - I NSTALLATI ON)
24 - 42 PLUMBING KJ
(3) To dupl i cate a hi gh-ambi ent temperature condi -
ti on (hi gh head pressure), restri ct the ai r fl ow
through the condenser. I nstal l a mani fol d gauge set
to be certai n that the di scharge pressure does not
exceed 2760 kPa (400 psi ).
(4) Check the refri gerant system pl umbi ng for
i ncorrect routi ng, rubbi ng or i nterference, whi ch can
cause unusual noi ses. Al so check the refri gerant l i nes
for ki nks or sharp bends that wi l l restri ct refri gerant
fl ow, whi ch can cause noi ses. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - CAU-
TI ON)
(5) I f the noi se i s from openi ng and cl osi ng of the
hi gh pressure rel i ef val ve, evacuate and recharge the
refri gerant system. (Refer to 24 - HEATI NG & AI R
CEDURE - REFRI GERANT SYSTEM EVACUATE)
PLUMBI NG - STANDARD PROCEDURE - REFRI G-
ERANT SYSTEM CHARGE) I f the hi gh pressure
rel i ef val ve sti l l does not seat properl y, repl ace the
compressor.
(6) I f the noi se i s from l i qui d sl uggi ng on the suc-
ti on l i ne, repl ace the accumul ator. (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/AC-
CUMULATOR - REMOVAL) Check the refri gerant oi l
l evel and the refri gerant system charge. (Refer to 24
- HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
REFRI GERANT OI L - STANDARD PROCEDURE)
PLUMBI NG - SPECI FI CATI ONS - CHARGE
CAPACI TY) I f the l i qui d sl uggi ng condi ti on conti nues
fol l owi ng accumul ator repl acement, repl ace the com-
pressor. (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/A/C COMPRESSOR -
REMOVAL)
(7) I f the noi se conti nues, repl ace the compressor
and repeat Step 1.
REMOVAL
The compressor may be removed and reposi ti oned
wi thout di sconnecti ng the refri gerant l i nes or di s-
chargi ng the refri gerant system. Di schargi ng i s not
necessary i f servi ci ng the compressor cl utch or cl utch
coi l , the engi ne, the cyl i nder head, or the generator.
(1) Recover the refri gerant from the refri gerant
system. (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG - STANDARD PROCEDURE -
REFRI GERANT RECOVERY)
cabl e.
(3) Remove the serpenti ne dri ve bel t(Refer to 7 -
REMOVAL).
(4) Unpl ug the compressor cl utch coi l wi re harness
connector.
(5) Remove the sucti on and di scharge refri gerant
l i ne mani fol d from the compressor. (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
SUCTI ON LI NE - REMOVAL) (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C
DI SCHARGE LI NE - REMOVAL) I nstal l pl ugs i n, or
tape over al l of the opened refri gerant fi tti ngs.
(6) Remove the bol ts that secure the compressor to
the mounti ng bracket (Fi g. 2) or (Fi g. 3) or (Fi g. 4).
(7) Remove the compressor from the mounti ng
bracket.
Fig. 2 A/C COMPRESSOR - 2.4L ENGINE
1 - COMPRESSOR BOLT
2 - COMPRESSOR BOLT
3 - COMPRESSOR CLUTCH AND PULLY
4 - IDLER PULLEY
5 - ENGINE BLOCK
6 - A/C COMPRESSOR
KJ PLUMBING 24 - 43
A/C COMPRESSOR (Continued)
INSTALLATION
AIR CONDITIONING/PLUMBING - CAUTION) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
The compressor may be removed and reposi ti oned
wi thout di sconnecti ng the refri gerant l i nes or di s-
chargi ng the refri gerant system. Di schargi ng i s not
necessary i f servi ci ng the compressor cl utch or cl utch
coi l , the engi ne, the cyl i nder head, or the generator.
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - STANDARD PRO-
CEDURE - REFRIGERANT OIL LEVEL) Use only
refrigerant oil of the type recommended for the
compressor in the vehicle. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/REFRIGERANT OIL -
DESCRIPTION)
(1) I nstal l the compressor to the mounti ng bracket.
Ti ghten the three mounti ng bol ts to 27 Nm (20 ft.
l bs.), (2.4L gasol i ne and 2.5L di esel engi nes onl y).
(2) On the 3.7L gasol i ne engi ne i nstal l and ti ghten
the bol ts i n the fol l owi ng sequence (Fi g. 5):
The number one bol t (rear) i s hand ti ghtened
fi rst then ti ghtened to 55 Nm (41 ft. l bs.)
The number three bol t i s then hand ti ghtened
and torqued to 40 Nm ( 30 ft. l bs.)
The number two bol t i s al so hand ti ghtened and
torqued to 55 Nm ( 41 ft. l bs.)
(3) Remove the tape or pl ugs from al l of the
opened refri gerant l i ne fi tti ngs. I nstal l the sucti on
and di scharge l i ne mani fol d to the compressor.
Ti ghten the fastener to 28 Nm (250 i n. l bs.).(Refer to
24 - HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/
SUCTI ON LI NE - I NSTALLATI ON) (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C
DI SCHARGE LI NE - I NSTALLATI ON)
(4) I nstal l the serpenti ne dri ve bel t(Refer to 7 -
I NSTALLATI ON).
1 - COMPRESSOR BOLT #1
4 - A/C COMPRESSOR
5 - A/C COMPRESSOR CLUTCH AND PULLEY
6 - COMPRESSOR MOUNT
Fig. 4 A/C COMPRESSOR - 2.5L DIESEL ENGINE
1 - SUCTION LINE MOUNTING NUT
2- SUCTION LINE MOUNTING CLIP
3- SUCTION LINE
4- MOUNTING SCREW FOR SUCTION LINE
5- SUCTION LINE MOUNTING FLANG
6- MOUNTING SCREW FOR DISCHARGE LINE
7- DISCHARGE LINE MOUNTING FLANG
8- A/C PRESSURE SENSOR
9- A/C DISCHARGE LINE
10- A/C COMPRESSOR ASSEMBLY
11- A/C DISCHARGE LINE SERVICE PORT
24 - 44 PLUMBING KJ
(5) Pl ug i n the compressor cl utch coi l wi re harness
connector.
TEM EVACUATE)
TEM CHARGE)
A/C CONDENSER
DESCRIPTION
The condenser i s l ocated i n the ai r fl ow i n front of
the engi ne cool i ng radi ator. The condenser i s a heat
exchanger that al l ows the hi gh-pressure refri gerant
gas bei ng di scharged by the compressor to gi ve up i ts
heat to the ai r passi ng over the condenser fi ns.
OPERATION
When the refri gerant gas gi ves up i ts heat, i t con-
denses. When the refri gerant l eaves the condenser, i t
has become a hi gh-pressure l i qui d refri gerant. The
vol ume of ai r fl owi ng over the condenser fi ns i s cri t-
i cal to the proper cool i ng performance of the ai r con-
di ti oni ng system. Therefore, i t i s i mportant that
there are no objects pl aced i n front of the radi ator
gri l l e openi ngs i n the front of the vehi cl e or forei gn
materi al on the condenser fi ns that mi ght obstruct
proper ai r fl ow. Al so, any factory-i nstal l ed ai r seal s or
shrouds must be properl y rei nstal l ed fol l owi ng radi a-
tor or condenser servi ce.
The condenser cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
REMOVAL
cabl e.
(3) Di sconnect the di scharge l i ne refri gerant l i ne
fi tti ng at the condenser i nl et. (Refer to 24 - HEAT-
DARD PROCEDURE - A/C LI NE COUPLERS)
I nstal l pl ugs i n, or tape over al l of the opened refri g-
erant l i ne fi tti ngs.
(4) Di sconnect the l i qui d l i ne (Left-Hand Dri ve) or
l i qui d l i ne jumper (Ri ght-Hand Dri ve) refri gerant
l i ne fi tti ng at the condenser outl et. (Refer to 24 -
STANDARD PROCEDURE - A/C LI NE COUPLERS)
(5) Remove the radi ator and the condenser from
the vehi cl e as a uni t. Refer to Cool i ng for the proce-
dures.
(6) Remove the two nuts that secure the condenser
studs to the upper brackets of the radi ator (Fi g. 6).
(7) Sl i de the condenser down from the radi ator far
enough for the condenser studs to cl ear the upper
radi ator bracket hol es, and for the l ower condenser
bracket hol es to cl ear the dowel pi ns on the bottom of
the radi ator.
(8) Remove the condenser from the radi ator.
4 - A/C COMPRESSOR
5 - A/C COMPRESSOR CLUTCH AND PULLEY
6 - COMPRESSOR MOUNT
KJ PLUMBING 24 - 45
INSTALLATION
PRECAUTIONS)
(1) I nstal l the hol es of the condenser l ower brack-
ets over the dowel pi ns on the bottom of the radi ator.
(2) Sl i de the condenser upwards unti l both of the
condenser studs are i nstal l ed through the hol es i n
the radi ator upper brackets. Ti ghten the mounti ng
nuts to 5.3 Nm (47 i n. l bs.).
(3) Rei nstal l the radi ator and condenser uni t i n
the vehi cl e(Refer to 7 - COOLI NG/ENGI NE/RADI A-
TOR - I NSTALLATI ON).
(4) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the condenser outl et and the l i qui d
l i ne (Left-Hand Dri ve) or the l i qui d l i ne jumper
(Ri ght-Hand Dri ve). I nstal l the l i qui d l i ne or the l i q-
ui d l i ne jumper to the condenser outl et. (Refer to 24 -
l i ne fi tti ngs on the condenser i nl et and the di scharge
l i ne. Connect the di scharge l i ne to the condenser
i nl et. (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE - A/C
LI NE COUPLERS)
TEM EVACUATE)
TEM CHARGE)
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
A/C DISCHARGE LINE
REMOVAL
cabl e.
hi gh pressure cut-off swi tch.
(4) Di sconnect the di scharge l i ne refri gerant l i ne
fi tti ng from the condenser i nl et tube (Fi g. 7). (Refer
to 24 - HEATI NG & AI R CONDI TI ONI NG/PLUMB-
I NG - STANDARD PROCEDURE - A/C LI NE COU-
PLERS) I nstal l pl ugs i n, or tape over al l of the
(5) Remove the nut that secures the sucti on l i ne
bl ock fi tti ng to the accumul ator outl et. I nstal l pl ugs
i n, or tape over al l of the opened refri gerant l i ne fi t-
ti ngs.
(6) Remove the screw that secures the sucti on and
di scharge l i ne mani fol d to the compressor. I nstal l
pl ugs i n, or tape over al l of the opened refri gerant
l i ne fi tti ngs.
Fig. 6 CONDENSER REMOVE/INSTALL
1 - NUT
2 - RADIATOR
3 - GROMMET
4 - LOWER CROSSMEMBER
5 - CONDENSER
6 - STUDS
24 - 46 PLUMBING KJ
A/C CONDENSER (Continued)
(7) Remove the sucti on and di scharge l i ne assem-
bl y from the vehi cl e.
INSTALLATION
PRECAUTIONS)
(1) Remove the tape or pl ugs from the sucti on and
di scharge l i ne mani fol d and the compressor. I nstal l
the sucti on and di scharge l i ne mani fol d to the com-
pressor. Ti ghten the fastener to 28 Nm (250 i n. l bs.).
(2) Remove the tape or pl ugs from the sucti on l i ne
and the accumul ator outl et bl ock fi tti ngs. I nstal l the
sucti on l i ne to the accumul ator outl et and ti ghten the
mounti ng nut to 9 Nm (80 i n. l bs.).
l i ne fi tti ngs on the di scharge l i ne and the condenser
i nl et tube. Connect the di scharge l i ne refri gerant l i ne
coupl er to the condenser i nl et tube. (Refer to 24 -
(4) Pl ug i n the wi re harness connector to the hi gh
pressure cut-off swi tch.
TEM EVACUATE)
TEM CHARGE)
A/C LIQUID LINE
REMOVAL
cabl e.
(2) Recover the refri gerant.(Refer to 24 - HEAT-
DARD PROCEDURE - REFRI GERANT RECOVERY)
(3) Di sconnect the l i qui d l i ne refri gerant l i ne cou-
pl ers at the evaporator i nl et and the condenser outl et
(Fi g. 8). (Refer to 24 - HEATI NG & AI R CONDI -
A/C LI NE COUPLERS) I nstal l pl ugs i n, or tape over
al l of the opened refri gerant l i ne fi tti ngs.
(4) Remove the l i qui d l i ne from the vehi cl e.
INSTALLATION
PRECAUTIONS)
l i ne fi tti ngs on the l i qui d l i ne, the evaporator i nl et
Fig. 7 SUCTION AND DISCHARGE LINE REMOVAL
1 - Condensor connection
2- Discharge line to condensor mounting nut
3- Discharge line
4- Discharge line charging port
5- Suction line
6- Evaporator mounting ports
7- Accumulator
8- High pressure cut off switch
9- AC compressor
10- AC condensor
KJ PLUMBING 24 - 47
A/C DISCHARGE LINE (Continued)
and the condenser outl et. Connect the l i qui d l i ne to
the evaporator i nl et and condenser outl et refri gerant
l i ne coupl ers. (Refer to 24 - HEATI NG & AI R CON-
DI TI ONI NG/PLUMBI NG - STANDARD PROCE-
DURE - A/C LI NE COUPLERS)
TEM EVACUATE)
TEM CHARGE)
A/C SUCTION LINE
REMOVAL
cabl e.
(2) Recover the refri gerant. (Refer to 24 - HEAT-
DARD PROCEDURE - REFRI GERANT RECOVERY)
(3) Unpl ug the wi re harness connector from the a/c
hi gh pressure swi tch (Fi g. 9).
(4) Di sconnect the di scharge l i ne refri gerant fi tti ng
from the condenser i nl et tube. (Refer to 24 - HEAT-
DARD PROCEDURE - A/C LI NE COUPLERS)
(5) Remove the nut that secures the sucti on l i ne
bl ock fi tti ng to the accumul ator outl et. I nstal l pl ugs i n,
or tape over al l of the opened refri gerant l i ne fi tti ngs.
(6) Remove the fastener that secures the sucti on and
di scharge l i ne mani fol d to the compressor. I nstal l pl ugs
i n, or tape over al l of the opened refri gerant l i ne fi t-
ti ngs.
Fig. 8 LIQUID LINE REMOVE/INSTALL
1 - AC Condensor
2- AC condensor connector ports
3- Liquid line to condensor connector
4- Mounting nut
5- Liquid line
6- Liquid line mounting clips (2)
7- Mounting nut
8- Liquid line to evaporator connection
9- Evaporator connection
Fig. 9 SUCTION AND DISCHARGE LINE REMOVAL
1 - Condensor connection
2- Discharge line to condensor mounting nut
3- Discharge line
4- Discharge line charging port
5- Suction line
6- Evaporator mounting ports
7- Accumulator
8- High pressure cut off switch
9- AC compressor
10- AC condensor
24 - 48 PLUMBING KJ
A/C LIQUID LINE (Continued)
(7) Remove the sucti on and di scharge l i ne assem-
bl y from the vehi cl e.
INSTALLATION
TIONS IN THE FRONT IF THIS SECTION BEFORE
PRECAUTIONS)
(1) Remove the tape or pl ugs from the sucti on and
di scharge l i ne mani fol d and the compressor. I nstal l
the sucti on and di scharge l i ne mani fol d to the com-
pressor. Ti ghten the fastener to 28 Nm (250 i n. l bs.).
(2) Remove the tape or pl ugs from the sucti on l i ne
and the accumul ator outl et bl ock fi tti ngs. I nstal l the
sucti on l i ne to the accumul ator outl et and ti ghten the
mounti ng nut to 9 Nm (80 i n. l bs.).
l i ne fi tti ngs on the di scharge l i ne and the condenser
i nl et tube. Connect the di scharge l i ne refri gerant l i ne
coupl er to the condenser i nl et tube. (Refer to 24 -
(4) Pl ug i n the wi re harness connector on the a/c
hi gh pressure swi tch.
TEM EVACUATE)
TEM CHARGE)
(8) Check the affected areas of the system for
l eaks.
A/C EVAPORATOR
DESCRIPTION
The evaporator coi l i s l ocated i n the HVAC hous-
i ng, under the i nstrument panel . The evaporator coi l
i s posi ti oned i n the HVAC housi ng so that al l ai r that
enters the housi ng must pass over the fi ns of the
evaporator before i t i s di stri buted through the sys-
tem ducts and outl ets. However, ai r passi ng over the
evaporator coi l fi ns wi l l onl y be condi ti oned when the
compressor i s engaged and ci rcul ati ng refri gerant
through the evaporator coi l tubes.
OPERATION
Refri gerant enters the evaporator from the fi xed
ori fi ce tube as a l ow-temperature, l ow-pressure l i q-
ui d. As ai r fl ows over the fi ns of the evaporator, the
humi di ty i n the ai r condenses on the fi ns, and the
heat from the ai r i s absorbed by the refri gerant. Heat
absorpti on causes the refri gerant to boi l and vapor-
i ze. The refri gerant becomes a l ow-pressure gas when
i t l eaves the evaporator.
The evaporator coi l cannot be repai red and, i f
REMOVAL
INJURY.
(2) Li ft the evaporator coi l uni t out of the l ower
hal f of the HVAC housi ng. (Fi g. 10).
INSTALLATION
PRECAUTIONS)
KJ PLUMBING 24 - 49
A/C SUCTION LINE (Continued)
(1) I nstal l the evaporator coi l uni t i nto of the l ower
hal f of the HVAC housi ng. Be certai n that the evap-
orator foam i nsul ator wrap and rubber tube seal are
rei nstal l ed.
(2) Reassembl e and i nstal l the HVAC housi ng.
DI STRI BUTI ON/HVAC HOUSI NG - ASSEMBLY)
DI STRI BUTI ON/HVAC HOUSI NG - I NSTALLA-
TI ON)
NOTE: If the evaporator was replaced, add 60 milli-
liters (2 fluid ounces) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
A/C ORIFICE TUBE
DESCRIPTION
The fi xed ori fi ce tube i s i nstal l ed i n the l i qui d l i ne
(l eft-hand dri ve) or l i qui d l i ne jumper (ri ght-hand
dri ve) between the outl et of the condenser and the
i nl et of the evaporator. The fi xed ori fi ce tube i s
l ocated i n the end of the l i qui d l i ne or l i qui d l i ne
jumper that i s cl osest to the condenser outl et tube.
The i nl et end of the fi xed ori fi ce tube has a nyl on
mesh fi l ter screen, whi ch fi l ters the refri gerant and
hel ps to reduce the potenti al for bl ockage of the
meteri ng ori fi ce by refri gerant system contami nants
(Fi g. 11). The outl et end of the tube has a nyl on
mesh di ffuser screen. The O-ri ngs on the pl asti c body
of the fi xed ori fi ce tube seal the tube to the i nsi de of
the l i qui d l i ne and prevent the refri gerant from
bypassi ng the fi xed meteri ng ori fi ce.
OPERATION
The fi xed ori fi ce tube i s used to meter the fl ow of
l i qui d refri gerant i nto the evaporator coi l . The hi gh-
pressure l i qui d refri gerant from the condenser
expands i nto a l ow-pressure l i qui d as i t passes
through the meteri ng ori fi ce and di ffuser screen of
the fi xed ori fi ce tube.
The fi xed ori fi ce tube cannot be repai red and, i f
faul ty or pl ugged, the l i qui d l i ne and fi xed ori fi ce
tube uni t or l i qui d l i ne jumper and fi xed ori fi ce tube
REMOVAL
The fi xed ori fi ce tube i s l ocated i n the l i qui d l i ne
(Left-Hand Dri ve) or the l i qui d l i ne jumper (Ri ght-
Hand Dri ve) near the condenser. The ori fi ce has fi l ter
screens on the i nl et and outl et ends of the tube body.
I f the fi xed ori fi ce tube i s faul ty or pl ugged, the l i q-
ui d l i ne uni t or l i qui d l i ne jumper uni t must be
repl aced. (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/LI QUI D LI NE - REMOVAL)
INSTALLATION
The fi xed ori fi ce tube i s l ocated i n the l i qui d l i ne
(Left-Hand Dri ve) or the l i qui d l i ne jumper (Ri ght-
Hand Dri ve) near the condenser. The ori fi ce has fi l ter
screens on the i nl et and outl et ends of the tube body.
I f the fi xed ori fi ce tube i s faul ty or pl ugged, the l i q-
ui d l i ne uni t or l i qui d l i ne jumper uni t must be
Fig. 10 Blend Door
1 - DEFROSTER DOOR
2- HEATER CORE
3- BLEND DOORS
Fig. 11 FIXED ORIFICE TUBE - TYPICAL
1 - DIFFUSER SCREEN
2 - O RINGS
3 - INLET FILTER SCREENS
4 - ORIFICE
24 - 50 PLUMBING KJ
A/C EVAPORATOR (Continued)
repl aced. (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/LI QUI D LI NE - REMOVAL)
ACCUMULATOR
DESCRIPTION
The accumul ator i s mounted i n the engi ne com-
partment between the evaporator coi l outl et tube and
the compressor i nl et.
OPERATION
Refri gerant enters the accumul ator cani ster as a
l ow pressure vapor through the i nl et tube. Any l i q-
ui d, oi l -l aden refri gerant fal l s to the bottom of the
cani ster, whi ch acts as a separator. A desi ccant bag i s
mounted i nsi de the accumul ator cani ster to absorb
any moi sture whi ch may have entered and become
trapped wi thi n the refri gerant system (Fi g. 12).
REMOVAL
cabl e.
l ow pressure cycl i ng cl utch swi tch.
(4) Loosen the screw that secures the accumul ator
retai ni ng band to the support bracket on the dash
panel (Fi g. 13).
(5) Di sconnect the sucti on l i ne from the accumul a-
tor outl et tube refri gerant l i ne fi tti ng. (Refer to 24 -
(6) Di sconnect the accumul ator i nl et tube refri ger-
ant l i ne fi tti ng from the evaporator outl et tube.
PLUMBI NG - STANDARD PROCEDURE - A/C LI NE
COUPLERS) I nstal l pl ugs i n, or tape over al l of the
(7) Pul l the accumul ator and retai ni ng band uni t
forward unti l the screw i n the band i s cl ear of the
sl otted hol e i n the support bracket on the dash panel .
(8) Remove the accumul ator from the vehi cl e.
INSTALLATION
PRECAUTIONS)
(1) I nstal l the accumul ator and retai ni ng band as
a uni t by sl i di ng the screw i n the band i nto the sl ot-
ted hol e i n the support bracket on the dash panel .
l i ne fi tti ngs on the accumul ator i nl et tube and the
Fig. 12 ACCUMULATOR - TYPICAL
2 - PRESSURE SWITCH FITTING
3 - OUTLET TO COMPRESSOR
4 - ANTI-SIPHON HOLE
5 - DESICCANT BAG
6 - OIL RETURN ORIFICE FILTER
7 - VAPOR RETURN TUBE
8 - ACCUMULATOR DOME
9 - O-RING SEAL
10 - INLET FROM EVAPORATOR
KJ PLUMBING 24 - 51
A/C ORIFICE TUBE (Continued)
evaporator outl et tube. Connect the accumul ator i nl et
tube refri gerant l i ne coupl er to the evaporator outl et
tube. (Refer to 24 - HEATI NG & AI R CONDI TI ON-
I NG/PLUMBI NG - STANDARD PROCEDURE - A/C
LI NE COUPLERS)
(3) Ti ghten the accumul ator retai ni ng band screw
to 5 Nm (45 i n. l bs.).
l i ne fi tti ngs on the sucti on l i ne and the accumul ator
outl et tube. Connect the sucti on l i ne to the accumu-
l ator outl et tube refri gerant l i ne coupl er. (Refer to 24
- HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG -
(5) Pl ug the wi re harness connector i nto the l ow
pressure cycl i ng cl utch swi tch.
TEM EVACUATE)
TEM CHARGE)
NOTE: If the accumulator is replaced, add 120 mil-
liliters (4 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle. (Refer to 24 - HEATING & AIR CONDITIONING/
HEATER CORE
DESCRIPTION
The heater core i s l ocated i n the HVAC housi ng,
under the i nstrument panel . I t i s a heat exchanger
made of rows of tubes and fi ns and uses warm engi ne
cool ant as i ts heat source.
OPERATION
Engi ne cool ant i s ci rcul ated through heater hoses
to the heater core at al l ti mes. As the cool ant fl ows
through the heater core, heat removed from the
engi ne i s transferred to the heater core fi ns and
tubes. Ai r di rected through the heater core pi cks up
the heat from the heater core fi ns. The temperature
control door al l ows control of the heater output ai r
temperature by control l i ng how much of the ai r fl ow-
i ng through the HVAC housi ng i s di rected through
the heater core. The bl ower motor speed control s the
vol ume of ai r fl owi ng through the HVAC housi ng.
The heater core cannot be repai red and, i f faul ty or
damaged, i t must be repl aced. Refer to Cool i ng for
more i nformati on on the engi ne cool i ng system, the
engi ne cool ant and the heater hoses.
REMOVAL
INJURY.
Fig. 13 A/C LOW PRESSURE SWITCH
1 - WIRING HARNESS CONNECTOR
3 - A/C LINE TO EVAPORATOR
4 - ACCUMULATOR MOUNTING BRACKET
5 - ACCUMULATOR
6 - A/C LOW PRESSURE LINE
24 - 52 PLUMBING KJ
ACCUMULATOR (Continued)
CAUTIONS IN THE FRONT OF THIS SECTION
BEFORE PERFORMING THE FOLLOWING OPERA-
TION. (Refer to 24 - HEATING & AIR CONDITIONING/
(1) Remove the HVAC housi ng. (Refer to 24 -
HVAC HOUSI NG - REMOVAL).
(2) Remove the two heater core retai ni ng screws (i f
equi pped). (Fi g. 14).
(3) Gentl y push back on two of the heater core
retai ni ng tabs and pul l up on heater core to remove.
INSTALLATION
CAUTIONS IN THE FRONT OF THIS SECTION
BEFORE PERFORMING THE FOLLOWING OPERA-
TION. (Refer to 24 - HEATING & AIR CONDITIONING/
PRECAUTIONS)
(1) I nstal l the heater core i nto the top of the
HVAC housi ng.
(2) Push on top of heater core unti l al l for tabs are
l ocked i nto pl ace.
(3) I nstal l the two heater core retai ner screws.
(4) I nstal l the HVAC housi ng. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/DI STRI BUTI ON/HVAC
HOUSI NG - I NSTALLATI ON)
REFRIGERANT
DESCRIPTION
The refri gerant used i n thi s ai r condi ti oni ng sys-
tem i s a HydroFl uoroCarbon (HFC), type R-134a.
Unl i ke R-12, whi ch i s a Chl oroFl uoroCarbon (CFC),
R-134a refri gerant does not contai n ozone-depl eti ng
chl ori ne. R-134a refri gerant i s a non-toxi c, non-fl am-
mabl e, cl ear, and col orl ess l i quefi ed gas.
Even though R-134a does not contai n chl ori ne, i t
must be recl ai med and recycl ed just l i ke CFC-type
refri gerants. Thi s i s because R-134a i s a greenhouse
gas and can contri bute to gl obal warmi ng.
OPERATION
R-134a refri gerant i s not compati bl e wi th R-12
refri gerant i n an ai r condi ti oni ng system. Even a
smal l amount of R-12 added to an R-134a refri gerant
system wi l l cause compressor fai l ure, refri gerant oi l
sl udge or poor ai r condi ti oni ng system performance.
I n addi ti on, the Pol yAl kyl ene Gl ycol (PAG) syntheti c
refri gerant oi l s used i n an R-134a refri gerant system
are not compati bl e wi th the mi neral -based refri ger-
ant oi l s used i n an R-12 refri gerant system.
R-134a refri gerant system servi ce ports, servi ce
tool coupl ers and refri gerant di spensi ng bottl es have
al l been desi gned wi th uni que fi tti ngs to ensure that
an R-134a system i s not acci dental l y contami nated
wi th the wrong refri gerant (R-12). There are al so
l abel s posted i n the engi ne compartment of the vehi -
cl e and on the compressor i denti fyi ng to servi ce tech-
ni ci ans that the ai r condi ti oni ng system i s equi pped
wi th R-134a.
REFRIGERANT OIL
DESCRIPTION
The refri gerant oi l used i n R-134a refri gerant sys-
tems i s a syntheti c-based, Pol yAl kyl ene Gl ycol (PAG),
wax-free l ubri cant. Mi neral -based R-12 refri gerant
Fig. 14 HEATER CORE REMOVAL/INSTALLATION
1 - HEATER CORE
3- INLET AND OUTLET TUBES
4- VACUUM HARNESS
5- ACTUATOR SCREWS (3)
6- ELECTRIC BLEND DOOR ACTUATOR
8- HEATER CORE RETAINER TABS (4)
KJ PLUMBING 24 - 53
HEATER CORE (Continued)
oi l s are not compati bl e wi th PAG oi l s, and shoul d
never be i ntroduced to an R-134a refri gerant system.
There are di fferent PAG oi l s avai l abl e, and each
contai ns a di fferent addi ti ve package. The PXF18
compressor used i n thi s vehi cl e i s desi gned to use an
SP10 PAG refri gerant oi l . Use onl y refri gerant oi l of
thi s same type to servi ce the refri gerant system.
OPERATION
After performi ng any refri gerant recovery or recy-
cl i ng operati on, al ways repl eni sh the refri gerant sys-
tem wi th the same amount of the recommended
refri gerant oi l as was removed. Too l i ttl e refri gerant
oi l can cause compressor damage, and too much can
reduce ai r condi ti oni ng system performance.
PAG refri gerant oi l i s much more hygroscopi c than
mi neral oi l , and wi l l absorb any moi sture i t comes
i nto contact wi th, even moi sture i n the ai r. The PAG
oi l contai ner shoul d al ways be kept ti ghtl y capped
unti l i t i s ready to be used. After use, recap the oi l
contai ner i mmedi atel y to prevent moi sture contami -
nati on.
STANDARD PROCEDURE - REFRIGERANT OIL
LEVEL
When an ai r condi ti oni ng system i s assembl ed at
the factory, al l components except the compressor are
refri gerant oi l free. After the refri gerant system has
been charged and operated, the refri gerant oi l i n the
compressor i s di spersed throughout the refri gerant
system. The accumul ator, evaporator, condenser, and
compressor wi l l each retai n a si gni fi cant amount of
the needed refri gerant oi l .
I t i s i mportant to have the correct amount of oi l i n
the refri gerant system. Thi s ensures proper l ubri ca-
ti on of the compressor. Too l i ttl e oi l wi l l resul t i n
damage to the compressor. Too much oi l wi l l reduce
the cool i ng capaci ty of the ai r condi ti oni ng system.
I t wi l l not be necessary to check the oi l l evel i n the
compressor or to add oi l , unl ess there has been an oi l
l oss. An oi l l oss may occur due to a rupture or l eak
from a refri gerant l i ne, a connector fi tti ng, a compo-
nent, or a component seal . I f a l eak occurs, add 30
mi l l i l i ters (1 fl ui d ounce) of refri gerant oi l to the
refri gerant system after the repai r has been made.
Refri gerant oi l l oss wi l l be evi dent at the l eak poi nt
by the presence of a wet, shi ny surface around the
l eak.
Refri gerant oi l must be added when a accumul ator,
evaporator coi l , or condenser are repl aced. See the
Refri gerant Oi l Capaci ti es chart. When a compressor
i s repl aced, the refri gerant oi l must be drai ned from
the ol d compressor and measured. Drai n al l of the
refri gerant oi l from the new compressor, then fi l l the
new compressor wi th the same amount of refri gerant
oi l that was drai ned out of the ol d compressor.
Refrigerant Oil Capacities
Component ml fl oz
A/C System 240 8
Accumulator 90 3
Condenser 22 .75
Evaporator 45 1.5
Compressor
drain and measure
the oil from the old
compressor as noted
24 - 54 PLUMBING KJ
REFRIGERANT OIL (Continued)
EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - STATE DISPLAY TEST
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - CIRCUIT ACTUATION TEST
MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - DIAGNOSTIC TROUBLE
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - TASK MANAGER . . . . . . . . . 17
DESCRIPTION - MONITORED SYSTEMS . . . 17
DESCRIPTION - TRIP DEFINITION . . . . . . . . 19
DESCRIPTION - COMPONENT MONITORS . . 19
DESCRIPTION - NON-MONITORED
CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION - HIGH AND LOW LIMITS . . . 20
DESCRIPTION - LOAD VALUE . . . . . . . . . . . 20
OPERATION - TASK MANAGER . . . . . . . . . . . . 21
EVAPORATIVE EMISSIONS . . . . . . . . . . . . . . . . 24
EMISSIONS CONTROL
DESCRIPTION
DESCRIPTION - EMISSION CONTROL SYSTEM
many di fferent ci rcui ts i n the fuel i njecti on, i gni ti on,
emi ssi on and engi ne systems. I f the PCM senses a
probl em wi th a moni tored ci rcui t often enough to
i ndi cate an actual probl em, i t stores a Di agnosti c
Troubl e Code (DTC) i n the PCMs memory. I f the
code appl i es to a non-emi ssi ons rel ated component or
system, and the probl em i s repai red or ceases to
exi st, the PCM cancel s the code after 40 warm-up
cycl es. Di agnosti c troubl e codes that affect vehi cl e
emi ssi ons i l l umi nate the Mal functi on I ndi cator Lamp
(MI L). The MI L i s di spl ayed as an engi ne i con on the
i nstrument panel . Refer to Mal functi on I ndi cator
Lamp (MI L) i n thi s secti on.
Certai n cri teri a must be met before the PCM
stores a DTC i n memory. The cri teri a may be a spe-
ci fi c range of engi ne RPM, engi ne temperature,
and/or i nput vol tage to the PCM.
The PCM mi ght not store a DTC for a moni tored
ci rcui t even though a mal functi on has occurred. Thi s
may happen because one of the DTC cri teri a for the
ci rcui t has not been met. For example , assume the
di agnosti c troubl e code cri teri a requi res the PCM to
moni tor the ci rcui t onl y when the engi ne operates
between 750 and 2000 RPM. Suppose the sensors
output ci rcui t shorts to ground when engi ne operates
above 2400 RPM (resul ti ng i n 0 vol t i nput to the
PCM). Because the condi ti on happens at an engi ne
speed above the maxi mum threshol d (2000 rpm), the
PCM wi l l not store a DTC.
There are several operati ng condi ti ons for whi ch
the PCM moni tors and sets DTCs. Refer to Moni -
tored Systems, Components, and Non-Moni tored Ci r-
cui ts i n thi s secti on.
Techni ci ans must retri eve stored DTCs by connect-
i ng the DRB scan tool (or an equi val ent scan tool ) to
the 16way data l i nk connector (Fi g. 1).
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, connect the DRB scan
tool to the 16way data link connector to erase all
DTCs and extinguish the MIL.
Fig. 1 DATA LINK CONNECTOR LOCATION
KJ EMISSIONS CONTROL 25 - 1
DESCRIPTION - STATE DISPLAY TEST MODE
The swi tch i nputs to the Powertrai n Control Mod-
ul e (PCM) have two recogni zed states; HI GH and
LOW. For thi s reason, the PCM cannot recogni ze the
di fference between a sel ected swi tch posi ti on versus
an open ci rcui t, a short ci rcui t, or a defecti ve swi tch.
I f the State Di spl ay screen shows the change from
HI GH to LOW or LOW to HI GH, assume the enti re
swi tch ci rcui t to the PCM functi ons properl y. Connect
the DRB scan tool to the data l i nk connector and
access the state di spl ay screen. Then access ei ther
State Di spl ay I nputs and Outputs or State Di spl ay
Sensors.
DESCRIPTION - CIRCUIT ACTUATION TEST
MODE
The Ci rcui t Actuati on Test Mode checks for proper
operati on of output ci rcui ts or devi ces the Powertrai n
Control Modul e (PCM) may not i nternal l y recogni ze.
The PCM attempts to acti vate these outputs and
al l ow an observer to veri fy proper operati on. Most of
the tests provi de an audi bl e or vi sual i ndi cati on of
devi ce operati on (cl i ck of rel ay contacts, fuel spray,
etc.). Except for i ntermi ttent condi ti ons, i f a devi ce
functi ons properl y duri ng testi ng, assume the devi ce,
i ts associ ated wi ri ng, and dri ver ci rcui t work cor-
rectl y. Connect the DRB scan tool to the data l i nk
connector and access the Actuators screen.
DESCRIPTION - DIAGNOSTIC TROUBLE CODES
A Di agnosti c Troubl e Code (DTC) i ndi cates the
PCM has recogni zed an abnormal condi ti on i n the
system.
Remember that DTCs are the results of a sys-
tem or circuit failure, but do not directly iden-
tify the failed component or components.
NOTE: For a list of DTCs, refer to the charts in this
section.
BULB CHECK
Each ti me the i gni ti on key i s turned to the ON
posi ti on, the mal functi on i ndi cator (check engi ne)
l amp on the i nstrument panel shoul d i l l umi nate for
approxi matel y 2 seconds then go out. Thi s i s done for
a bul b check.
OBTAINING DTCS USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data l i nk
(di agnosti c) connector. Thi s connector i s l ocated i n
the passenger compartment; at the l ower edge of
i nstrument panel ; near the steeri ng col umn.
(2) Turn the i gni ti on swi tch on and access the
Read Faul t screen.
(3) Record al l the DTCs and freeze frame i nfor-
mati on shown on the DRB scan tool .
(4) To erase DTCs, use the Erase Troubl e Code
data screen on the DRB scan tool . Do not erase any
DTCs until problems have been investigated
and repairs have been performed.
(M) Mal functi on I ndi cator Lamp (MI L) i l l umi nated duri ng engi ne operati on i f thi s DTC was recorded
(dependi ng i f requi red by CARB and/or EPA). MI L i s di spl ayed as an engi ne i con on i nstrument panel .
(G) Generator l amp i l l umi nated
Generic Scan
Tool P-Code
DRB Scan Tool Display Brief Description of DTC
P0030 (M) 1/1 O2 Sensor Heater Circuit
Malfunction
Problem detected in oxygen sensor heater relay circuit.
P0031 (M) 1/1 O2 Sensor Heater Circuit Low Problem detected in oxygen sensor heater relay circuit.
P0032 (M) 1/1 O2 Sensor Heater Circuit High Problem detected in oxygen sensor heater relay circuit.
Malfunction
Problem detected in oxygen sensor heater relay circuit.
25 - 2 EMISSIONS CONTROL KJ
EMISSIONS CONTROL (Continued)
Generic Scan
Tool P-Code
P0071 (M) Amb/Bat Temp Sensor Performance
P0106 Barometric Pressure Out of Range MAP sensor input voltage out of an acceptable range
detected during reading of barometric pressure at key-on.
P0107 (M) Map Sensor Voltage Too Low MAP sensor input below minimum acceptable voltage.
P0108 (M) Map Sensor Voltage Too High MAP sensor input above maximum acceptable voltage.
PO111 (M) Intake Air Temp Sensor Performance
P0112 (M) Intake Air Temp Sensor Voltage Low Intake air (charge) temperature sensor input below the
minimum acceptable voltage.
P0113 (M) Intake Air Temp Sensor Voltage High Intake air (charge) temperature sensor input above the
maximum acceptable voltage.
P0116 Coolant Temp Sensor Performance A rationatilty error has been detected in the coolant temp
sensor.
P0117 (M) ECT Sensor Voltage Too Low Engine coolant temperature sensor input below the
P0118 (M) ECT Sensor Voltage Too High Engine coolant temperature sensor input above the
P0121 (M) TPS Voltage Does Not Agree With
MAP
TPS signal does not correlate to MAP sensor signal.
P0121 (M) Accelerator Position Sensor (APPS)
Signal Voltage Too Low
APPS voltage input below the minimum acceptable
voltage.
P0122 (M) Throttle Position Sensor Voltage Low Throttle position sensor input below the acceptable
voltage range.
Signal Voltage Too Low
APPS voltage input below the minimum acceptable
voltage.
P0123 (M) Throttle Position Sensor Voltage
High
Throttle position sensor input above the maximum
acceptable voltage.
Signal Voltage Too High
APPS voltage input above the maximum acceptable
voltage.
P0125 (M) Closed Loop Temp Not Reached Time to enter Closed Loop Operation (Fuel Control) is
excessive.
P0125 (M) Engine is Cold Too Long Engine does not reach operating temperature.
Malfunction
Oxygen sensor heater element malfunction.
P0131 (M) 1/1 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
P0132 (M) 1/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal
operating range.
P0133 (M) 1/1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
switching frequency.
P0134 (M) 1/1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor input.
Generic Scan
Tool P-Code
P0135 (M) 1/1 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
Malfunction
Oxygen sensor heater element malfunction.
operating range.
operating range.
P0139 (M) 1/2 O2 Sensor Slow Response Oxygen sensor response not as expected.
sensor.
operating range.
operating range.
sensor.
operating range.
P0152 (M) 2/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage sustained above normal
operating range.
sensor.
operating range.
operating range.
P0159 2/2 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
sensor.
PO165 Starter Relay Circuit Problem detected in starter relay circuit.
P0168 Decreased Engine Performance Due
To High Injection Pump Fuel Temp
Fuel temperature is above the engine protection limit.
Engine power will be derated.
P0171 (M) 1/1 Fuel System Lean A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
Generic Scan
Tool P-Code
P0172 (M) 1/1 Fuel System Rich A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
P0174 (M) 2/1 Fuel System Lean A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
P0175 (M) 2/1 Fuel System Rich A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
P0176 Loss of Flex Fuel Calibration Signal No calibration voltage present from flex fuel sensor.
P0177 Water In Fuel Excess water found in fuel by water-in-fuel sensor.
P0178 Flex Fuel Sensor Volts Too Low Flex fuel sensor input below minimum acceptable voltage.
P0178 Water In Fuel Sensor Voltage Too
Low
Loss of water-in-fuel circuit or sensor.
P0179 Flex Fuel Sensor Volts Too High Flex fuel sensor input above maximum acceptable
voltage.
P0181 Fuel Injection Pump Failure Low power, engine derated, or engine stops.
P0182 (M) CNG Temp Sensor Voltage Too Low Compressed natural gas temperature sensor voltage
below acceptable voltage.
P0183 (M) CNG Temp Sensor Voltage Too High Compressed natural gas temperature sensor voltage
above acceptable voltage.
P0201 (M) Injector #1 Control Circuit An open or shorted condition detected in control circuit for
injector #1 or the INJ 1 injector bank.
P0204 (M) Injector #4 Control Circuit Injector #4 or INJ 4 injector bank output driver stage does
not respond properly to the control signal.
P0205 (M) Injector #5 Control Circuit Injector #5 output driver stage does not respond properly
to the control signal.
P0215 Fuel Injection Pump Control Circuit Failure in fuel pump relay control circuit.
P0216 (M) Fuel Injection Pump Timing Failure High fuel supply restriction, low fuel pressure or possible
wrong or incorrectly installed pump keyway.
To Engine Overheat Condition
Engine overheating. ECM will derate engine performance.
Generic Scan
Tool P-Code
P0219 Crankshaft Position Sensor
Overspeed Signal
Engine has exceeded rpm limits.
P0222 (M) Idle Validation Signals Both Low Problem detected with idle validation circuits within APPS.
P0223 (M) Idle Validation Signals Both High
(Above 5 Volts)
Problem detected with idle validation circuits within APPS.
P0230 Transfer Pump (Lift Pump) Circuit
Out of Range
Problem detected in fuel transfer pump circuits.
P0232 Fuel Shutoff Signal Voltage Too High Fuel shut-off signal voltage too high from ECM to fuel
injection pump.
P0234 (M) Turbo Boost Limit Exceeded Problem detected in turbocharger wastegate.
P0236 (M) Map Sensor Too High Too Long Problem detected in turbocharger wastegate.
P0237 (M) Map Sensor Voltage Too Low MAP sensor voltage input below the minimum acceptable
voltage.
P0238 (M) Map Sensor Voltage Too High MAP sensor voltage input above the maximum
acceptable voltage.
PO243 Wastegate Solenoid Circuit
P0251 (M) Fuel Inj. Pump Mech. Failure Fuel
Valve Feedback Circuit
Problem sensed with fuel circuit internal to fuel injection
pump.
P0253 (M) Fuel Injection Pump Fuel Valve
Open Circuit
Problem sensed with fuel circuit internal to fuel injection
pump.
P0254 Fuel Injection Pump Fuel Valve
Current Too High
Problem caused by internal fuel injection pump failure.
P0300 (M) Multiple Cylinder Mis-fire Misfire detected in multiple cylinders.
P0301 (M) CYLINDER #1 MISFIRE Misfire detected in cylinder #1.
P0307 (M) CYLINDER #7 MISFIRE Misfire detected in cylinder #7
P0320 (M) No Crank Referance Signal at PCM No reference signal (crankshaft position sensor) detected
during engine cranking.
P0320 (M) No RPM Signal to PCM (Crankshaft
Position Sensor Signal to JTEC)
A CKP signal has not been detected at the PCM.
P0325 Knock Sensor #1 Circuit Knock sensor (#1) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
P0330 Knock Sensor #2 Circuit Knock sensor (#2) signal above or below minimum
acceptable threshold voltage at particular engine speeds.
Generic Scan
Tool P-Code
P0336 (M) Crankshaft Position (CKP) Sensor
Signal
Problem with voltage signal from CKP.
P0340 (M) No Cam Signal At PCM No fuel sync
P0341 (M) Camshaft Position (CMP) Sensor
Signal
Problem with voltage signal from CMP.
P0350 Ignition Coil Draws Too Much
Current
A coil (1-5) is drawing too much current.
P0351 (M) Ignition Coil # 1 Primary Circuit Peak primary circuit current not achieved with maximum
dwell time.
dwell time.
dwell time.
dwell time (High Impedance).
dwell time (High Impedance).
dwell time (high impedance).
P0370 Fuel Injection Pump Speed/Position
Sensor Sig Lost
Problem caused by internal fuel injection pump failure.
P0380 (M) Intake Air Heater Relay #1 Control
Circuit
Problem detected in #1 air heater solenoid/relay circuit
(not heater element)
P0381 (M) Wait To Start Lamp Inoperative Problem detected in wait-to-start bulb circuit.
P0382 (M) Intake Air Heater Relay #2 Control
Circuit
Problem detected in #2 air heater solenoid/relay circuit
(not heater element)
P0387 Crankshaft Position Sensor Supply
Voltage Too Low
CKP sensor voltage input below the minimum acceptable
voltage.
P0388 Crankshaft Position Sensor Supply
Voltage Too High
CKP sensor voltage input above the maximum acceptable
voltage.
PO0400 Diesel EGR System Failure
P0401 EGR System Failure Required change in air/fuel ration not detected during
diagnostic test.
P0403 EGR Solenoid Circuit An open or shorted condition detected in the EGR
solenoid control circuit.
P0404 EGR Position Sensor Rationality EGR position sensor signal does not correlate to EGR
duty cycle.
P0405 EGR Position Sensor Volts Too Low EGR position sensor input below the acceptable voltage
range.
Generic Scan
Tool P-Code
P0406 EGR Position Sensor Volts Too High EGR position sensor input above the acceptable voltage
range.
P0412 Secondary Air Solenoid Circuit An open or shorted condition detected in the secondary
air (air switching/aspirator) solenoid control circuit.
P0420 (M) 1/1 Catalytic Converter Efficiency Catalyst 1/1 efficiency below required level.
P0432 (M) 1/2 Catalytic Converter Efficiency Catalyst 2/1 efficiency below required level.
P0441 (M) Evap Purge Flow Monitor Insufficient or excessive vapor flow detected during
evaporative emission system operation.
P0442 (M) Evap Leak Monitor Medium Leak
Detected
A small leak has been detected in the evaporative
system.
P0443 (M) Evap Purge Solenoid Circuit An open or shorted condition detected in the EVAP purge
solenoid control circuit.
P0455 (M) Evap Leak Monitor Large Leak
Detected
A large leak has been detected in the evaporative system.
P0456 (M) Evap Leak Monitor Small Leak
Detected
Leak has been detected in the evaporative system.
P0460 Fuel Level Unit No Change Over
Miles
During low fuel
P0460 Fuel Level Unit No Change Over
Miles
Fuel level sending unit voltage does not change for more
than 40 miles.
PO061 Fuel Level Unit No Change Over
Time
P0462 Fuel Level Sending Unit Volts Too
Low
Fuel level sensor input below acceptable voltage.
P0462 (M) Fuel Level Sending Unit Volts Too
Low
Open circuit between PCM and fuel gauge sending unit.
P0463 Fuel Level Sending Unit Volts Too
High
Fuel level sensor input above acceptable voltage.
P0463 (M) Fuel Level Sending Unit Volts Too
High
Circuit shorted to voltage between PCM and fuel gauge
sending unit.
P0500 (M) No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during road load
conditions.
P0500 (M) No Vehicle Speed Sensor Signal A vehicle speed signal was not detected.
P0505 (M) Idle Air Control Motor Circuits
P0508 (M) IAC Motor Sense Circuit Low
P0509 (M) IAC Motor Sense Circuit High
P0521 Oil Pressure Switch Rationality
P0522 Oil Pressure Voltage Too Low Oil pressure sending unit (sensor) voltage input below the
P0523 Oil Pressure Voltage Too High Oil pressure sending unit (sensor) voltage input above the
P0524 Oil Pressure Too Low Engine oil pressure is low. Engine power derated.
Generic Scan
Tool P-Code
P0545 A/C Clutch Relay Circuit Problem detected in air conditioning clutch relay control
circuit.
P0551 Power Steering Switch Failure Incorrect input state detected for the power steering
switch circuit. PL: High pressure seen at high speed.
P0562 Charging System Voltage Too Low Supply voltage sensed at ECM too low.
P0563 Charging System Voltage Too High Supply voltage sensed at ECM too high.
P0572 Brake Switch Input #1 Signal
Missing
P0573 Brake Switch Input #2 Signal
Missing
P0575 Cruise Control Switch Voltage Low
P0576 Cruise Control Switch Voltage High
P0577 Cruise Control Switch Voltage High
P0600 PCM Failure SPI Communications No communication detected between co-processors in the
control module.
P0601 (M) Internal Controller Failure Internal control module fault condition (check sum)
detected.
P0602 (M) ECM Fueling Calibration Error ECM Internal fault condition detected.
P0604 RAM Check Failure Transmission control module RAM self test fault detected.
-Aisin transmission
P0605 ROM Check Falure Transmission control module ROM self test fault detected
-Aisin transmission
P0606 (M) ECM Failure ECM Internal fault condition detected.
P0615 Starter Relay Control Circuit An open or shorted condition detected in the starter relay
control circuit.
P0622 (G) Generator Field Not Switching
Properly
An open or shorted condition detected in the generator
field control circuit.
P0645 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch
relay control circuit.
P0700 EATX Controller DTC Present This SBEC III or JTEC DTC indicates that the EATX or
Aisin controller has an active fault and has illuminated the
MIL via a CCD (EATX) or SCI (Aisin) message. The
specific fault must be acquired from the EATX via CCD or
from the Aisin via ISO-9141.
P0703 Brake Switch Stuck Pressed or
Released
Incorrect input state detected in the brake switch circuit.
(Changed from P1595)
P0703 Brake Switch Sense Circuit
P0711 (M) Trans Temp Sensor, No Temp Rise
After Start
Relationship between the transmission temperature and
overdrive operation and/or TCC operation indicates a
failure of the Transmission Temperature Sensor. OBD II
Rationality. Was MIL code 37.
P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below
acceptable voltage. Was MIL code 37.
Generic Scan
Tool P-Code
P0712 (M) Trans Temp Sensor Voltage Too Low Voltage less than 1.55 volts (4-speed auto. trans. only).
P0713 Trans Temp Sensor Voltage Too
High
Transmission fluid temperature sensor input above
acceptable voltage. Was MIL code 37.
P0713 (M) Trans Temp Sensor Voltage Too
High
Voltage greater than 3.76 volts (4-speed auto. trans.
only).
P0720 (M) Low Output SPD Sensor RPM,
Above 15 MPH
The relationship between the Output Shaft Speed Sensor
and vehicle speed is not within acceptable limits.
P0720 (M) Low Output Spd Sensor RPM Above
15 mph
Output shaft speed is less than 60 rpm with vehicle speed
above 15 mph (4-speed auto. trans. only).
P0740 (M) Torq Con Clu, No RPM Drop at
Lockup
Relationship between engine and vehicle speeds
indicated failure of torque convertor clutch lock-up system
(TCC/PTU solenoid)
P0743 (M) Torque Converter Clutch Solenoid/
Trans Relay Circuits
An open or shorted condition detected in the torque
converter clutch (part throttle unlock) solenoid control
circuit. Shift solenoid C electrical fault - Aisin transmission
P0743 (M) Torque Converter Clutch Solenoid/
Trans Relay Circuits
An open or shorted condition detected in the torque
converter part throttle unlock solenoid control circuit (3 or
4-speed auto. trans. only).
P0748 (M) Governor Pressur Sol Control/Trans
Relay Circuits
An open or shorted condition detected in the Governor
Pressure Solenoid circuit or Trans Relay Circuit in JTEC
RE transmissions.
P0748 (M) Governor Pressure Sol Control/Trans
Relay Circuits
An open or shorted condition detected in the governor
pressure solenoid or relay circuits (4-speed auto. trans.
only).
P0751 (M) O/D Switch Pressed (Lo) More Than
5 Minutes
Overdrive override switch input is in a prolonged
depressed state.
P0751 (M) O/D Switch Pressed (LO) More Than
5 Min
Overdrive Off switch input too low for more than 5
minutes (4-speed auto. trans. only).
P0753 (M) Trans 3-4 Shift Sol/Trans Relay
Circuits
An open or shorted condition detected in the overdrive
solenoid control circuit or Trans Relay Circuit in JTEC RE
transmissions. Was MIL code 45.
P0753 (M) Trans 3-4 Shift Sol/Trans Relay
Circuits
An open or shorted condition detected in the transmission
2-4 shift solenoid circuit (4-speed auto. trans. only).
P0756 AW4 Shift Sol B (2-3) Functional
Failure
Shift solenoid B (2-3) functional fault - Aisin transmission
P0783 (M) 3-4 Shift Sol, No RPM Drop at
Lockup
The overdrive solenoid is unable to engage the gear
change from 3rd gear to the overdrive gear.
P0801 Reverse Gear Lockout Circuit Open
or Short
An open or shorted condition detected in the transmission
reverse gear lock-out solenoid control circuit.
P0830 Clutch Depressed Switch Circuit Problem detected in clutch switch circuit.
P0833 Clutch Released Switch Circuit Problem detected in clutch switch circuit.
P0836 4WD Mux Switch Circuit
P0837 4WD Mux Switch Performance
Generic Scan
Tool P-Code
P1110 Decrease Engine Performance Due
To High Intake Air Temperature
Intake manifold air temperature is above the engine
protection limit. Engine power will be derated.
To High Injection Pump Fuel Temp
Fuel temperature is above the engine protection limit.
P1192 Intake Air Temp Sensor Voltage Low
P1193 Intake Air Temp Sensor Voltage High
P1194 O2 Heater Performance
P1195 (M) 1/1 O2 Sensor Slow During Catalyst
Monitor
A slow switching oxygen sensor has been detected in
bank 1/1 during catalyst monitor test. (Also see SCI DTC
$66) (was P0133)
P1196 (M) 2/1 O2 Sensor Slow During Catalyst
Monitor
$7A) (was P0153)
P1197 1/2 O2 Sensor Slow During Catalyst
Monitor
$68) (was P0139)
P1198 Radiator Temperature Sensor Volts
Too High
Radiator coolant temperature sensor input above the
P1199 Radiator Temperature Sensor Volts
Too Low
Radiator coolant temperature sensor input below the
P1280 Fuel System Relay Circuit
P1281 Engine is Cold Too Long Engine coolant temperature remains below normal
operating temperatures during vehicle travel (Thermostat).
P1282 Fuel Pump/System Relay Control
Circuit
An open or shorted condition detected in the fuel pump
relay control circuit.
P1283 Idle Select Signal Invalid ECM or fuel injection pump module internal fault condition
detected.
P1284 (M) Fuel Injection Pump Battery Voltage
Out-Of-Range
Fuel injection pump module internal fault condition
detected. Engine power will be derated.
P1285 (M) Fuel Injection Pump Controller
Always On
Fuel injection pump module relay circuit failure detected.
P1286 Accelerator Position Sensor (APPS)
Supply Voltage Too High
High voltage detected at APPS.
P1287 Fuel Injection Pump Controller
Supply Voltage Low
ECM or fuel injection pump module internal fault condition
detected. Engine power will be derated.
P1288 Intake Manifold Short Runner
Solenoid Circuit
An open or shorted condition detected in the short runner
tuning valve circuit.
P1289 Manifold Tune Valve Solenoid Circuit An open or shorted condition detected in the manifold
tuning valve solenoid control circuit.
P1290 High Pressure Solenoid Relay Ckt. CNG Fuel System Pressure Too HighCompressed
natural gas system pressure above normal operating
range.
P1291 No Temp Rise Seen From Intake
Heaters
Energizing Heated Air Intake does not change intake air
temperature sensor an acceptable amount.
Generic Scan
Tool P-Code
P1291 (M) No Temperature Rise Seen From
Intake Air Heaters
Problem detected in intake manifold air heating system.
P1292 CNG Pressure Sensor Voltage Too
High
Compressed natural gas pressure sensor reading above
acceptable voltage.
P1293 CNG Pressure Sensor Voltage Too
Low
Compressed natural gas pressure sensor reading below
acceptable voltage.
P1294 (M) Target Idle Not Reached Target RPM not achieved during drive idle condition.
Possible vacuum leak or IAC (AIS) lost steps.
P1295 (M) No 5 Volts to TP Sensor Loss of a 5 volt feed to the Throttle Position Sensor has
been detected.
Supply Voltage Too Low
APPS supply voltage input below the minimum
acceptable voltage.
P1296 No 5 Volts to MAP Sensor Loss of a 5 volt feed to the MAP Sensor has been
detected.
P1297 (M) No Change in MAP From Start To
Run
No difference is recognized between the MAP reading at
engine idle and the stored barometric pressure reading.
P1298 Lean Operation at Wide Open
Throttle
A prolonged lean condition is detected during Wide Open
Throttle
P1299 Vacuum Leak Found (IAC Fully
Seated)
MAP Sensor signal does not correlate to Throttle Position
Sensor signal. Possible vacuum leak.
P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the ASD or CNG
shutoff relay control ckt.
P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the auto
shutdown relay circuit.
P1389 No ASD Relay Output Voltage At
PCM
No Z1 or Z2 voltage sensed when the auto shutdown
relay is energized.
P1389 (M) No ASD Relay Output Voltage at
PCM
An open condition detected In the ASD relay output
circuit.
P1390 Timing Belt Skipped 1 Tooth or More Relationship between Cam and Crank signals not correct
P1391 (M) Intermittent Loss of CMP or CKP Loss of the Cam Position Sensor or Crank Position
sensor has occurred. For PL 2.0L
P1398 (M) Mis-Fire Adaptive Numerator at Limit PCM is unable to learn the Crank Sensors signal in
preparation for Misfire Diagnostics. Probable defective
Crank Sensor
P1399 Wait To Start Lamp Cicuit An open or shorted condition detected in the Wait to Start
Lamp circuit.
P1403 No 5V to EGR Sensor Loss of 5v feed to the EGR position sensor.
P01475 Aux 5 Volt Supply Voltage High Sensor supply voltage for ECM sensors is too high.
P1476 Too Little Secondary Air Insufficient flow of secondary air injection detected during
aspirator test (was P0411)
P1477 Too Much Secondary Air Excessive flow of secondary air injection detected during
aspirator test (was P0411).
Generic Scan
Tool P-Code
P1478 Battery Temp Sensor Volts Out of
Limit
Internal temperature sensor input voltage out of an
acceptable range.
P1479 Transmission Fan Relay Circuit An open or shorted condition detected in the transmission
fan relay circuit.
P1480 PCV Solenoid Circuit An open or shorted condition detected in the PCV
solenoid circuit.
P1481 EATX RPM Pulse Perf EATX RPM pulse generator signal for misfire detection
does not correlate with expected value.
P1482 Catalyst Temperature Sensor Circuit
Shorted Low
Catalyst temperature sensor circuit shorted low.
P1483 Catalyst Temperature Sensor Circuit
Shorted High.
Catalyst temperature sensor circuit shorted high.
P1484 Catalytic Converter Overheat
Detected
A catalyst overheat condition has been detected by the
catalyst temperature sensor.
P1485 Air Injection Solenoid Circuit An open or shorted condition detected in the air assist
solenoid circuit.
P1486 Evap Leak Monitor Pinched Hose
Found
LDP has detected a pinched hose in the evaporative hose
system.
P1487 Hi Speed Rad Fan CTRL Relay
Circuit
An open or shorted condition detected in the control
circuit of the #2 high speed radiator fan control relay.
P1488 Auxiliary 5 Volt Supply Output Too
Low
Auxiliary 5 volt sensor feed is sensed to be below an
acceptable limit.
P1488 5 Volt Supply Voltage Low Sensor supply voltage for ECM sensors is too low.
P1489 High Speed Fan CTRL Relay Circuit An open or shorted condition detected in the control
circuit of the high speed radiator fan control relay.
P1490 Low Speed Fan CTRL Relay Circuit An open or shorted condition detected in control circuit of
the low speed radiator fan control relay.
P1491 Rad Fan Control Relay Circuit An open or shorted condition detected in the radiator fan
control relay control circuit. This includes PWM solid state
relays.
P1492 Ambient/Batt Temp Sen Volts Too
High
External temperature sensor input above acceptable
voltage.
P1492 (M) Ambient/Batt Temp Sensor Volts Too
High
Battery temperature sensor input voltage above an
acceptable range.
P1493 (M) Ambient/Batt Temp Sen Volts Too
Low
External temperature sensor input below acceptable
voltage.
P1493 (M) Ambient/Batt Temp Sen Volts Too
Low
Battery temperature sensor input voltage below an
acceptable range.
P1494 (M) Leak Detection Pump Sw or
Mechanical Fault
Incorrect input state detected for the Leak Detection
Pump (LDP) pressure switch.
P1495 Leak Detection Pump Solenoid
Circuit
An open or shorted condition detected in the Leak
Detection Pump (LDP) solenoid circuit.
P1496 5 Volt Supply, Output Too Low 5 volt sensor feed is sensed to be below an acceptable
limit. ( less than 4v for 4 sec )
Generic Scan
Tool P-Code
P1498 High Speed Rad Fan Ground CTRL
Rly Circuit
An open or shorted condition detected in the control
circuit of the #3 high speed radiator fan control relay.
P1499 Hydraulic cooling fan solenoid circuit An open or shorted condition detected in the cooling fan
control solenoid circuit.
P1594 (G) Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1594 Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in either of the
speed control vacuum or vent solenoid control circuits.
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in the speed
control vacuum or vent solenoid circuits.
P1596 Speed Control Switch Always High Speed control switch input above maximum acceptable
voltage.
P1597 Speed Control Switch Always Low Speed control switch input below minimum acceptable
voltage.
P1597 Speed Control Switch Always Low Speed control switch input below the minimum acceptable
voltage.
P1598 A/C Pressure Sensor Volts Too High A/C pressure sensor input above maximum acceptable
voltage.
P1598 A/C Sensor Input Hi Problem detected in air conditioning electrical circuit.
P1599 A/C Pressure Sensor Volts Too Low A/C pressure sensor input below minimum acceptable
voltage.
P1599 A/C Sensor Input Lo Problem detected in air conditioning electrical circuit.
P1602 PCM not programmed
P1680 Clutch Released Switch Circuit Problem detected in clutch switch electrical circuit.
P1681 No I/P Cluster CCD/J1850
Messages Received
No CCD/J1850 messages received from the cluster
control module.
P1682 (G) Charging System Voltage Too Low Battery voltage sense input below target charging voltage
during engine operation and no significant change in
voltage detected during active test of generator output
circuit.
P1682 Charging System Voltage Too Low Charging system output voltage low.
P1683 SPD CTRL PWR Relay; or S/C 12v
Driver CKT
An open or shorted condition detected in the speed
control servo power control circuit.
P1683 Spd ctrl pwr rly, or s/c 12v driver
circuit
An open or shorted condition detected in the speed
control servo power control circuit.
P1684 Batt Loss (disconnected) in last 50
Starts
The battery has been disconnected within the last 50
starts
P1685 SKIM Invalid Key - (Wrong or Invalid
Key MSG Received From SKIM)
The engine controler has received an invalid key from the
SKIM.
P1686 No SKIM BUS Messages Received No CCD/J1850 messages received from the Smart Key
Immobilizer Module (SKIM).
Generic Scan
Tool P-Code
P1687 No MIC BUS Message (No Cluster
BUS Message)
No CCD/J1850 messages received from the Mechanical
Instrument Cluster (MIC) module.
P1688 (M) Internal Fuel Injection Pump
Controller Failure
Internal problem within the fuel injection pump. Low
power, engine derated, or engine stops.
P1689 (M) No Communication Between ECM
and Injection Pump Module
Data link circuit failure between ECM and fuel injection
pump. Low power, engine derated, or engine stops.
P1690 (M) Fuel Injection Pump CKP Sensor
Does Not Agree With ECM CKP
Sensor
Problem in fuel sync signal. Possible injection pump
timing problem. Low power, engine derated, or engine
stops.
P1691 Fuel Injection Pump Controller
Calibration Error
Internal fuel injection pump failure. Low power, engine
derated, or engine stops.
P1692 DTC Set In ECM A Companion DTC was set in both the ECM and PCM.
P1693 (M) DTC Detected in Companion Module A fault has been generated in the companion engine
control module.
P1693 (M) DTC Detected in PCM/ECM or DTC
Detected in ECM
A Companion DTC was set in both the ECM and PCM.
P1694 Fault In Companion Module No CCD/J1850 messages received from the powertrain
control module-Aisin transmission
P1694 (M) No BUS (CCD) Messages received
from ECM
Bus communication failure to PCM.
P1695 No CCD/J1850 Message From Body
Control Module
No CCD/J1850 messages received from the body control
module.
P1696 PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM location by
the control module.
P1697 PCM Failure SRI Mile Not Stored Unsuccessful attempt to update Service Reminder
Indicator (SRI or EMR) mileage in the control module
EEPROM.
P1698 No CCD/J1850 Message From TCM No CCD/J1850 messages received from the electronic
transmission control module (EATX) or the Aisin
transmission controller.
P1698 No CCD Messages received from
PCM
Bus communication failure to PCM. A Companion DTC
was set in both the ECM and PCM.
P1699 No Climate Control Bus Messages
P1719 Skip Shift Solenoid Circuit An open or shorted condition detected in the transmission
2-3 gear lock-out solenoid control circuit.
P1740 TCC or OD Sol Perf A rationality error has been detected in either the TCC
solenoid or overdrive solenoid systems.
P1740 (M) TCC OR O/D Solenoid Performance Problem detected in transmission convertor clutch and/or
overdrive circuits (diesel engine with 4-speed auto. trans.
only).
Generic Scan
Tool P-Code
P1756 (M) GOV Press Not Equal to Target @
15-20 PSI
The requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control
shifts for 1st, 2nd, and 3rd gear. (Mid Pressure
Malfunction)
P1756 (M) Governor Pressure Not Equal to
Target @ 15-20 PSI
Governor sensor input not between 10 and 25 psi when
requested (4-speed auto. trans. only).
P1757 GOV Press Not Equal to Target @
15-20 PSI
The requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control
shifts for 1st, 2nd, and 3rd gear (Zero Pressure
Malfunction)
P1757 (M) Governor Pressure Above 3 PSI In
Gear With 0 MPH
Governor pressure greater than 3 psi when requested to
be 0 psi (4-speed auto. trans. only).
P1762 (M) Gov Press Sen Offset Volts Too Lo
or High
The Governor Pressure Sensor input is greater than a
calibration limit or is less than a calibration limit for 3
consecutive park/neutral calibrations.
P1762 (M) Governor Press Sen Offset Volts Too
Low or High
Sensor input greater or less than calibration for 3
consecutive Neutral/Park occurrences (4-speed auto.
trans. only).
P1763 Governor Pressure Sensor Volts Too
Hi
The Governor Pressure Sensor input is above an
acceptable voltage level.
P1763 (M) Governor Pressure Sensor Volts Too
HI
Voltage greater than 4.89 volts (4-speed auto. trans.
only).
Low
The Governor Pressure Sensor input is below an
acceptable voltage level.
Low
Voltage less than .10 volts (4-speed auto. trans. only).
P1765 (M) Trans 12 Volt Supply Relay CTRL
Circuit
An open or shorted condition is detected in the
Transmission Relay control circuit. This relay supplies
power to the TCC
P1765 (M) Trans 12 Volt Supply Relay Ctrl
Circuit
Current state of solenoid output port is different than
expected (4-speed auto. trans. only).
P1830 Clutch Override Relay Circuit Problem detected in clutch pedal switch override relay
circuit.
P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch.
P1899 (M) P/N Switch Stuck in Park or in Gear Incorrect input state detected for the Park/Neutral switch
(3 or 4-speed auto. trans. only).
DESCRIPTION - TASK MANAGER
The PCM i s responsi bl e for effi ci entl y coordi nati ng
the operati on of al l the emi ssi ons-rel ated compo-
nents. The PCM i s al so responsi bl e for determi ni ng i f
the di agnosti c systems are operati ng properl y. The
software desi gned to carry out these responsi bi l i ti es
i s referred to as the Task Manager.
DESCRIPTION - MONITORED SYSTEMS
There are new el ectroni c ci rcui t moni tors that
check fuel , emi ssi on, engi ne and i gni ti on perfor-
mance. These moni tors use i nformati on from vari ous
sensor ci rcui ts to i ndi cate the overal l operati on of the
fuel , engi ne, i gni ti on and emi ssi on systems and thus
the emi ssi ons performance of the vehi cl e.
The fuel , engi ne, i gni ti on and emi ssi on systems
moni tors do not i ndi cate a speci fi c component prob-
l em. They do i ndi cate that there i s an i mpl i ed prob-
l em wi thi n one of the systems and that a speci fi c
probl em must be di agnosed.
I f any of these moni tors detect a probl em affecti ng
vehi cl e emi ssi ons, the Mal functi on I ndi cator Lamp
(MI L) wi l l be i l l umi nated. These moni tors generate
Di agnosti c Troubl e Codes that can be di spl ayed wi th
the MI L or a scan tool .
The fol l owi ng i s a l i st of the system moni tors:
Mi sfi re Moni tor
Fuel System Moni tor
Oxygen Sensor Moni tor
Oxygen Sensor Heater Moni tor
Catal yst Moni tor
Leak Detecti on Pump Moni tor (i f equi pped)
Al l these system moni tors requi re two consecuti ve
tri ps wi th the mal functi on present to set a faul t.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
The fol l owi ng i s an operati on and descri pti on of
each system moni tor:
OXYGEN SENSOR (O2S) MONITOR
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The O2S i s al so the mai n sensi ng el ement for the
Catal yst and Fuel Moni tors.
The O2S can fai l i n any or al l of the fol l owi ng
manners:
sl ow response rate
reduced output vol tage
dynami c shi ft
shorted or open ci rcui ts
Response rate i s the ti me requi red for the sensor to
swi tch from l ean to ri ch once i t i s exposed to a ri cher
than opti mum A/F mi xture or vi ce versa. As the sen-
sor starts mal functi oni ng, i t coul d take l onger to
detect the changes i n the oxygen content of the
exhaust gas.
The output vol tage of the O2S ranges from 0 to 1
vol t. A good sensor can easi l y generate any output
vol tage i n thi s range as i t i s exposed to di fferent con-
centrati ons of oxygen. To detect a shi ft i n the A/F
mi xture (l ean or ri ch), the output vol tage has to
change beyond a threshol d val ue. A mal functi oni ng
sensor coul d have di ffi cul ty changi ng beyond the
threshol d val ue.
OXYGEN SENSOR HEATER MONITOR
I f there i s an oxygen sensor (O2S) shorted to vol t-
age DTC, as wel l as a O2S heater DTC, the O2S
faul t MUST be repai red fi rst. Before checki ng the
O2S faul t, veri fy that the heater ci rcui t i s operati ng
correctl y.
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The vol tage readi ngs taken from the O2S sensor
are very temperature sensi ti ve. The readi ngs are not
accurate bel ow 300C. Heati ng of the O2S sensor i s
done to al l ow the engi ne control l er to shi ft to cl osed
l oop control as soon as possi bl e. The heati ng el ement
used to heat the O2S sensor must be tested to ensure
that i t i s heati ng the sensor properl y.
The O2S sensor ci rcui t i s moni tored for a drop i n
vol tage. The sensor output i s used to test the heater
by i sol ati ng the effect of the heater el ement on the
O2S sensor output vol tage from the other effects.
LEAK DETECTION PUMP MONITOR (IF EQUIPPED)
The l eak detecti on assembl y i ncorporates two pri -
mary functi ons: i t must detect a l eak i n the evapora-
ti ve system and seal the evaporati ve system so the
l eak detecti on test can be run.
The pri mary components wi thi n the assembl y are:
A three port sol enoi d that acti vates both of the func-
ti ons l i sted above; a pump whi ch contai ns a swi tch,
two check val ves and a spri ng/di aphragm, a cani ster
vent val ve (CVV) seal whi ch contai ns a spri ng l oaded
vent seal val ve.
I mmedi atel y after a col d start, between predeter-
mi ned temperature threshol ds l i mi ts, the three port
sol enoi d i s bri efl y energi zed. Thi s i ni ti al i zes the
pump by drawi ng ai r i nto the pump cavi ty and al so
cl oses the vent seal . Duri ng non test condi ti ons the
vent seal i s hel d open by the pump di aphragm
assembl y whi ch pushes i t open at the ful l travel posi -
ti on. The vent seal wi l l remai n cl osed whi l e the
pump i s cycl i ng due to the reed swi tch tri ggeri ng of
the three port sol enoi d that prevents the di aphragm
assembl y from reachi ng ful l travel . After the bri ef
i ni ti al i zati on peri od, the sol enoi d i s de-energi zed
al l owi ng atmospheri c pressure to enter the pump
cavi ty, thus permi tti ng the spri ng to dri ve the di a-
phragm whi ch forces ai r out of the pump cavi ty and
i nto the vent system. When the sol enoi d i s energi zed
and de energi zed, the cycl e i s repeated creati ng fl ow
i n typi cal di aphragm pump fashi on. The pump i s con-
trol l ed i n 2 modes:
Pump Mode: The pump i s cycl ed at a fi xed rate to
achi eve a rapi d pressure bui l d i n order to shorten the
overal l test l ength.
Test Mode: The sol enoi d i s energi zed wi th a fi xed
durati on pul se. Subsequent fi xed pul ses occur when
the di aphragm reaches the Swi tch cl osure poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5
water. The cycl e rate of pump strokes i s qui te rapi d
as the system begi ns to pump up to thi s pressure. As
the pressure i ncreases, the cycl e rate starts to drop
off. I f there i s no l eak i n the system, the pump woul d
eventual l y stop pumpi ng at the equal i zed pressure. I f
there i s a l eak, i t wi l l conti nue to pump at a rate rep-
resentati ve of the fl ow characteri sti c of the si ze of the
l eak. From thi s i nformati on we can determi ne i f the
l eak i s l arger than the requi red detecti on l i mi t (cur-
rentl y set at .040 ori fi ce by CARB). I f a l eak i s
reveal ed duri ng the l eak test porti on of the test, the
test i s termi nated at the end of the test mode and no
further system checks wi l l be performed.
After passi ng the l eak detecti on phase of the test,
system pressure i s mai ntai ned by turni ng on the
LDPs sol enoi d unti l the purge system i s acti vated.
Purge acti vati on i n effect creates a l eak. The cycl e
rate i s agai n i nterrogated and when i t i ncreases due
to the fl ow through the purge system, the l eak check
porti on of the di agnosti c i s compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
Evaporati ve system functi onal i ty wi l l be veri fi ed by
usi ng the stri cter evap purge fl ow moni tor. At an
appropri ate warm i dl e the LDP wi l l be energi zed to
seal the cani ster vent. The purge fl ow wi l l be cl ocked
up from some smal l val ue i n an attempt to see a
shi ft i n the 02 control system. I f fuel vapor, i ndi cated
by a shi ft i n the 02 control , i s present the test i s
passed. I f not, i t i s assumed that the purge system i s
not functi oni ng i n some respect. The LDP i s agai n
turned off and the test i s ended.
MISFIRE MONITOR
Excessi ve engi ne mi sfi re resul ts i n i ncreased cata-
l yst temperature and causes an i ncrease i n HC emi s-
si ons. Severe mi sfi res coul d cause catal yst damage.
To prevent catal yti c convertor damage, the PCM
moni tors engi ne mi sfi re.
for mi sfi re duri ng most engi ne operati ng condi ti ons
(posi ti ve torque) by l ooki ng at changes i n the crank-
shaft speed. I f a mi sfi re occurs the speed of the
crankshaft wi l l vary more than normal .
FUEL SYSTEM MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de. The catal yst works best
when the Ai r Fuel (A/F) rati o i s at or near the opti -
mum of 14.7 to 1.
The PCM i s programmed to mai ntai n the opti mum
ai r/fuel rati o of 14.7 to 1. Thi s i s done by maki ng
short term correcti ons i n the fuel i njector pul se wi dth
based on the O2S sensor output. The programmed
memory acts as a sel f cal i brati on tool that the engi ne
control l er uses to compensate for vari ati ons i n engi ne
speci fi cati ons, sensor tol erances and engi ne fati gue
over the l i fe span of the engi ne. By moni tori ng the
actual fuel -ai r rati o wi th the O2S sensor (short term)
and mul ti pl yi ng that wi th the program l ong-term
(adapti ve) memory and compari ng that to the l i mi t,
i t can be determi ned whether i t wi l l pass an emi s-
si ons test. I f a mal functi on occurs such that the PCM
cannot mai ntai n the opti mum A/F rati o, then the
MI L wi l l be i l l umi nated.
CATALYST MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de.
Normal vehi cl e mi l es or engi ne mi sfi re can cause a
catal yst to decay. Thi s can i ncrease vehi cl e emi ssi ons
and deteri orate engi ne performance, dri veabi l i ty and
fuel economy.
The catal yst moni tor uses dual oxygen sensors
(O2Ss) to moni tor the effi ci ency of the converter. The
dual O2Ss sensor strategy i s based on the fact that
as a catal yst deteri orates, i ts oxygen storage capaci ty
and i ts effi ci ency are both reduced. By moni tori ng
the oxygen storage capaci ty of a catal yst, i ts effi -
ci ency can be i ndi rectl y cal cul ated. The upstream
O2S i s used to detect the amount of oxygen i n the
exhaust gas before the gas enters the catal yti c con-
verter. The PCM cal cul ates the A/F mi xture from the
output of the O2S. A l ow vol tage i ndi cates hi gh oxy-
gen content (l ean mi xture). A hi gh vol tage i ndi cates a
l ow content of oxygen (ri ch mi xture).
When the upstream O2S detects a l ean condi ti on,
there i s an abundance of oxygen i n the exhaust gas.
A functi oni ng converter woul d store thi s oxygen so i t
can use i t for the oxi dati on of HC and CO. As the
converter absorbs the oxygen, there wi l l be a l ack of
oxygen downstream of the converter. The output of
the downstream O2S wi l l i ndi cate l i mi ted acti vi ty i n
thi s condi ti on.
As the converter l oses the abi l i ty to store oxygen,
the condi ti on can be detected from the behavi or of
the downstream O2S. When the effi ci ency drops, no
chemi cal reacti on takes pl ace. Thi s means the con-
centrati on of oxygen wi l l be the same downstream as
upstream. The output vol tage of the downstream
O2S copi es the vol tage of the upstream sensor. The
onl y di fference i s a ti me l ag (seen by the PCM)
between the swi tchi ng of the O2Ss.
To moni tor the system, the number of l ean-to-ri ch
swi tches of upstream and downstream O2Ss i s
counted. The rati o of downstream swi tches to
upstream swi tches i s used to determi ne whether the
catal yst i s operati ng properl y. An effecti ve catal yst
wi l l have fewer downstream swi tches than i t has
upstream swi tches i .e., a rati o cl oser to zero. For a
total l y i neffecti ve catal yst, thi s rati o wi l l be one-to-
one, i ndi cati ng that no oxi dati on occurs i n the devi ce.
The system must be moni tored so that when cata-
l yst effi ci ency deteri orates and exhaust emi ssi ons
i ncrease to over the l egal l i mi t, the MI L wi l l be i l l u-
mi nated.
DESCRIPTION - TRIP DEFINITION
The term Tri p has di fferent meani ngs dependi ng
on what the ci rcumstances are. I f the MI L (Mal func-
ti on I ndi cator Lamp) i s OFF, a Tri p i s defi ned as
when the Oxygen Sensor Moni tor and the Catal yst
Moni tor have been compl eted i n the same dri ve cycl e.
When any Emi ssi on DTC i s set, the MI L on the
dash i s turned ON. When the MI L i s ON, i t takes 3
good tri ps to turn the MI L OFF. I n thi s case, i t
depends on what type of DTC i s set to know what a
Tri p i s.
For the Fuel Moni tor or Mi s-Fi re Moni tor (conti n-
uous moni tor), the vehi cl e must be operated i n the
Si mi l ar Condi ti on Wi ndow for a speci fi ed amount of
ti me to be consi dered a Good Tri p.
I f a Non-Conti uous OBDI I Moni tor fai l s twi ce i n a
row and turns ON the MI L, re-runni ng that moni tor
whi ch previ ousl y fai l ed, on the next start-up and
passi ng the moni tor, i s consi dered to be a Good Tri p.
These wi l l i ncl ude the fol l owi ng:
Oxygen Sensor
Catal yst Moni tor
Purge Fl ow Moni tor
Leak Detecti on Pump Moni tor (i f equi pped)
EGR Moni tor (i f equi pped)
Oxygen Sensor Heater Moni tor
I f any other Emi ssi on DTC i s set (not an OBDI I
Moni tor), a Good Tri p i s consi dered to be when the
Oxygen Sensor Moni tor and Catal yst Moni tor have
been compl eted; or 2 Mi nutes of engi ne run ti me i f
the Oxygen Sensor Moni tor or Catal yst Moni tor have
been stopped from runni ng.
I t can take up to 2 Fai l ures i n a row to turn on the
MI L. After the MI L i s ON, i t takes 3 Good Tri ps to
turn the MI L OFF. After the MI L i s OFF, the PCM
wi l l sel f-erase the DTC after 40 Warm-up cycl es. A
Warm-up cycl e i s counted when the ECT (Engi ne
Cool ant Temperature Sensor) has crossed 160F and
has ri sen by at l east 40F si nce the engi ne has been
started.
DESCRIPTION - COMPONENT MONITORS
There are several components that wi l l affect vehi -
cl e emi ssi ons i f they mal functi on. I f one of these com-
ponents mal functi ons the Mal functi on I ndi cator
Lamp (MI L) wi l l i l l umi nate.
Some of the component moni tors are checki ng for
proper operati on of the part. El ectri cal l y operated
components now have i nput (rati onal i ty) and output
(functi onal i ty) checks. Previ ousl y, a component l i ke
the Throttl e Posi ti on sensor (TPS) was checked by
the PCM for an open or shorted ci rcui t. I f one of
these condi ti ons occurred, a DTC was set. Now there
i s a check to ensure that the component i s worki ng.
Thi s i s done by watchi ng for a TPS i ndi cati on of a
greater or l esser throttl e openi ng than MAP and
engi ne rpm i ndi cate. I n the case of the TPS, i f engi ne
vacuum i s hi gh and engi ne rpm i s 1600 or greater
and the TPS i ndi cates a l arge throttl e openi ng, a
DTC wi l l be set. The same appl i es to l ow vacuum i f
the TPS i ndi cates a smal l throttl e openi ng.
Al l open/short ci rcui t checks or any component that
has an associ ated l i mp i n wi l l set a faul t after 1 tri p
wi th the mal functi on present. Components wi thout
an associ ated l i mp i n wi l l take two tri ps to i l l umi -
nate the MI L.
Refer to the Di agnosti c Troubl e Codes Descri pti on
Charts i n thi s secti on and the appropri ate Power-
trai n Di agnosti c Procedure Manual for di agnosti c
procedures.
DESCRIPTION - NON-MONITORED CIRCUITS
The PCM does not moni tor the fol l owi ng ci rcui ts,
systems and condi ti ons that coul d have mal functi ons
causi ng dri veabi l i ty probl ems. The PCM mi ght not
store di agnosti c troubl e codes for these condi ti ons.
However, probl ems wi th these systems may cause the
PCM to store di agnosti c troubl e codes for other sys-
tems or components. For exampl e, a fuel pressure
probl em wi l l not regi ster a faul t di rectl y, but coul d
cause a ri ch/l ean condi ti on or mi sfi re. Thi s coul d
cause the PCM to store an oxygen sensor or mi sfi re
di agnosti c troubl e code
FUEL PRESSURE
The fuel pressure regul ator control s fuel system
pressure. The PCM cannot detect a cl ogged fuel
pump i nl et fi l ter, cl ogged i n-l i ne fuel fi l ter, or a
pi nched fuel suppl y or return l i ne. However, these
coul d resul t i n a ri ch or l ean condi ti on causi ng the
PCM to store an oxygen sensor or fuel system di ag-
nosti c troubl e code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an i noperati ve i gni ti on coi l ,
foul ed or worn spark pl ugs, i gni ti on cross fi ri ng, or
open spark pl ug cabl es.
CYLINDER COMPRESSION
The PCM cannot detect uneven, l ow, or hi gh engi ne
cyl i nder compressi on.
EXHAUST SYSTEM
The PCM cannot detect a pl ugged, restri cted or
l eaki ng exhaust system, al though i t may set a fuel
system faul t.
FUEL INJECTOR MECHANICAL MALFUNCTIONS
The PCM cannot determi ne i f a fuel i njector i s
cl ogged, the needl e i s sti cki ng or i f the wrong i njector
i s i nstal l ed. However, these coul d resul t i n a ri ch or
l ean condi ti on causi ng the PCM to store a di agnosti c
troubl e code for ei ther mi sfi re, an oxygen sensor, or
the fuel system.
EXCESSIVE OIL CONSUMPTION
Al though the PCM moni tors engi ne exhaust oxygen
content when the system i s i n cl osed l oop, i t cannot
determi ne excessi ve oi l consumpti on.
THROTTLE BODY AIRFLOW
The PCM cannot detect a cl ogged or restri cted ai r
cl eaner i nl et or fi l ter el ement.
VACUUM ASSIST
The PCM cannot detect l eaks or restri cti ons i n the
vacuum ci rcui ts of vacuum assi sted engi ne control
system devi ces. However, these coul d cause the PCM
to store a MAP sensor di agnosti c troubl e code and
cause a hi gh i dl e condi ti on.
PCM SYSTEM GROUND
The PCM cannot determi ne a poor system ground.
However, one or more di agnosti c troubl e codes may
be generated as a resul t of thi s condi ti on. The mod-
ul e shoul d be mounted to the body at al l ti mes, al so
duri ng di agnosti c.
PCM CONNECTOR ENGAGEMENT
The PCM may not be abl e to determi ne spread or
damaged connector pi ns. However, i t mi ght store
di agnosti c troubl e codes as a resul t of spread connec-
tor pi ns.
DESCRIPTION - HIGH AND LOW LIMITS
The PCM compares i nput si gnal vol tages from each
i nput devi ce wi th establ i shed hi gh and l ow l i mi ts for
the devi ce. I f the i nput vol tage i s not wi thi n l i mi ts
and other cri teri a are met, the PCM stores a di agnos-
ti c troubl e code i n memory. Other di agnosti c troubl e
code cri teri a mi ght i ncl ude engi ne RPM l i mi ts or
i nput vol tages from other sensors or swi tches that
must be present before veri fyi ng a di agnosti c troubl e
code condi ti on.
DESCRIPTION - LOAD VALUE
ENGINE IDLE/NEUTRAL 2500 RPM/NEUTRAL
All Engines 2% to 8% of Maximum Load 9% to 17% of Maximum Load
OPERATION - TASK MANAGER
The Task Manager determi nes whi ch tests happen
when and whi ch functi ons occur when. Many of the
di agnosti c steps requi red by OBD I I must be per-
formed under speci fi c operati ng condi ti ons. The Task
Manager software organi zes and pri ori ti zes the di ag-
nosti c procedures. The job of the Task Manager i s to
determi ne i f condi ti ons are appropri ate for tests to be
run, moni tor the parameters for a tri p for each test,
and record the resul ts of the test. Fol l owi ng are the
responsi bi l i ti es of the Task Manager software:
Test Sequence
MI L I l l umi nati on
Di agnosti c Troubl e Codes (DTCs)
Tri p I ndi cator
Freeze Frame Data Storage
Si mi l ar Condi ti ons Wi ndow
Test Sequence
I n many i nstances, emi ssi ons systems must fai l
di agnosti c tests more than once before the PCM i l l u-
mi nates the MI L. These tests are know as two tri p
moni tors. Other tests that turn the MI L l amp on
after a si ngl e fai l ure are known as one tri p moni -
tors. A tri p i s defi ned as start the vehi cl e and oper-
ate i t to meet the cri teri a necessary to run the gi ven
moni tor.
Many of the di agnosti c tests must be performed
under certai n operati ng condi ti ons. However, there
are ti mes when tests cannot be run because another
test i s i n progress (confl i ct), another test has fai l ed
(pendi ng) or the Task Manager has set a faul t that
may cause a fai l ure of the test (suspend).
Pendi ng
Under some si tuati ons the Task Manager wi l l not
run a moni tor i f the MI L i s i l l umi nated and a faul t i s
stored from another moni tor. I n these si tuati ons, the
Task Manager postpones moni tors pending resol u-
ti on of the ori gi nal faul t. The Task Manager does not
run the test unti l the probl em i s remedi ed.
For exampl e, when the MI L i s i l l umi nated for an
Oxygen Sensor faul t, the Task Manager does not run
the Catal yst Moni tor unti l the Oxygen Sensor faul t i s
remedi ed. Si nce the Catal yst Moni tor i s based on si g-
nal s from the Oxygen Sensor, runni ng the test woul d
produce i naccurate resul ts.
Confl i ct
There are si tuati ons when the Task Manager does
not run a test i f another moni tor i s i n progress. I n
these si tuati ons, the effects of another moni tor run-
ni ng coul d resul t i n an erroneous fai l ure. I f thi s con-
flict i s present, the moni tor i s not run unti l the
confl i cti ng condi ti on passes. Most l i kel y the moni tor
wi l l run l ater after the confl i cti ng moni tor has
passed.
For exampl e, i f the Fuel System Moni tor i s i n
progress, the Task Manager does not run the EGR
Moni tor. Si nce both tests moni tor changes i n ai r/fuel
rati o and adapti ve fuel compensati on, the moni tors
wi l l confl i ct wi th each other.
Suspend
Occasi onal l y the Task Manager may not al l ow a two
tri p faul t to mature. The Task Manager wi l l sus-
pend the maturi ng of a faul t i f a condi ti on exi sts
that may i nduce an erroneous fai l ure. Thi s prevents
i l l umi nati ng the MI L for the wrong faul t and al l ows
more preci s di agnosi s.
For exampl e, i f the PCM i s stori ng a one tri p faul t
for the Oxygen Sensor and the EGR moni tor, the
Task Manager may sti l l run the EGR Moni tor but
wi l l suspend the resul ts unti l the Oxygen Sensor
Moni tor ei ther passes or fai l s. At that poi nt the Task
Manager can determi ne i f the EGR system i s actu-
al l y fai l i ng or i f an Oxygen Sensor i s fai l i ng.
MIL Illumination
The PCM Task Manager carri es out the i l l umi na-
ti on of the MI L. The Task Manager tri ggers MI L i l l u-
mi nati on upon test fai l ure, dependi ng on moni tor
fai l ure cri teri a.
The Task Manager Screen shows both a Requested
MI L state and an Actual MI L state. When the MI L i s
i l l umi nated upon compl eti on of a test for a thi rd tri p,
the Requested MI L state changes to OFF. However,
the MI L remai ns i l l umi nated unti l the next key
cycl e. (On some vehi cl es, the MI L wi l l actual l y turn
OFF duri ng the thi rd key cycl e) Duri ng the key cycl e
for the thi rd good tri p, the Requested MI L state i s
OFF, whi l e the Actual MI L state i s ON. After the
next key cycl e, the MI L i s not i l l umi nated and both
MI L states read OFF.
Diagnostic Trouble Codes (DTCs)
Wi th OBD I I , di fferent DTC faul ts have di fferent
pri ori ti es accordi ng to regul ati ons. As a resul t, the
pri ori ti es determi ne MI L i l l umi nati on and DTC era-
sure. DTCs are entered accordi ng to i ndi vi dual pri or-
i ty. DTCs wi th a hi gher pri ori ty overwri te l ower
pri ori ty DTCs.
Priorities
Pri ori ty 0 Non-emi ssi ons rel ated troubl e codes
Pri ori ty 1 One tri p fai l ure of a two tri p faul t
for non-fuel system and non-mi sfi re.
Pri ori ty 2 One tri p fai l ure of a two tri p faul t
for fuel system (ri ch/l ean) or mi sfi re.
Pri ori ty 3 Two tri p fai l ure for a non-fuel sys-
tem and non-mi sfi re or matured one tri p comprehen-
si ve component faul t.
Pri ori ty 4 Two tri p fai l ure or matured faul t
for fuel system (ri ch/l ean) and mi sfi re or one tri p cat-
al yst damagi ng mi sfi re.
Non-emi ssi ons rel ated fai l ures have no pri ori ty.
One tri p fai l ures of two tri p faul ts have l ow pri ori ty.
Two tri p fai l ures or matured faul ts have hi gher pri -
ori ty. One and two tri p fai l ures of fuel system and
mi sfi re moni tor take precedence over non-fuel system
and non-mi sfi re fai l ures.
DTC Self Erasure
Wi th one tri p components or systems, the MI L i s
i l l umi nated upon test fai l ure and DTCs are stored.
Two tri p moni tors are components requi ri ng fai l ure
i n two consecuti ve tri ps for MI L i l l umi nati on. Upon
fai l ure of the fi rst test, the Task Manager enters a
maturi ng code. I f the component fai l s the test for a
second ti me the code matures and a DTC i s set.
After three good tri ps the MI L i s exti ngui shed and
the Task Manager automati cal l y swi tches the tri p
counter to a warm-up cycl e counter. DTCs are auto-
mati cal l y erased fol l owi ng 40 warm-up cycl es i f the
component does not fai l agai n.
For mi sfi re and fuel system moni tors, the compo-
nent must pass the test under a Si mi l ar Condi ti ons
Wi ndow i n order to record a good tri p. A Si mi l ar Con-
di ti ons Wi ndow i s when engi ne RPM i s wi thi n 375
RPM and l oad i s wi thi n 10% of when the faul t
occurred.
NOTE: It is important to understand that a compo-
nent does not have to fail under a similar window of
operation to mature. It must pass the test under a
Similar Conditions Window when it failed to record
a Good Trip for DTC erasure for misfire and fuel
system monitors.
DTCs can be erased anyti me wi th a DRB I I I . Eras-
i ng the DTC wi th the DRB I I I erases al l OBD I I
i nformati on. The DRB I I I automati cal l y di spl ays a
warni ng that erasi ng the DTC wi l l al so erase al l
OBD I I moni tor data. Thi s i ncl udes al l counter i nfor-
mati on for warm-up cycl es, tri ps and Freeze Frame.
Trip Indicator
The Trip i s essenti al for runni ng moni tors and
exti ngui shi ng the MI L. I n OBD I I terms, a tri p i s a
set of vehi cl e operati ng condi ti ons that must be met
for a speci fi c moni tor to run. Al l tri ps begi n wi th a
key cycl e.
Good Trip
The Good Tri p counters are as fol l ows:
Speci fi c Good Tri p
Fuel System Good Tri p
Mi sfi re Good Tri p
Al ternate Good Tri p (appears as a Gl obal Good
Tri p on DRB I I I )
Comprehensi ve Components
Major Moni tor
Warm-Up Cycl es
Specific Good Trip
The term Good Tri p has di fferent meani ngs
dependi ng on the ci rcumstances:
I f the MI L i s OFF, a tri p i s defi ned as when the
Oxygen Sensor Moni tor and the Catal yst Moni tor
have been compl eted i n the same dri ve cycl e.
I f the MI L i s ON and a DTC was set by the Fuel
Moni tor or Mi sfi re Moni tor (both conti nuous moni -
tors), the vehi cl e must be operated i n the Si mi l ar
Condi ti on Wi ndow for a speci fi ed amount of ti me.
I f the MI L i s ON and a DTC was set by a Task
Manager commanded once-per-tri p moni tor (such as
the Oxygen Sensor Moni tor, Catal yst Moni tor, Purge
Fl ow Moni tor, Leak Detecti on Pump Moni tor, EGR
Moni tor or Oxygen Sensor Heater Moni tor), a good
tri p i s when the moni tor i s passed on the next start-
up.
I f the MI L i s ON and any other emi ssi ons DTC
was set (not an OBD I I moni tor), a good tri p occurs
when the Oxygen Sensor Moni tor and Catal yst Mon-
i tor have been compl eted, or two mi nutes of engi ne
run ti me i f the Oxygen Sensor Moni tor and Catal yst
Moni tor have been stopped from runni ng.
Fuel System Good Trip
To count a good tri p (three requi red) and turn off
the MI L, the fol l owi ng condi ti ons must occur:
Engi ne i n cl osed l oop
Operati ng i n Si mi l ar Condi ti ons Wi ndow
Short Term mul ti pl i ed by Long Term l ess than
threshol d
Less than threshol d for a predetermi ned ti me
I f al l of the previ ous cri teri a are met, the PCM wi l l
count a good tri p (three requi red) and turn off the
MI L.
Misfire Good Trip
I f the fol l owi ng condi ti ons are met the PCM wi l l
count one good tri p (three requi red) i n order to turn
off the MI L:
Operati ng i n Si mi l ar Condi ti on Wi ndow
1000 engi ne revol uti ons wi th no mi sfi re
Warm-Up Cycles
Once the MI L has been exti ngui shed by the Good
Tri p Counter, the PCM automati cal l y swi tches to a
Warm-Up Cycl e Counter that can be vi ewed on the
DRB I I I . Warm-Up Cycl es are used to erase DTCs
and Freeze Frames. Forty Warm-Up cycl es must
occur i n order for the PCM to sel f-erase a DTC and
Freeze Frame. A Warm-Up Cycl e i s defi ned as fol -
l ows:
Engi ne cool ant temperature must start bel ow
and ri se above 160 F
Engi ne cool ant temperature must ri se by 40 F
No further faul ts occur
Freeze Frame Data Storage
Once a fai l ure occurs, the Task Manager records
several engi ne operati ng condi ti ons and stores i t i n a
Freeze Frame. The Freeze Frame i s consi dered one
frame of i nformati on taken by an on-board data
recorder. When a faul t occurs, the PCM stores the
i nput data from vari ous sensors so that techni ci ans
can determi ne under what vehi cl e operati ng condi -
ti ons the fai l ure occurred.
The data stored i n Freeze Frame i s usual l y
recorded when a system fai l s the fi rst ti me for two
tri p faul ts. Freeze Frame data wi l l onl y be overwri t-
ten by a di fferent faul t wi th a hi gher pri ori ty.
CAUTION: Erasing DTCs, either with the DRB III or
by disconnecting the battery, also clears all Freeze
Frame data.
Similar Conditions Window
The Si mi l ar Condi ti ons Wi ndow di spl ays i nforma-
ti on about engi ne operati on duri ng a moni tor. Abso-
l ute MAP (engi ne l oad) and Engi ne RPM are stored
i n thi s wi ndow when a fai l ure occurs. There are two
di fferent Si mi l ar condi ti ons Wi ndows: Fuel System
and Mi sfi re.
FUEL SYSTEM
Fuel System Similar Conditions Window
An i ndi cator that Absol ute MAP When Fuel Sys Fai l
and RPM When Fuel Sys Fai l ed are al l i n the same
range when the fai l ure occurred. I ndi cated by swi tch-
i ng from NO to YES.
Absolute MAP When Fuel Sys Fail The
stored MAP readi ng at the ti me of fai l ure. I nforms
the user at what engi ne l oad the fai l ure occurred.
Absolute MAP A l i ve readi ng of engi ne l oad
to ai d the user i n accessi ng the Si mi l ar Condi ti ons
Wi ndow.
RPM When Fuel Sys Fail The stored RPM
readi ng at the ti me of fai l ure. I nforms the user at
what engi ne RPM the fai l ure occurred.
Engine RPM A l i ve readi ng of engi ne RPM
Wi ndow.
Adaptive Memory Factor The PCM uti l i zes
both Short Term Compensati on and Long Term Adap-
ti ve to cal cul ate the Adapti ve Memory Factor for
total fuel correcti on.
Upstream O2S Volts A l i ve readi ng of the
Oxygen Sensor to i ndi cate i ts performance. For
exampl e, stuck l ean, stuck ri ch, etc.
SCW Time in Window (Similar Conditions
Window Time in Window) A ti mer used by the
PCM that i ndi cates that, after al l Si mi l ar Condi ti ons
have been met, i f there has been enough good engi ne
runni ng ti me i n the SCW wi thout fai l ure detected.
Thi s ti mer i s used to i ncrement a Good Tri p.
Fuel System Good Trip Counter A Tri p
Counter used to turn OFF the MI L for Fuel System
DTCs. To i ncrement a Fuel System Good Tri p, the
engi ne must be i n the Si mi l ar Condi ti ons Wi ndow,
Adapti ve Memory Factor must be l ess than cal i -
brated threshol d and the Adapti ve Memory Factor
must stay bel ow that threshol d for a cal i brated
amount of ti me.
Test Done This Trip I ndi cates that the
moni tor has al ready been run and compl eted duri ng
the current tri p.
MISFIRE
Same Misfire Warm-Up State I ndi cates i f
the mi sfi re occurred when the engi ne was warmed up
(above 160 F).
In Similar Misfire Window An i ndi cator
that Absol ute MAP When Mi sfi re Occurred and
RPM When Mi sfi re Occurred are al l i n the same
range when the fai l ure occurred. I ndi cated by swi tch-
i ng from NO to YES.
Absolute MAP When Misfire Occurred
The stored MAP readi ng at the ti me of fai l ure.
I nforms the user at what engi ne l oad the fai l ure
occurred.
Absolute MAP A l i ve readi ng of engi ne l oad
Wi ndow.
RPM When Misfire Occurred The stored
RPM readi ng at the ti me of fai l ure. I nforms the user
at what engi ne RPM the fai l ure occurred.
Engine RPM A l i ve readi ng of engi ne RPM
Wi ndow.
Adaptive Memory Factor The PCM uti l i zes
both Short Term Compensati on and Long Term Adap-
ti ve to cal cul ate the Adapti ve Memory Factor for
total fuel correcti on.
200 Rev Counter Counts 0100 720 degree
cycl es.
SCWCat 200 Rev Counter Counts when i n
si mi l ar condi ti ons.
SCW FTP 1000 Rev Counter Counts 04
when i n si mi l ar condi ti ons.
Misfire Good Trip Counter Counts up to
three to turn OFF the MI L.
Misfire Data Data col l ected duri ng test.
Test Done This Trip I ndi cates YES when the
test i s done.
EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
DESCRIPTION - EVAPORATION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
EVAP/PURGE SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
FUEL FILLER CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
LEAK DETECTION PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
ORVR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PCV VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIAGNOSIS AND TESTING - PCV VALVE . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
VACUUM LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
VAPOR CANISTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
DESCRIPTION - EVAPORATION CONTROL
SYSTEM
The evaporati on control system prevents the emi s-
si on of fuel tank vapors i nto the atmosphere. When
fuel evaporates i n the fuel tank, the vapors pass
through the control val ve l ocated i n the top secti on of
the fuel pump modul e, through the fuel management
val ve, and through vent hoses and tubes to a char-
coal fi l l ed evaporati ve cani ster. The cani ster tempo-
rari l y hol ds the vapors. The Powertrai n Control
Modul e (PCM) al l ows i ntake mani fol d vacuum to
draw vapors i nto the combusti on chambers duri ng
certai n operati ng condi ti ons.
Gas powered engi nes use a duty cycl e purge sys-
tem. The PCM control s vapor fl ow by operati ng the
duty cycl e EVAP purge sol enoi d. Refer to Duty Cycl e
EVAP Cani ster Purge Sol enoi d.
When equi pped wi th certai n emi ssi ons packages, a
Leak Detecti on Pump (LDP) wi l l be used as part of
the evaporati ve system for OBD I I requi rements.
Al so refer to Leak Detecti on Pump.
Vehi cl es powered wi th gasol i ne engi nes are al so
equi pped wi th ORVR (On-Board Refuel i ng Vapor
Recovery). Refer to ORVR for addi ti onal i nformati on.
NOTE: The evaporative system uses specially man-
ufactured lines/hoses. If replacement becomes nec-
essary, only use fuel resistant, low permeation
hose.
Certai n components can be found i n (Fi g. 1).
25 - 24 EVAPORATIVE EMISSIONS KJ
Fig. 1 FUEL DELIVERY COMPONENTS
1 - FUEL TANK 10 - EVAP CANISTER
2 - FUEL TANK STRAPS 11 - FLOW MANAGEMENT VALVE
3 - FUEL PUMP MODULE LOCK RING 12 - FRESH AIR TUBE
4 - CHECK (CONTROL) VALVE 13 - HOSE SLEEVE
5 - FUEL PUMP MODULE FLANGE 14 - FUEL FILTER
6 - FUEL FILL HOSE 15 - LEAK DETECTION PUMP
7 - FRESH AIR FILTER 16 - HEAT SHIELD
8 - FUEL FILL CAP/BEZEL 17 - SKID PLATE
9 - FUEL FILL TUBE
KJ EVAPORATIVE EMISSIONS 25 - 25
EVAPORATIVE EMISSIONS (Continued)
SPECIFICATIONS
TORQUE
Accelerator Pedal Bracket
Mounting Nuts
12 - 105
Engine Coolant Temperature
Sensor
11 - 96
EVAP Canister-to-Body Bolts 48 35 -
EVAP Canister-to-Canis. Bracket
Bolt/Nut
11 - 100
Fuel Filler Hose Clamp at Tank 3 - 30
Fuel Filler Housing-to-Body
Screws
2 - 17
Fuel Filter Mounting Nut at Tank 5.5 - 49
Fuel Pump Module Access Plate
Nuts
3 - 26
Fuel Tank Heat Sheild Nuts 5.5 - 49
Fuel Tank Mounting Strap Bolts 61 45 -
Fuel Tank Skid Plate and Trailer
Hitch
88 65 -
IAC Motor Mounting Screws 7 - 60
Leak Detection Pump Mounting
Bracket-to-Fuel Tank Nuts
5.5 - 49
Leak Detection Pump-to-Bracket
Nuts
1.2 - 11
Map Sensor Mounting Screws 3 - 25
PCM-to-Mounting Bracket
Mounting Screws
4 - 35
Power Steering Pressure Switch 14-22 - 124-195
TPS Mounting Screws 7 - 60
Throttle Body Mounting Bolts 11 - 100
Oxygen Sensors 30 22 -
EVAPORATIVE EMISSIONS (Continued)
EVAP/PURGE SOLENOID
DESCRIPTION
The duty cycl e EVAP cani ster purge sol enoi d (DCP)
i s l ocated i n the engi ne compartment. I t i s attached
to a bracket l ocated between the battery and the
Power Di stri buti on Center (PDC). The EVAP system
test port i s l ocated near the sol enoi d.
OPERATION
regul ates the rate of vapor fl ow from the EVAP can-
i ster to the i ntake mani fol d. The Powertrai n Control
Modul e (PCM) operates the sol enoi d.
Duri ng the col d start warm-up peri od and the hot
start ti me del ay, the PCM does not energi ze the sol e-
noi d. When de-energi zed, no vapors are purged. The
PCM de-energi zes the sol enoi d duri ng open l oop oper-
ati on.
The engi ne enters cl osed l oop operati on after i t
reaches a speci fi ed temperature and the ti me del ay
ends. Duri ng cl osed l oop operati on, the PCM cycl es
(energi zes and de-energi zes) the sol enoi d 5 or 10
ti mes per second, dependi ng upon operati ng condi -
ti ons. The PCM vari es the vapor fl ow rate by chang-
i ng sol enoi d pul se wi dth. Pul se wi dth i s the amount
of ti me that the sol enoi d i s energi zed. The PCM
adjusts sol enoi d pul se wi dth based on engi ne operat-
i ng condi ti on.
REMOVAL
i s l ocated i n the engi ne compartment (Fi g. 2). I t i s
attached to a bracket l ocated between the battery
and the Power Di stri buti on Center (PDC). The EVAP
system test port i s l ocated near the sol enoi d (Fi g. 2).
(1) Di sconnect el ectri cal wi ri ng connector at sol e-
noi d.
(2) Di sconnect vacuum harness at sol enoi d.
(3) Remove sol enoi d and i ts support bracket (pul l
strai ght up).
INSTALLATION
(1) Sl i p EVAP cani ster purge sol enoi d onto i ts
mounti ng bracket.
(2) Connect vacuum harness to sol enoi d.
(3) Connect el ectri cal connector to sol enoi d.
FUEL FILLER CAP
DESCRIPTION
The pl asti c fuel tank fi l l er tube cap i s threaded
onto the end of the fuel fi l l tube. Al l model s are
equi pped wi th a 1/4 turn cap.
OPERATION
The l oss of any fuel or vapor out of fuel fi l l er tube
i s prevented by the use of a pressure-vacuum fuel fi l l
cap. Rel i ef val ves i nsi de the cap wi l l rel ease fuel tank
pressure at predetermi ned pressures. Fuel tank vac-
uum wi l l al so be rel eased at predetermi ned val ues.
Thi s cap must be repl aced by a si mi l ar uni t i f
repl acement i s necessary. Thi s i s i n order for the sys-
tem to remai n effecti ve.
CAUTION: Remove fill cap before servicing any fuel
system component to relieve tank pressure. If
equipped with an ORVR system and a Leak Detec-
tion Pump (LDP), the cap must be tightened
securely. If cap is left loose, a Diagnostic Trouble
Code (DTC) may be set.
LEAK DETECTION PUMP
DESCRIPTION
The Leak Detecti on Pump (LDP) i s bol ted to the
front of the fuel tank (Fi g. 1).
The Leak Detecti on Pump (LDP) i s used onl y wi th
certai n emi ssi on packages.
The LDP i s a devi ce used to detect a l eak i n the
evaporati ve system.
Fig. 2 EVAP / PURGE SOLENOID LOCATION
1 - BATTERY
2 - EVAP/PURGE SOLENOID LOCATION
4 - POWER DISTRIBUTION CENTER (PDC)
5 - SOLENOID ELECTRICAL CONNECTOR
6 - EVAP SYSTEM TEST PORT
The pump contai ns a 3 port sol enoi d, a pump that
contai ns a swi tch, a spri ng l oaded cani ster vent val ve
seal , 2 check val ves and a spri ng/di aphragm.
OPERATION
I mmedi atel y after a col d start, engi ne temperature
between 40F and 86F, the 3 port sol enoi d i s bri efl y
energi zed. Thi s i ni ti al i zes the pump by drawi ng ai r
i nto the pump cavi ty and al so cl oses the vent seal .
Duri ng non-test test condi ti ons, the vent seal i s hel d
open by the pump di aphragm assembl y whi ch pushes
i t open at the ful l travel posi ti on. The vent seal wi l l
remai n cl osed whi l e the pump i s cycl i ng. Thi s i s due
to the operati on of the 3 port sol enoi d whi ch prevents
the di aphragm assembl y from reachi ng ful l travel .
After the bri ef i ni ti al i zati on peri od, the sol enoi d i s
de-energi zed, al l owi ng atmospheri c pressure to enter
the pump cavi ty. Thi s permi ts the spri ng to dri ve the
di aphragm whi ch forces ai r out of the pump cavi ty
and i nto the vent system. When the sol enoi d i s ener-
gi zed and de-energi zed, the cycl e i s repeated creati ng
fl ow i n typi cal di aphragm pump fashi on. The pump
i s control l ed i n 2 modes:
PUMP MODE: The pump i s cycl ed at a fi xed rate
to achi eve a rapi d pressure bui l d i n order to shorten
the overal l test ti me.
TEST MODE: The sol enoi d i s energi zed wi th a
fi xed durati on pul se. Subsequent fi xed pul ses occur
when the di aphragm reaches the swi tch cl osure
poi nt.
The spri ng i n the pump i s set so that the system
wi l l achi eve an equal i zed pressure of about 7.5 i nches
of water.
When the pump starts, the cycl e rate i s qui te hi gh.
As the system becomes pressuri zed pump rate drops.
I f there i s no l eak the pump wi l l qui t. I f there i s a
l eak, the test i s termi nated at the end of the test
mode.
I f there i s no l eak, the purge moni tor i s run. I f the
cycl e rate i ncreases due to the fl ow through the
purge system, the test i s passed and the di agnosti c i s
compl ete.
The cani ster vent val ve wi l l unseal the system
after compl eti on of the test sequence as the pump
di aphragm assembl y moves to the ful l travel posi ti on.
REMOVAL
The Leak Detecti on Pump (LDP) i s attached (bol t-
ed) to the front of the fuel tank (Fi g. 3). The LDP
fresh ai r fi l ter i s l ocated on the end of a hose. Thi s
hose i s attached to the fuel fi l l tube assembl y bel ow
and near the fuel fi l l openi ng (Fi g. 1). The LDP and
LDP fi l ter are typi cal l y repl aced (servi ced) as one
uni t.
(2) Careful l y remove two 3/4 vent hoses at si des
of LDP.
(3) Careful l y remove other vapor/vacuum hoses
from LDP.
(4) Pl ace a hydraul i c jack under fuel tank.
(5) Loosen 2 fuel tank strap mounti ng bol ts at
front of tank about 10 turns.
(6) Lower front of fuel tank about 1/2.
(7) Remove 2 LDP mounti ng nuts (Fi g. 3) and
l ower LDP sl i ghtl y to gai n access to el ectri cal connec-
tor (Fi g. 4).
(8) Di sconnect el ectri cal connector at LDP. To di s-
connect: Sl i de red col ored tab upward. Push on bl ack
col ored tab whi l e removi ng connector.
(9) Remove LDP from vehi cl e.
INSTALLATION
The Leak Detecti on Pump (LDP) i s attached (bol t-
ed) to the front of the fuel tank. The LDP fi l ter i s
l ocated on the end of a hose. Thi s hose i s attached to
the fuel fi l l tube assembl y bel ow and near the fuel
fi l l openi ng. The LDP and LDP fi l ter are repl aced
(servi ced) as one uni t.
(1) I nstal l el ectri cal connector to LDP. Push red
col ored tab downward to l ock connector to LDP.
(2) Posi ti on LDP and LDP bracket to fuel tank
mounti ng studs and i nstal l 2 nuts. Ti ghten nuts to 1
(3) Rai se fuel tank to body and ti ghten 2 strap
bol ts to 61 Nm (45 ft. l bs.) torque.
Fig. 3 LDP LOCATION / MOUNTING
1 - LDP
3 - MOUNTING NUTS
4 - FRONT OF FUEL TANK
LEAK DETECTION PUMP (Continued)
(4) Careful l y i nstal l vapor/vacuum l i nes to LDP,
and i nstal l hose to LDP fi l ter. The vapor/vacuum
lines and hoses must be firmly connected.
Check the vapor/vacuum lines at the LDP, LDP
filter and EVAP canister duty cycle purge sole-
noid for damage or leaks. If a leak is present, a
Diagnostic Trouble Code (DTC) may be set.
ORVR
DESCRIPTION
The ORVR (On-Board Refuel i ng Vapor Recovery)
system consi sts of a uni que fuel tank, fl ow manage-
ment val ve, fl ui d control val ve, one-way check val ve
and vapor cani ster (Fi g. 1).
OPERATION
The ORVR (On-Board Refuel i ng Vapor Recovery)
system i s used to remove excess fuel tank vapors.
Thi s i s done whi l e the vehi cl e i s bei ng refuel ed. Cer-
tai n ORVR components can be found i n (Fi g. 1).
Fuel fl owi ng i nto the fuel fi l l er tube (approx. 1
I .D.) creates an aspi rati on effect drawi ng ai r i nto the
fuel fi l l tube. Duri ng refuel i ng, the fuel tank i s
vented to the EVAP cani ster to capture escapi ng
vapors. Wi th ai r fl owi ng i nto the fi l l er tube, there are
no fuel vapors escapi ng to the atmosphere. Once the
refuel i ng vapors are captured by the EVAP cani ster,
the vehi cl es computer control l ed purge system draws
vapor out of the cani ster for the engi ne to burn. The
vapor fl ow i s metered by the purge sol enoi d so that
there i s no, or mi ni mal i mpact on dri veabi l i ty or
tai l pi pe emi ssi ons.
As fuel starts to fl ow through the fuel fi l l tube, i t
opens the normal l y cl osed check val ve and enters the
fuel tank. Vapor or ai r i s expel l ed from the tank
through the control val ve and on to the vapor cani s-
ter. Vapor i s absorbed i n the EVAP cani ster unti l
vapor fl ow i n the l i nes stops. Thi s stoppage occurs
fol l owi ng fuel shut-off, or by havi ng the fuel l evel i n
the tank ri se hi gh enough to cl ose the control val ve.
Thi s control val ve contai ns a fl oat that ri ses to seal
the l arge di ameter vent path to the EVAP cani ster.
At thi s poi nt i n the refuel i ng process, fuel tank pres-
sure i ncreases, the check val ve cl oses (preventi ng l i q-
ui d fuel from spi ti ng back at the operator), and fuel
then ri ses up the fuel fi l l er tube to shut off the di s-
pensi ng nozzl e.
PCV VALVE
DESCRIPTION
2. 4L
The 2.4L 4-cyl i nder engi ne i s equi pped wi th a
cl osed crankcase venti l ati on system and a Posi ti ve
Crankcase Venti l ati on (PCV) val ve.
Thi s system consi sts of:
a PCV val ve attached to the l eft/front si de of the
val ve cover (Fi g. 5). I t i s secured wi th 1 bol t. An
o-ri ng i s used to seal val ve to val ve cover (Fi g. 6).
the ai r cl eaner housi ng
tubes and hoses to connect the system compo-
nents.
3. 7L
The 3.7L V-6 engi ne i s equi pped wi th a cl osed
crankcase venti l ati on system and a Posi ti ve Crank-
case Venti l ati on (PCV) val ve.
Thi s system consi sts of:
a PCV val ve mounted to the oi l fi l l er housi ng
(Fi g. 7). The PCV val ve i s seal ed to the oi l fi l l er
housi ng wi th an o-ri ng.
the ai r cl eaner housi ng
two i nterconnected breathers threaded i nto the
rear of each cyl i nder head (Fi g. 8).
tubes and hoses to connect the system compo-
nents.
Fig. 4 LDP ELECTRICAL CONNECTOR
3 - FUEL FILTER
LEAK DETECTION PUMP (Continued)
Fig. 5 PCV VALVE LOCATION - 2.4L
1 - PCV VALVE
2 - HOSE
3 - MOUNTING BOLT
4 - VALVE COVER (LEFT SIDE)
Fig. 6 PCV VALVE AND O-RING - 2.4L
1 - PCV VALVE
2 - O-RING
3 - MOUNTING BOLT
Fig. 7 PCV VALVE - 3.7L
1 - O-RING
2 - LOCATING TABS
3 - CAM LOCK
4 - OIL FILLER TUBE
5 - PCV LINE/HOSE
6 - PCV VALVE
Fig. 8 CRANKCASE BREATHERS (2) - 3.7L
1 - CRANKCASE BREATHERS (2)
2 - REAR OF ENGINE
PCV VALVE (Continued)
OPERATION
The PCV system operates by engi ne i ntake mani -
fol d vacuum. Fi l tered ai r i s routed i nto the crankcase
through the ai r cl eaner hose and crankcase breath-
er(s) (i f used). The metered ai r, al ong wi th crankcase
vapors, are drawn through the PCV val ve and i nto a
passage i n the i ntake mani fol d. The PCV system
manages crankcase pressure and meters bl ow-by
gases to the i ntake system, reduci ng engi ne sl udge
formati on.
The PCV val ve contai ns a spri ng l oaded pl unger.
Thi s pl unger meters the amount of crankcase vapors
routed i nto the combusti on chamber based on i ntake
mani fol d vacuum.
TYPICAL PCV val ves are shown i n (Fi g. 9), (Fi g.
10) and (Fi g. 11).
When the engi ne i s not operati ng, or duri ng an
engi ne pop-back, the spri ng forces the pl unger back
agai nst the seat (Fi g. 9). Thi s wi l l prevent vapors
from fl owi ng through the val ve.
Duri ng peri ods of hi gh mani fol d vacuum, such as
i dl e or crui si ng speeds, vacuum i s suffi ci ent to com-
pl etel y compress spri ng. I t wi l l then pul l the pl unger
to the top of the val ve (Fi g. 10). I n thi s posi ti on there
i s mi ni mal vapor fl ow through the val ve.
Duri ng peri ods of moderate mani fol d vacuum, the
pl unger i s onl y pul l ed part way back from i nl et. Thi s
resul ts i n maxi mum vapor fl ow through the val ve
(Fi g. 11).
DIAGNOSIS AND TESTING - PCV VALVE
3. 7L
(1) Di sconnect PCV l i ne/hose (Fi g. 7) by di scon-
necti ng rubber connecti ng hose at PCV val ve fi tti ng.
(2) Remove PCV val ve at oi l fi l l er tube by rotati ng
PCV val ve downward unti l l ocati ng tabs have been
freed at cam l ock (Fi g. 7). After tabs have cl eared,
pul l val ve strai ght out from fi l l er tube. To prevent
damage to PCV valve locating tabs, valve must
be pointed downward for removal. Do not force
valve from oil filler tube.
(3) After val ve i s removed, check condi ti on of val ve
o-ri ng (Fi g. 7). Al so, PCV val ve shoul d rattl e when
shaken.
(4) Reconnect PCV val ve to i ts connecti ng l i ne/
hose.
(5) Start engi ne and bri ng to i dl e speed.
(6) I f val ve i s not pl ugged, a hi ssi ng noi se wi l l be
heard as ai r passes through val ve. Al so, a strong vac-
uum shoul d be fel t wi th a fi nger pl aced at val ve
i nl et.
(7) I f vacuum i s not fel t at val ve i nl et, check l i ne/
hose for ki nks or for obstructi on. I f necessary, cl ean
out i ntake mani fol d fi tti ng at rear of mani fol d. Do
thi s by turni ng a 1/4 i nch dri l l (by hand) through the
fi tti ng to di sl odge any sol i d parti cl es. Bl ow out the
fi tti ng wi th shop ai r. I f necessary, use a smal l er dri l l
to avoi d removi ng any metal from the fi tti ng.
(8) Do not attempt to clean the old PCV valve.
(9) Return PCV val ve back to oi l fi l l er tube by
pl aci ng val ve l ocati ng tabs (Fi g. 7) i nto cam l ock.
Press PCV val ve i n and rotate val ve upward. A sl i ght
cl i ck wi l l be fel t when tabs have engaged cam l ock.
Val ve shoul d be poi nted towards rear of vehi cl e.
(10) Connect PCV l i ne/hose and connecti ng rubber
hose to PCV val ve.
(11) Di sconnect rubber hose from fresh ai r fi tti ng
at ai r cl eaner resonator box. Start engi ne and bri ng
to i dl e speed. Hol d a pi ece of sti ff paper (such as a
parts tag) l oosel y over the openi ng of the di scon-
nected rubber hose.
(12) The paper shoul d be drawn agai nst the hose
openi ng wi th noti ceabl e force. Thi s wi l l be after
al l owi ng approxi matel y one mi nute for crankcase
pressure to reduce.
Fig. 9 Engine Off or Engine Pop-BackNo Vapor
Flow
Fig. 10 High Intake Manifold VacuumMinimal
Vapor Flow
Fig. 11 Moderate Intake Manifold Vacuum
Maximum Vapor Flow
(13) I f vacuum i s not present, di sconnect each PCV
system hose at top of each crankcase breather (Fi g.
8). Check for obstructi ons or restri cti ons.
(14) I f vacuum i s sti l l not present, remove each
PCV system crankcase breather (Fi g. 8) from each
cyl i nder head. Check for obstructi ons or restri cti ons.
I f pl ugged, repl ace breather. Ti ghten breather to 12
Nm (106 i n. l bs.) torque. Do not attempt to cl ean
breather
(15) I f vacuum i s sti l l not present, di sconnect each
PCV system hose at each fi tti ng and check for
obstructi ons or restri cti ons.
REMOVAL
2. 4L
The PCV val ve i s attached to the l eft/front si de of
the val ve cover (Fi g. 5). I t i s secured wi th 1 bol t. An
o-ri ng i s used to seal val ve to val ve cover (Fi g. 6).
(1) Remove hose from val ve (Fi g. 5). Check condi -
ti on of hose.
(2) Remove 1 bol t.
(3) Remove PCV val ve from val ve cover.
(4) Check condi ti on of val ve o-ri ng.
3. 7L
The PCV val ve i s l ocated on the oi l fi l l er tube (Fi g.
12). Two l ocati ng tabs are l ocated on the si de of the
val ve (Fi g. 12). These 2 tabs fi t i nto a cam l ock i n the
oi l fi l l er tube. An o-ri ng seal s the val ve to the fi l l er
tube.
(1) Di sconnect PCV l i ne/hose (Fi g. 12) by di scon-
necti ng rubber hose at PCV val ve fi tti ng.
(2) Remove PCV val ve at oi l fi l l er tube by rotati ng
PCV val ve downward (counter-cl ockwi se) unti l l ocat-
i ng tabs have been freed at cam l ock (Fi g. 12). After
tabs have cl eared, pul l val ve strai ght out from fi l l er
tube. To prevent damage to PCV valve locating
tabs, valve must be pointed downward for
removal. Do not force valve from oil filler tube.
(3) After val ve i s removed, check condi ti on of val ve
o-ri ng (Fi g. 12).
INSTALLATION
2. 4L
(1) Check condi ti on of PCV val ve o-ri ng.
(2) I nstal l PCV val ve i nto val ve cover.
(3) I nstal l PCV val ve mounti ng bol t.
(4) I nstal l hose to val ve.
3. 7L
The PCV val ve i s l ocated on the oi l fi l l er tube. Two
l ocati ng tabs are l ocated on the si de of the val ve.
These 2 tabs fi t i nto a cam l ock i n the oi l fi l l er tube.
An o-ri ng seal s the val ve to the fi l l er tube.
(1) Return PCV val ve back to oi l fi l l er tube by
pl aci ng val ve l ocati ng tabs i nto cam l ock. Press PCV
val ve i n and rotate val ve upward. A sl i ght cl i ck wi l l
be fel t when tabs have engaged cam l ock. Val ve
shoul d be poi nted towards rear of vehi cl e.
(2) Connect PCV l i ne/hose and rubber hose to PCV
val ve.
Fig. 12 PCV Valve/Oil Filler Tube Location
1 - O-RING
2 - LOCATING TABS
3 - CAM LOCK
4 - OIL FILLER TUBE
5 - PCV LINE/HOSE
6 - PCV VALVE
VACUUM LINES
DESCRIPTION
A vacuum schemati c for emi ssi on rel ated i tems can
be found on the VECI l abel . Refer to Vehi cl e Emi s-
si on Control I nformati on (VECI ) Label for l abel l oca-
ti on.
VAPOR CANISTER
DESCRIPTION
A mai ntenance free, EVAP cani ster i s used on al l
gasol i ne powered model s. The EVAP cani ster i s
l ocated near the l eft/front corner of the fuel tank.
OPERATION
The EVAP cani ster i s fi l l ed wi th granul es of an
acti vated carbon mi xture. Fuel vapors enteri ng the
EVAP cani ster are absorbed by the charcoal granul es.
The cani ster serves two functi ons: as a temporary
fuel vapor storage poi nt whi l e refuel i ng the vehi cl e
for the ORVR system, as a temporary vapor storage
poi nt whi l e the engi ne i s runni ng.
Fuel tank pressure vents i nto the EVAP cani ster.
Fuel vapors are temporari l y hel d i n the cani ster unti l
they can be drawn i nto the i ntake mani fol d. The duty
cycl e EVAP cani ster purge sol enoi d al l ows the EVAP
cani ster to be purged at predetermi ned ti mes and at
certai n engi ne operati ng condi ti ons.
Refer to ORVR for addi ti onal i nformati on.
REMOVAL
The EVAP cani ster i s l ocated near front of fuel
tank and next to l eft/rear spri ng. (Fi g. 13).
(2) Di sconnect vacuum hoses/l i nes at EVAP cani s-
ter. Note l ocati on of l i nes before removal .
(3) Remove EVAP cani ster and mounti ng bracket
assembl y from body (2 bol ts).
(4) Remove cani ster-to-mounti ng bracket bol t.
(5) Sl i de 2 cani ster mounti ng pi ns from mounti ng
bracket (Fi g. 14).
INSTALLATION
(1) Sl i de 2 cani ster mounti ng pi ns i nto mounti ng
bracket (Fi g. 14).
(2) I nstal l cani ster-to-mounti ng bracket bol t.
(3) Posi ti on cani ster and bracket assembl y to body.
(4) I nstal l 2 mounti ng bracket bol ts. Ti ghten to 47
Nm (35 ft. l bs.) torque.
(5) Connect vacuum hoses/l i nes at EVAP cani ster.
Fig. 13 EVAP CANISTER LOCATION
1 - LEFT/REAR SPRING
2 - EVAP CANISTER
4 - BRACKET BOLTS
5 - VACUUM LINES
Fig. 14 EVAP CANISTER MOUNTING PINS
1 - MOUNTING PINS
3 - EVAP CANISTER

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