INTRODUCTION
MEASUREMENT AND TORQUE SPECIFICATIONS
INDEX
page
page
Torque Specifications
SPECIFICATION NOTATIONS
TORQUE SPECIFICATIONS
TORQUE CHARTS
A torque chart for fasteners is provided at the end
of each group (of service information). Refer to the
Standard Torque Specifications chart to determine
torque values not listed in the group (Figs. 1 and 2).
....................... 8
INTRODUCTION
10
INTRODUCTION
METRIC CONVERSION
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page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
JUMP STARTING, HOISTING AND TOWING . . . . 9
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
INDEX
page
Classification of Lubricants . . . . . . . .
Components Requiring No Lubrication
Fluid Capacities . . . . . . . . . . . . . . . .
Fuel Requirements . . . . . . . . . . . . . .
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1
2
3
1
page
International Symbols . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Lubrication and Replacement Parts
Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION
Lubrication and maintenance is divided into required and recommended service tasks. The required
service tasks must be completed to verify the emission controls function correctly. The recommended
service tasks should be completed to maintain safety
and durability.
This information will assist the service personnel
in providing maximum protection for each owners
vehicle.
Conditions can vary with individual driving habits.
It is necessary to schedule maintenance as a time interval as well as a distance interval.
It is the owners responsibility to determine the applicable driving condition. Also to have the vehicle
serviced according to the maintenance schedule, and
to pay for the necessary parts and labor.
Additional maintenance and lubrication information is listed in the Owners Manual.
INTERNATIONAL SYMBOLS
Chrysler Corporation uses international symbols to
identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1).
FUEL REQUIREMENTS
All gasoline engines require the use of unleaded
fuel to reduce the potentially harmful effects of lead
to the environment. Also unleaded fuel is necessary
to prevent damage to the catalytic converter/O2 sensor. The fuel must have a minimum octane rating of
87 based on the (R + M)/2 calculation method.
CLASSIFICATION OF LUBRICANTS
Lubricating fluids and chassis lubricants are classified according to standards recommended by the:
Society of Automotive Engineers (SAE).
American Petroleum Institute (API).
0 - 2
ENGINE OIL
API CERTIFICATION MARK
For maximum engine protection during all driving
conditions, install an engine oil that contains the API
Certification Mark (Fig. 2). The API Certification
Mark indicates that the oil is certified to meet the
most critical requirements established by the manufacturer.
Conformance to API specifications is determined by
tests that measure the ability of an oil to control:
Engine wear.
Bearing corrosion.
Sludge.
Varnish.
Oil thickening.
Rust.
Piston deposits.
GEAR LUBRICANTS
A dual grade is also used to specify the viscosity of
multi-purpose gear lubricants.
FLUID CAPACITIES
Fuel Tank
Standard ................................................57 L (15
Optional .................................................83 L (22
Engine Oil W/Filter change
2.5L ......................................................4.2 L (4.5
3.9L ......................................................3.8 L (4.0
5.2L ......................................................4.8 L (5.0
Engine Oil W/O Filter change
2.5L ......................................................3.8 L (4.0
3.9L ......................................................3.3 L (3.5
5.2L ......................................................4.2 L (4.5
gal.)
gal.)
qts.)
qts.)
qts.)
qts.)
qts.)
qts.)
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Cooling System
2.5L ....................................................9.27 L (9.8 qts.)
3.9L ................................................13.25 L (14.0 qts.)
5.2L ................................................13.53 L (14.3 qts.)
Automatic Transmission
Dry fill capacity.*
42RH & 46RH ........................9.0-10.4 L (19-22 pts.)
*Depending on type and size of internal cooler,
length and inside diameter of cooler lines, or use of
an auxiliary cooler, these figures may vary. Refer to
Group-21, Transmission for proper fluid fill procedure.
Manual Transmission
NV3500 ................................................2.0 L (2.1 qts.)
AX15.....................................................3.1 L (3.3 qts.)
Transfer Case
NP231 ..................................................1.2 L (2.5 pts.)
Fill to bottom of fill hole.
Front Axle
N5 W/7-1/4 in......................................1.4 L (3.0 pts.)
Rear Axle
7-1/4 in.................................................1.4 L (3.0 pts.)
8-1/4 in.................................................2.1 L (4.4 pts.)
Power Steering
N1(2WD) ............................................0.81 L (1.7 pts.)
N5(4WD) ............................................1.18 L (2.5 pts.)
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SCHEDULE-A
ONCE A MONTH
Check tire pressure and look for unusual tire wear
or damage.
Check fluid levels of coolant reservoir, brake master cylinder, power steering and transmission. Add
fluid as required.
Check all lights and other electrical items for correct operation.
Inspect battery and clean and tighten terminals as
required.
AT EACH OIL CHANGE
Inspect exhaust system.
Inspect brake hoses.
Rotate the tires at each oil change interval shown
on Schedule- A: (7,500 Miles) or every other interval
shown on Schedule-B (6,000 Miles).
Check engine coolant level, hoses, and clamps.
If your mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
Lubricate 4x4 steering linkage.
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SCHEDULE-B
3,000 MILES (4 800KM)
Change engine oil.
Lubricate steering linkage.
6,000 MILES (9 600KM)
Change engine oil.
Replace engine oil filter.
Lubricate steering linkage.
9,000 MILES (14 400KM)
Change engine oil.
Lubricate steering linkage.
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page
Towing Recommendations . . . . . . . . . . . . . . . . . . . 10
Towing When Keys Are Not Available . . . . . . . . . . 13
Two-Wheel-Drive Vehicle Towing . . . . . . . . . . . . . . 11
JUMP STARTING
CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle
charging system can result.
0 - 10
start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
When using a Booster vehicle, disconnect BLACK
cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal.
Disconnect RED cable clamp from battery positive
terminal on disabled vehicle.
HOISTING RECOMMENDATIONS
Refer to the Owners Manual for emergency vehicle
lifting procedures.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a Dakota vehicle (Fig. 2). Support the vehicle
in the raised position with jack stands at the front
and rear ends of the frame rails.
HOIST
A vehicle can be lifted with:
A single-post, frame-contact hoist.
A twin-post, chassis hoist.
A ramp-type, drive-on hoist.
When a frame-contact type hoist is used, verify that the lifting pads are positioned properly
(Fig. 2).
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST.
TOWING RECOMMENDATIONS
A vehicle equipped with SAE approved sling-type
towing equipment or a wheel-lift towing device can
be used to tow all DAKOTA vehicles. When towing a
4WD vehicle, use tow dollies under the opposite end
of the vehicle. A vehicle with a flat-bed device can
also be used to transport a disabled vehicle (Fig. 3).
A wooden crossbeam may be required for proper
connection when using the sling-type, front-end towing method.
SAFETY PRECAUTIONS
The following safety precautions must be observed when towing a vehicle.
Secure loose and protruding parts.
Always use a safety chain system that is independent of the lifting and towing equipment.
Do not allow towing equipment to contact the disabled vehicles fuel tank.
Do not allow anyone under the disabled vehicle
while it is lifted by the towing device.
Do not allow passengers to ride in a vehicle being
towed.
Always observe state and local laws regarding towing regulations.
Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other
motorists.
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0 - 12
2WDAUTOMATIC TRANSMISSION
Provided the transmission is operable, tow only in
NEUTRAL at speeds not to exceed 30 mph (50
km/h) and distances less than 15 miles (25km/h).
If the vehicle is to be towed more than 15 miles,
the propeller shaft should be disconnected or place
tow dollies under rear wheels.
2WDMANUAL TRANSMISSION
To reduce the possible damage of transmission components, the propeller shaft must be removed or
place tow dollies under the rear wheels before towing.
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17
19
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19
14
16
page
Engine Oil . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Change and Filter Replacement
Exhaust System . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . .
Ignition Cables, Distributor Cap and Rotor
PCV/Crankcase Air Inlet Filter . . . . . . . . .
Rubber/Plastic Components . . . . . . . . . .
Spark Plugs . . . . . . . . . . . . . . . . . . . . . .
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14
15
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18
ENGINE BREAK-IN
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER.
DO NOT WASH SKIN WITH GASOLINE, DIESEL
FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT.
DO NOT POLLUTE, DISPOSE OF USED ENGINE
OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.
0 - 15
FILTER SPECIFICATION
All engines are equipped with a high quality fullflow, throw-away type oil filter. The same type of filter is recommended when the filter is changed.
OIL FILTER REMOVAL
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter
(Fig. 4).
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0 - 17
SERVICE/REPLACEMENT
(1) Remove the air cleaner cover.
(2) Remove the air cleaner element (Figs. 6 and 7).
(3) Remove paper element from air cleaner body.
Hold a shop light on throttle body side of element.
Inspect air intake side of element. If element is saturated with oil or light is not visible, replace element. If element is saturated with oil, perform
crankcase ventilation system tests.
(4) Wash the air cleaner cover and body/housing
with cleaning solvent and wipe dry.
(5) Install the air cleaner element and attach the
cover to the body/housing (Figs. 6 and 7).
FUEL SYSTEM
INSPECTION
It is recommended that the fuel system filler cap,
nozzle, tubes, hoses, and connections be inspected periodically.
FUEL FILTER
The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diagnostic and service procedures refer to Group 14, Fuel
System.
FUEL USAGE STATEMENTGASOLINE
ENGINES
Dakota vehicles are designed to meet all emission
regulations and provide excellent fuel economy using
high quality unleaded gasoline. Only use unleaded
gasolines having a minimum posted octane of 87.
If the vehicle develops occasional light spark knock
(ping) at low engine speeds, this is not harmful. However, continued heavy knock at high speeds can
cause damage and should be checked immediately.
0 - 18
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
materials that contain oxygen such as alcohol, MTBE
and ETBE. The type and amount of oxygenate used
in the blend is important. The following are generally
used in gasoline blends:
ETHANOL
Ethanol (Ethyl or Grain Alcohol) properly blended,
is used as a mixture of 10 percent ethanol and 90
percent gasoline. Gasoline with ethanol may be
used in your vehicle.
METHANOL
CAUTION: Do not use gasolines containing methanol. Use of methanol/gasoline blends may result in
starting and driveability problems. In addition, damage may be done to critical fuel system components.
Methanol (Methyl or Wood Alcohol) is used in a variety of concentrations blended with unleaded gasoline. You may encounter fuels containing 3 percent or
more methanol along with other alcohols called cosolvents.
Problems that are the result of using methanol/gasoline blends are not the responsibility of Chrysler
Corporation. They may not be covered by the vehicle
warranty.
MTBE/ETBE
Gasoline and MTBE (Methyl Tertiary Butyl Ether)
blends are a mixture of unleaded gasoline and up to
15 percent MTBE. Gasoline and ETBE (Ethyl Tertiary Butyl Ether) are blends of gasoline and up to
17 percent ETBE. Gasoline blended with MTBE or
ETBE may be used.
CLEAN AIR GASOLINE
Many gasolines are now being blended that contribute to cleaner air, especially in those areas of the
country where air pollution levels are high. These
new blends provide a cleaner burning fuel and some
are referred to as Reformulated Gasoline.
In areas of the country where carbon monoxide levels are high, gasolines are being treated with oxygenated materials such as MTBE, ETBE and ethanol.
Chrysler Corporation supports these efforts toward
cleaner air and recommends the use of these gasolines as they become available.
IGNITION TIMING
Test and adjust, if necessary, the timing at the time
specified in the maintenance schedule. Refer to the
specifications on the engine Emission Control label
(located in the engine compartment). Refer to Group
8D, Ignition Systems and to Group 25, Emission Control Systems for additional service information.
SPARK PLUGS
Ignition spark plugs should be replaced at the
mileage interval described in the Lubrication and
Maintenance Schedules. Refer to the General Information section of this group. For proper service procedures refer to Group 8D, Ignition Systems.
BATTERY
WARNING: WEAR SAFETY GLASSES, RUBBER
GLOVES AND PROTECTIVE CLOTHING WHEN HANDLING/SERVICING A BATTERY. THE BATTERY
ELECTROLYTE CONTAINS SULFURIC ACID AND
WILL CAUSE HARM IF IT CONTACTS SKIN, EYES
OR CLOTHING. IT WILL ALSO DAMAGE PAINTED
(AS WELL AS UN-PAINTED) SURFACES OF A VEHICLE. IF SULFURIC ACID CONTACTS ANY OF
THESE, FLUSH IMMEDIATELY WITH LARGE
AMOUNTS OF WATER. IF SULFURIC ACID CONTACTS SKIN OR EYES, GET IMMEDIATE MEDICAL
ATTENTION. DO NOT SMOKE IN THE VICINITY OF A
BATTERY. KEEP OPEN FLAMES AND SPARKS
AWAY FROM BATTERY FILLER CAPS BECAUSE
EXPLOSIVE GAS IS ALWAYS PRESENT.
Inspect battery tray, hold down and terminal connections when other under hood service is performed.
For proper diagnostic procedures refer to Group 8A,
Battery/Starting/Charging System Diagnostics. For
service and cleaning procedures refer to Group 8B,
Battery/Starter Service.
RUBBER/PLASTIC COMPONENTS
CAUTION: Plastic hoses or wire harness covers will
melt or deform when exposed to heat from exhaust
system or engine manifolds.
Position plastic or rubber components away from
moving parts in engine compartment or under vehicle, or damage will result.
Do not allow rubber engine mounts or other components to become oil contaminated, repair cause
of oil contamination and clean area.
All rubber and plastic components should be inspected when engine compartment or under vehicle
service is performed. When evidence of deterioration
exists, replacement is required. To reduce deterioration of rubber components, Chrysler Corporation recommends Mopar Foamy Engine Degreaser or
equivalent be used to clean engine compartment of
oil and road grime.
ENGINE MOUNTS
Inspect the rubber in the engine mounts for excessive wear. Slight wear at the ends will not affect the
functioning of an engine mount. If excessive engine
movement is detected, the engine mount(s) should be
replaced.
0 - 19
EXHAUST SYSTEM
The exhaust system should be inspected when under vehicle service is performed or as specified in the
Lubrication and Maintenance Schedules.
INSPECTION
When inspecting an exhaust system, inspect for
cracked or loose joints, stripped screw/bolt threads,
corrosion damage, and worn or broken hangers
(Slight cracking in rubber isolator or hanger is acceptable). Replace all components that are corroded
or damaged. Do not attempt repair. Also, inspect for
the following obvious conditions and correct as necessary:
Exhaust system leaks, damage, misalignment.
Contact with body panels metal or the frame.
Catalytic converter bulging or excessive heat damage.
CAUTION: A catalytic converter will become contaminated if leaded gasoline is burned in the engine. If this occurs, the complete converter must be
replaced.
For proper service procedures see Group 11, Exhaust System and Intake Manifold.
AIR-CONDITIONER COMPRESSOR
The lubricant level in the air-conditioner compressor should be checked if there are indications that oil
was lost. Loss of lubricating oil usually accompanies
a loss of refrigerant.
For additional information involving the A/C system, refer to Group 24, Heater And Air Conditioning.
0 - 20
Automatic Transmission . . . . . .
Clutch and Brake Pedal Bushings
Clutch Master Cylinder . . . . . . .
Drive Shafts . . . . . . . . . . . . . . .
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22
20
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23
page
Front and Rear Axles . . . . . . . .
Manual Transmission . . . . . . . .
Rubber and Plastic Hoses/Tubing
Transfer Case (4WD Vehicles) . .
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23
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MANUAL TRANSMISSION
The manual transmission should be inspected for
oil leaks and proper oil level when other under vehicle service is performed.
LUBRICANT SPECIFICATION
When it becomes necessary to add to or change the
lube oil in a Dakota manual transmission, use the
following lubricant:
AX-15SAE 75W-90, API Quality Grade GL-5
gear lubricant (MOPAR P/N 4649264).
NV3500MOPAR Manual Trans. Lubricant (P/N
4761526).
LUBRICANT LEVEL
The fill-hole plug for the AX-15 manual transmissions is located on the left side of the case (Fig. 4)
and the fill-hole plug for the NV3500 manual transmissions is located on the right side of the case (Fig.
5). Determine the lubricant level according to the following procedure.
0 - 22
AUTOMATIC TRANSMISSION
The automatic transmission fluid should be
changed and bands adjusted at the intervals described in the Maintenance Schedules section of this
Group. The automatic transmission should be inspected for fluid leaks and proper fluid level when
other under hood service is performed. Refer to
Group 21, Transmission for proper service procedures.
CAUTION: To minimize fluid contamination, verify
that dipstick is seated in the fill tube after fluid level
reading is taken.
FLUID LEVEL
The transfer case fill hole plug is located at the
rear of the housing (Fig. 7).
0 - 23
FLUID SPECIFICATION
If it becomes necessary to add fluid (ATF) to a Dakota transfer case, use MOPAR ATF PLUS or an
equivalent Dexron III ATF.
LUBRICANT SPECIFICATION
MOPAR Hypoid Lubricant, SAE 80W-90 or equivalent should be used in all Dakota axles.
In addition, a friction additive (friction modifier)
must also be used in a limited-slip differential.
LUBRICANT LEVEL
(1) Raise and support the vehicle.
(2) The rear and front axles (4WD vehicles) differential housings have a rubber, PRESS-IN type fill
hole plug (Figs. 8 and 9). Pry the fill hole plug from
the differential housing.
(3) The lubricant level should be within 10 mm
(3/8 in.) of the bottom edge of the fill hole plug opening for rear axles. It should be between 10 mm (3/8
in.) and 13-mm (1/2-in.) below the bottom edge of the
fill hole plug opening for front axles (4WD vehicles).
DRIVE SHAFTS
Lubricate at the intervals described in the Maintenance Schedule section of this Group. Refer to Group
16, Propeller Shafts for proper service procedures.
CAUTION: It is very important that drive shafts be
lubricated at periodic intervals and that the specified type of lubricant be used. Failure to properly
lubricate could result in premature wear of drive
shaft components.
0 - 24
HOSE/TUBING INSPECTION
Vehicle operating conditions determine the useable
life of underbody hoses and tubing (Figs. 10 and 11).
These conditions include:
The extent and quality of vehicle maintenance.
The geographic area of vehicle operation.
The length of exposure time to excess heat and
chemical contaminants.
(1) Inspect all hose and tubing fittings for looseness and corrosion. Inspect the rubber hoses for brit-
0 - 25
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28
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page
Power Brake System . .
Power Steering System
Speedometer Cable . .
Steering Linkage . . . . .
Tires . . . . . . . . . . . . . .
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STEERING LINKAGE
The steering linkage (Figs. 2 and 3) should be lubricated and inspected at the intervals described in
the Maintenance Schedules section of this Group. Refer to Group 2, Front Suspension and Axles for
proper service procedures.
LUBRICANT SPECIFICATION
Use Mopar, Multi-purpose Grease or NLGI GC-LB
lubricant equivalent to lubricate the steering linkage.
0 - 26
LUBRICANT SPECIFICATION
Wheel bearings should be lubricated with a lubricant that is identified as NLGI GC-LB lubricant.
CAUTION: Do not add lubricant to the wheel bearings. Re-pack completely. Mixing of different types
of lubricants in wheel bearings should be avoided.
This could possibly result in excessive thinning and
leakage of the lubricant.
INSPECTION/LUBRICATION
Refer to Group 2, Front Suspension and Axle for
inspection and service procedures.
4WD VEHICLES
All 4WD Dakota vehicles are equipped with permanently sealed front wheel bearings. Refer to Group 2,
Front Suspension for inspection and service procedures.
PRECAUTIONS
Whenever a CV drive shaft is removed from the
steering knuckle, be aware of the following precautions:
Foreign particles must be prevented from the lubricated areas between the bearing and external seal,
and from contacting the outer joint wear sleeve
Inspect the lubricant on the external seal for adequate quantity and quality. If the lubricant is sparse
or is contaminated, the seal should be cleaned and
packed with lubricant
Clean the face of the external seal. Replace any lubricant that was lost during seal cleaning or the disengagement of the shaft
Clean the wear sleeve surface area completely and
add approximately 3 grams of lubricant
LUBRICANT SPECIFICATION
Use high temperature, multi-purpose NLGI GC-LB
lubricant MOPAR Wheel Bearing Lubricant or an
equivalent.
0 - 27
RECOMMENDED MAINTENANCE
The brake fluid level (Fig. 8) should be inspected
when other underhood service is done. With discbrakes, the fluid level can be expected to fall as the
brake pads wear. However, a low fluid level can also
be caused by a leak, and repair will then be necessary. Refer to Group 5, Brakes for proper service procedures.
FLUID LEVEL
The fluid level indicator (dipstick) is attached to
the reservoir cap (Fig. 7). The fluid level in the reservoir can be determined with the fluid either hot or
cold.
CAUTION: Use of a brake fluid that has a lower initial boiling point then specified by FMVSS No. 116,
DOT 3 and SAE J-1703 could result in sudden brake
failure during hard, prolonged braking.
Do not allow petroleum base fluids to contaminate
the brake fluid. Seal damage will result.
0 - 28
TIRES
The condition of the tires should be inspected. The
inflation pressures tested/corrected at the same time
as the engine oil is changed and the oil filter is replaced.
The tires/wheels should be rotated at the intervals
described in the Maintenance Schedules section of
this Group.
INSPECTION
Inspect the tires for excessive wear, damage. Test
the tires for the recommended inflation pressure and
adjust the pressure accordingly. Refer to the tire inflation pressure decal located on the left door face.
Also to Group 22, Tires And Wheels for tire pressure
charts, tire replacement, and tread wear indicators.
ROTATION
Tires/wheels should be rotated according to the recommended interval. The first tire/wheel rotation is
the most important for establishing the prevention of
uneven tread wear. After rotation, adjust the tire inflation pressure to the air pressure recommended on
the decal located on the left door face.
Refer to Group 22, Tires And Wheels for the recommended method of tire/wheel rotation.
BODY COMPONENTS
LUBRICATION REQUIREMENTS
All Dakota cab and cargo box operating mechanisms and linkages should be lubricated when necessary. The door weatherstrip seals should be
lubricated to prolong their life as well as to improve
door sealing.
LUBRICANT SPECIFICATIONS
All applicable exterior and interior vehicle operating mechanisms should be:
Inspected
Cleaned
Pivot/sliding contact areas on the mechanisms
should then be lubricated.
Multi-purpose NLGI GC-LB MOPAR Multi-Mileage
Lubricant or an equivalent, should be used to lubricate the mechanisms. The door weatherstrip seals
should be lubricated with silicone lubricant spray.
Refer to the Body Lubricant Specifications chart below for additional lubricant applications.
LUBRICATION
(1) When necessary, lubricate the cab and cargo
box operating mechanisms with the specified lubricants.
(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray that can soil passenger clothing.
0 - 29
HEADLAMPS
MAINTENANCE SCHEDULE
Every six months check the headlamp beams to ensure that the headlamp beams are correctly positioned.
AIM ADJUSTMENT
Refer to Group 8L, Lamps for headlamp aim adjustment procedures.
SPEEDOMETER CABLE
SERVICE INFORMATION
Speedometer cable lubrication is not necessary. For
service information involving noisy cables, refer to
Group 8E, Instrument Panel and Gauges.
2 - 1
page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 19
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 47
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
FRONT SUSPENSION
Dakota front suspensions are comprised of (Fig 1,
2);
Frame mounted drive axle with CV drive shafts
(4WD)
Steering knuckles
Stabilizer bar
Suspension arms
Coil springs (2WD)
Torsion-bar springs (4WD)
Dual-action shock absorbers
Jounce bumpers (used to limit the travel of the
suspension)
2 - 2
The axle has a fitting for a vent hose used to relieve internal pressure caused by lubricant vaporization and internal expansion.
2 - 3
2 - 4
page
Pre-Alignment Inspection
.................... 4
GENERAL INFORMATION
Front wheel alignment involves the correct positioning of the tire contact patch in relation to the
pavement. The positioning is accomplished through
the suspension and steering linkage adjustments. An
alignment is considered essential maintenance. It
will maintain efficient steering, good directional stability and prevent abnormal tire wear. The most important factors of front end alignment are camber,
caster and toe position.
Routine inspection of the front suspension
and steering components is a good preventative
maintenance practice. Inspection also helps to
ensure safe operation of the vehicle.
CAMBER is the number of degrees the top of the
wheel is tilted either inward or outward. An excessive negative camber angle will cause tread wear at
the inside of the tire. An excessive positive camber
angle will cause tread wear at the outside of the tire
(Fig. 1).
CASTER is the number of degrees of forward or
rearward tilt of the steering knuckles. Forward tilt
provides a negative caster angle. Rearward tilt provides a positive caster angle (Fig. 1).
WHEEL TOE POSITION is the difference between
the leading inside edges and trailing inside edges of
the front tires (Fig. 1). Incorrect wheel toe position is
the most common cause of unstable steering and uneven tire wear. The wheel toe position is the final
front wheel alignment adjustment.
STEERING AXIS INCLINATION ANGLE is measured in degrees and is the angle that the steering
knuckles are tilted (Fig. 1). The inclination angle has
a fixed relationship with the camber angle. This angle will not change except when a spindle or ball
stud is damaged or bent. The angle is not adjustable
and the damaged component(s) must be replaced to
correct mis-alignment.
CAUTION: Do not attempt to modify any suspension or steering component by heating and bending.
PRE-ALIGNMENT INSPECTION
Before starting a front wheel alignment, the following inspection and necessary corrections must be
completed.
2 - 5
2 - 6
TOE POSITION
The wheel toe position adjustment should be the final adjustment.
(1) Start the engine and turn wheels both ways before straightening the wheels. Secure the steering
wheel with the front wheels in the straight-ahead position.
(2) Loosen the tie rod adjustment sleeve clamp
bolts/nuts.
Each front wheel should be adjusted for onehalf of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
29
(3) Adjust the wheel toe position by turning the tie
rod adjustment sleeves as necessary (Fig. 5, 6).
(3) Tighten the tie rod adjustment:
2WD: locknuts to 75 Nzm (55 ft. lbs.) torque
4WD: clamp bolts to 23 Nzm (17 ft. lbs.) torque.
Position the clamp nut/bolt so that it does not
extend above the top of the sleeve
2 - 7
2 - 8
page
Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lower Ball Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lower Suspension Arm . . . . . . . . . . . . . . . . . . . . . 10
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Steering Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Upper Ball Stud . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Upper Suspension Arm . . . . . . . . . . . . . . . . . . . . . 12
Wheel Hub and Bearings . . . . . . . . . . . . . . . . . . . . 8
SERVICE INFORMATION
Periodic lubrication of the front suspension (steering) system components is required. Refer to Group
0, Lubrication And Maintenance for the recommended maintenance schedule.
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber
bushings must never be lubricated.
2 - 9
INSTALLATION
(1) Install the new bearing cup(s) with an appropriate installation tool.
(2) Apply a coating of MOPARt Wheel Bearing
Grease (or an equivalent lubricant) to entire inner
surface area of hub/rotor. Install inner wheel bearing
in the hub/rotor. Install a new bearing seal.
(3) Inspect bearing and seal contact surfaces on
spindle for burrs and/or roughness.
(4) Remove all rough contact surfaces from spindle.
Apply a coating of lubricant.
CAUTION: Use care to prevent inner wheel bearing
and seal from contacting spindle threads during installation (Fig. 1).
(5) Carefully slide the hub/rotor onto spindle (Fig.
1). Install outer wheel bearing, washer and retaining
nut.
(6) Tighten the nut to 41-54 Nzm (30-40 ft. lbs.)
torque to preload bearing while rotating the hub/rotor. Stop hub/rotor and loosen nut to completely release bearing preload torque. Tighten the nut fingertight and install the nut lock. Install a new cotter
pin.
(7) The adjustment (above) should have 0 to 0.076
mm (0 to 0.003 in.) end play.
(8) Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust
cap with lubricant. Install the cap.
(9) Install disc brake caliper. Refer to Group 5,
Brakes.
(10) Install the wheel and tire.
SHOCK ABSORBER
REMOVAL
(1) Remove the hardware from the shock absorber
stud (Fig. 2).
(2) Raise the vehicle, remove the lower bolts and
remove the shock absorber (Fig. 2).
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the nut and washer from the stabilizer
bar link bolt at the lower suspension arm on each
side of the vehicle (Fig. 3).
(3) Remove the link bolt, retainers, insulators and
spacer from each lower suspension arm (Fig. 3).
(4) Remove the bolts from the U-shaped retainer.
Remove the retainer, and stabilizer bar from the vehicle (Fig. 3).
(5) If necessary, remove the bushings from the stabilizer bar (Fig. 3).
2 - 10
INSTALLATION
(1) If removed, install the bushings on the stabilizer bar (Fig. 3).
Ensure the stabilizer bushings are prealigned before the bar is installed to the
bracket.
(2) Place the stabilizer bar adjacent to the frame
side rail brackets (Fig. 3). Install the U-shaped retainer and the bolts. Tighten the bolts finger-tight.
Check the alignment of the bar to ensure
there is no interference with the either frame
rail or chassis component. Spacing should be
equal on both sides.
(3) Install the link bolt, retainers, spacer and insulators at the lower suspension arm (Fig. 3) on each
side.
(4) Install the washers and the nuts on the anchor
bolts (Fig. 3). Tighten the nuts to 23 Nzm (17 ft. lbs.)
torque.
(5) Tighten the U-shaped support bracket bolts
(Fig. 3) to 54 Nzm (40 ft. lbs.) torque.
INSTALLATION
(1) Tape the isolator pad to the top of the coil
spring. Position the spring in the lower suspension
arm well. Be sure that the coil spring is seated in the
well (Fig. 2). The top of the spring is flat or
closed with groves at the end of the coil. The
ramped or open end of the coil spring is the
bottom.
(2) Install Spring Compressor DD-1278 up through
the lower suspension arm and coil spring.
(3) Tighten the tool nut to compress the coil
spring.
(4) Place two jack stands under the lower suspension arm immediately outward from where the bushings are located. Adjust the jack stands tight against
the lower suspension arm.
(5) Raise the jack stands until the isolator pad/coil
spring is correctly seated top and bottom (Fig. 2).
(6) Install the lower suspension arm bolts and
nuts. Tighten the front nut to 176 Nzm (130 ft. lbs.)
torque and the rear nut to 108 Nzm (80 ft. lbs.)
torque.
(7) Remove the spring compressor tool and the jack
stands.
(8) Install the stabilizer bar.
(9) Install the shock absorber.
(10) Install the wheel and tire.
COIL SPRING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the applicable front wheel.
(3) Disconnect the stabilizer bar from the lower
suspension arm.
(4) Remove the shock absorber.
(5) Install Spring Compressor DD-1278 up through
the lower suspension arm and coil spring (Fig. 2).
Spring Compressor DD-1278 will maintain the
spring in a semi-compressed condition. This
will retain the spring in place until the lower
suspension arm is detached from and lowered
for spring removal.
(6) Tighten the tool nut to compress the coil
spring.
REMOVAL
(1) Raise and support vehicle.
(2) Remove disc brake caliper from steering
knuckle and rotor. Refer to Group 5, Brakes.
(3) Remove shock absorber.
(4) Follow the procedure outlined in Coil Spring
Removal.
(5) Position Ball Stud Remover C-3564-A as shown
(Fig. 4). Rotate threaded portion of tool to apply force
to the lower ball stud.
(6) Strike steering knuckle sharply with a hammer
to loosen ball stud from knuckle. Do not force ball
stud out from knuckle with the tool.
(7) Separate ball stud from steering knuckle arm.
2 - 11
2 - 12
2 - 13
REMOVAL
(1) Place a jack under outer end of lower suspension arm. Raise and support the vehicle.
(2) Remove the wheel and tire.
(3) Remove cotter pin and nut from upper ball
stud.
(4) Position Ball Stud Remover C-3564-A as shown
(Fig. 7). Rotate threaded portion of tool to apply force
to the upper ball stud.
(5) Strike steering knuckle sharply with a hammer
to loosen ball stud from knuckle. Do not force ball
stud out from knuckle with the tool.
(6) Remove ball stud seal.
(7) Use Removal/Installation Tool C-3561 to unthread ball stud from suspension arm.
INSTALLATION
(1) Thread new ball stud in with Tool C-3561.
Tighten ball stud to 170 Nzm (125 ft. lbs.) torque. The
gap between ball stud Hex and suspension arm bore
is 0.25 to 1.25mm (0.01 to 0.05 inch).
(2) Install new seal over ball stud. Make sure seal
is securely locked in-place.
(3) Position steering knuckle on upper ball stud.
Tighten the upper ball stud nut to 142 Nzm (105 ft.
lbs.) torque. Install a new cotter pin.
(4) Install the wheel and tire.
STEERING KNUCKLE
REMOVAL
(1) Raise and support the vehicle. Place a jack under outer end of lower suspension arm.
(2) Remove the wheel and tire.
(3) Remove disc brake caliper. Refer to Group 5,
Brakes.
(4) Remove tie-rod from steering knuckle arm. Refer to Group 19, Steering.
(5) Remove ABS sensor wire from lower suspension
arm. Remove the rotor dust shield and ABS pick-up
from knuckle (Fig. 9).
(6) Remove cotter pins and nuts from upper and
lower ball studs.
(7) Use Ball Stud Remover C-3564-A to free upper
and lower ball joints from steering knuckle (Fig. 4, 7).
(8) Remove tool and steering knuckle assembly.
(9) Remove steering arm from steering knuckle
(Fig. 10).
INSTALLATION
(1) Install steering arm on knuckle. Tighten the
nuts to 294 Nzm (217 ft. lbs.) torque (Fig. 10).
(2) Position steering knuckle on upper and lower
ball studs and install nuts. Tighten lower nut to 183
Nzm (135 ft. lbs.) torque. Tighten upper nut to 142
Nzm (105 ft. lbs.) torque. Install new cotter pins.
2 - 14
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16
14
14
15
17
SERVICE INFORMATION
Periodic lubrication of the front suspension (steering) system components is required. Refer to Group
0, Lubrication And Maintenance for the recommended maintenance schedule.
page
Torsion Bar . . . . . . . . . .
Upper Ball Stud . . . . . .
Upper Suspension Arm .
Wheel Hub and Bearings
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15
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16
14
REMOVAL
(1) Remove the CV drive shaft. Refer to CV Drive
Shaft Removal in this Group.
(2) Remove disc brake caliper from steering
knuckle and rotor. Refer to Group 5, Brakes.
(3) Remove brake rotor from the hub (Fig. 1).
SHOCK ABSORBER
REMOVAL
(1) Remove the hardware from the shock absorber
stud (Fig. 3).
(2) Raise the vehicle, remove the lower bolts and
remove the shock absorber (Fig. 3).
INSTALLATION
(1) Install the lower retainer and grommet on the
shock absorber stud. Insert the replacement shock
absorber through the frame hole. Install the lower
bolt (Fig. 3).
STABILIZER BAR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the bolts attaching the stabilizer bar
rear support bracket to the frame crossmember
bracket (Fig. 4).
(3) Remove the bolts attaching the retainer to the
lower suspension arm. Remove the retainer and stabilizer bar from the vehicle (Fig. 4).
(4) If necessary, remove the rear support brackets
and the bushings from the stabilizer bar (Fig. 4).
INSTALLATION
(1) If removed, install the bushings and the rear
support brackets on the stabilizer bar (Fig. 4).
(2) Place the stabilizer bar rear support brackets
adjacent to the frame crossmember brackets (Fig. 4)
and install the bolts. Tighten the bolts finger-tight.
Check the alignment of the bar to ensure there
is no interference with the either frame rail or
chassis component. Spacing should be equal on
both sides.
(3) Attach the stabilizer bar to the lower suspension arm with the retainer and bolts (Fig. 4). Tighten
the bolts to 27 Nzm (20 ft. lbs.) torque.
(4) Tighten the rear support bracket bolts (Fig. 4)
to 27 Nzm (20 ft. lbs.) torque.
2 - 15
TORSION BAR
SERVICE INFORMATION
The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or
L, for right or left. The bars do not have a front or
rear end and can be installed with either end facing
forward.
REMOVAL
(1) Remove the suspension arm jounce bumpers
before raising vehicle.
(2) Raise and support the vehicle with the front
suspension hanging.
(3) Turn the adjustment bolt counterclockwise to
release spring load (Fig. 5). Remove the adjustment
bolt from swivel.
2 - 16
INSTALLATION
(1) Insert torsion bar ends into anchor and suspension arm (Fig. 5).
(2) Position anchor and bushing in frame crossmember. Install adjustment bolt through bushing
and anchor and into swivel (Fig. 5).
(3) Turn adjustment bolt clockwise to apply a
spring load.
(4) Lower vehicle and adjust the front suspension
height. Refer to Wheel Alignment in this group.
(5) Install suspension arm jounce bumpers.
INSTALLATION
(1) Position the lower suspension arm at the frame
rail brackets. Install the pivot bolts and nuts (Fig. 6).
Tighten the nuts finger-tight.
(2) Insert the ball stud into steering knuckle. Install and tighten the retaining nut to 142 Nzm (115
ft. lbs.) torque. Install a new cotter pin.
(3) Follow the procedure outlined in Torsion Bar
Installation.
(4) Install shock absorber lower bolt.
(5) Install the CV drive shaft. Refer to CV Drive
Shaft Installation in this group.
(6) Install the stabilizer bar to the lower suspension arm.
(7) Tighten the lower suspension front pivot nut to
108 Nzm (80 ft. lbs.) torque. Tighten rear pivot bolt to
176 Nzm (130 ft. lbs.) torque.
(8) Adjust the front suspension height. Refer to
Wheel Alignment in this Group.
2 - 17
REMOVAL
(1) Place a jack under outer end of lower suspension arm. Raise and support the vehicle.
(2) Remove the wheel and tire.
(3) Remove cotter pin and nut from upper ball
stud.
(4) Position Ball Stud Remover C-3564-A. Rotate
threaded portion of tool to apply force to the upper
ball stud.
(5) Strike steering knuckle sharply with a hammer
to loosen ball stud from knuckle. Do not force ball
stud out from knuckle with the tool.
(6) Remove ball stud seal.
(7) Use Removal/ Installation Tool C-3561 to unthread ball stud from suspension arm.
INSTALLATION
(1) Thread new ball stud in with Tool C-3561.
Tighten ball stud to 170 Nzm (125 ft. lbs.) torque. The
gap between ball stud Hex and suspension arm bore
is 0.25 to 1.25mm (0.01 to 0.05 inch).
(2) Install new seal over ball stud. Make sure seal
securely locked in-place.
(3) Position steering knuckle on upper ball stud.
Tighten the upper ball stud nut to 142 Nzm (105 ft.
lbs.) torque. Install a new cotter pin.
(4) Install the wheel and tire.
STEERING KNUCKLE
REMOVAL
(1) Remove the CV drive shaft. Refer to CV Drive
Shaft Removal in this Group.
(2) Turn torsion bar adjustment bolt counter-clockwise to completely remove tension from torsion bar.
Count the number of turns for installation reference.
(3) Remove shock absorber lower bolt.
(4) Disconnect the stabilizer bar from suspension
arm.
2 - 18
INSTALLATION
(1) Position steering knuckle on upper and lower
ball studs and install nuts. Tighten lower nut to 156
2 - 19
SERVICE DIAGNOSIS
INDEX
page
page
Driveline Snap . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Gear and Bearing Noise . . . . . . . . . . . . . . . . . . . . 19
General Information . . . . . . . . . . . . . . . . . . . . . . . 19
GENERAL INFORMATION
GEAR NOISE
Axle gear noise can be caused by insufficient lubricant. Incorrect backlash, tooth contact, or worn/damaged gears can cause noise.
Gear noise usually happens at a specific speed
range. The range is 30 to 40 mph, or above 50 mph.
The noise can also occur during a specific type of
driving condition. These conditions are acceleration,
deceleration, coast, or constant load.
When road testing, accelerate the vehicle to the
speed range where the noise is the greatest. Shift
out-of-gear and coast through the peak-noise range.
If the noise stops or changes greatly, check for insufficient lubricant. Incorrect ring gear backlash, or
gear damage can cause noise changes.
Differential side and pinion gears can be checked
by turning the vehicle. They usually do not cause
noise in straight-ahead driving. These gears are
loaded during vehicle turns. If noise does occur during vehicle turns, the side or pinion gears could be
worn or damaged. A worn pinion gear mate shaft can
also cause a snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion gear bearings can all produce noise when worn or damaged.
Bearing noise can be either a whining, or a growling
sound.
Pinion gear bearings have a constant-pitch noise.
This noise changes only with vehicle speed. Pinion
bearing noise will be higher because it rotates at a
faster rate. Drive the vehicle and load the differential. If bearing noise occurs the pinion rear bearing is
the source of the noise. If the bearing noise is heard
during a coast, front bearing is the source.
Worn, damaged differential bearings usually produce a low pitch noise. Differential bearing noise is
similar to pinion bearing. The pitch of differential
bearing noise is also constant and varies only with
vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
2 - 20
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
Damaged drive shaft
Missing drive shaft balance weight
Worn, out-of-balance wheels
Loose wheel lug nuts
Worn U-joint
Loose spring U-bolts
Loose/broken rear springs or shackles
Damaged axle shaft bearings
Loose pinion gear nut
Excessive pinion yoke run out
Bent axle shaft
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rear-end vibration. Do not overlook engine accessories, brackets
and drive belts.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
High engine idle speed
Loose engine/transmission/transfer case mounts
Worn U-joints
Loose spring shackles or U-bolts
Loose pinion gear nut and yoke
Excessive ring gear backlash
Excessive differential side gear-to-case clearance
With 2WD vehicles, a worn bushing in the
transmission extension housing can also cause
noise.
The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the vehicle on a hoist with the wheels free to rotate.
Instruct the helper to shift the transmission into
gear. Listen for the noise, a mechanics stethoscope is
helpful in isolating the source of a noise.
2 - 21
2 - 22
2 - 23
CV DRIVE SHAFT
INDEX
page
page
Inner CV Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Outer CV Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rubber Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Service Information . . . . . . . . . . . . . . . . . . . . . . . . 23
Shaft Removal/Installation . . . . . . . . . . . . . . . . . . . 24
SERVICE INFORMATION
outer CV joints. Apply only the specified lubricant amount to each CV joint.
2 - 24
SHAFT REMOVAL/INSTALLATION
REMOVAL
(1) Remove the cotter pin, nut lock, and spring
washer from the stub shaft (Fig. 2).
INNER CV JOINT
INSTALLATION
(1) Insert the CV drive shaft stub into the hub
bearing.
(2) Attach the inner joint flange to the axle shaft
flange (Fig. 5). Tighten the bolts to 90 Nzm (65 ft.
lbs.) torque.
DISASSEMBLY
(1) Remove the CV drive shaft. Refer to CV Drive
Shaft Removal in this Group.
(2) Place the inner CV joint housing in a vise.
(3) Remove the inner rubber boot retaining clamps
and clamp protector. Pull the inner boot back onto
the interconnecting shaft. Discard the retaining
clamps.
(4) Pull the tripod and shaft straight out from the
inner CV joint housing.
(5) Move the snap retaining ring from the groove
behind the tripod (Fig. 7). Slide the tripod toward the
center of the shaft. Remove the C-clip on the outer
end of the shaft (Fig. 8).
(6) Remove the tripod from the shaft. Replace the
boot as necessary.
(7) Remove the lubricant from the interior of the
housing and from the tripod.
(8) Inspect the needle bearing raceways in the
housing and tripod components for excessive wear
and damage. Replace the tripod as a unit only if
necessary.
ASSEMBLY
(1) Slide the boot down enough for work access.
The inner boot will be marked and MUST only be
used on the tripod end.
(2) Install the snap ring past the ring grove (toward the center of the shaft). Slide the tripod onto
the end of the interconnecting shaft. Be sure the
chamfered end of the tripod is adjacent to the C-
2 - 25
2 - 26
OUTER CV JOINT
If the outer CV joint is excessively worn, replace the entire CV joint and rubber boot.
DISASSEMBLY
(1) Remove the CV drive shaft. Refer to CV Drive
Shaft Removal in this Group.
(2) Unsnap the clamp protectors (if installed). Remove retaining clamps from the outer CV joint and
discard. Slide the boot off the outer joint and down
the shaft.
(3) Remove the lubricant to expose the outer CV
joint components (Fig. 10).
2 - 27
(11) Tilt the bearing cage and hub to a vertical position. Remove the cage from the housing. Pull cage
upward and away from the housing (Fig. 14).
(5) Inspect the bearing cage for wear, grooves, ripples, cracks and chipping.
(6) Inspect the bearing hub (Fig. 10) for excessive
wear and scoring on ball raceways.
Polished contact surface areas on the raceways and on the bearing cage spheres are normal. If the joints cause a noise or a vibration,
replace them.
ASSEMBLY
(1) Lightly apply lubricating oil to all the outer CV
joint components (Fig. 9) before assembling them.
(2) Align the bearing hub, cage and housing (Fig.
12) according to the alignment reference marks.
(3) Insert one of the bearing hub lands into a bearing cage window (Fig. 15). Roll the hub into the cage.
Rotate the bearing hub 90 to complete the installation (Fig. 16).
INSPECTION
Inspect the lubricant for contamination. Inspect the
outer CV joint components for defects according to
the following instructions.
(1) Clean all the components with an appropriate
solvent and dry them with compressed air.
(2) Inspect the ball raceways in the housing for excessive wear and scoring.
(3) Examine the stub shaft splines and threads for
damage.
(4) Inspect the balls for pitting, cracks, scoring and
excessive wear. A dull exterior surface is normal.
2 - 28
(8) Position the small-diameter end of the replacement rubber boot on the interconnecting shaft. Retain the boot with a replacement clamp. Refer to CV
Joint Rubber Boots in this Section.
(9) Align the shaft splines to the outer CV joint
splines. Push the outer CV joint until the snap ring
seats in the groove (Fig. 22).
2 - 29
and outer large clamps. The clamps are installed according to the provided instructions below.
RUBBER BOOTS
HANDLING AND CLEANING PRECAUTIONS
Extreme care must be exercised to avoid puncturing or tearing the boots.
The rubber material in shaft boots is not compatible with oil, gasoline, or petroleum-based
cleaning solvents. Do not expose the rubber
boots to any of these fluids. Use only soap and
water to clean the rubber boots. After cleaning,
the rubber boot must be thoroughly rinsed and
dried.
INSPECTION
Look for lubricant around the exterior of a boot.
When a CV drive shaft is removed from the vehicle
for service, the boot should be properly cleaned. Inspect for cracks, tears and scuffed areas on the surfaces. If any of these conditions exist, boot
replacement is recommended.
RETAINING CLAMPS
Two different sizes of ladder type clamps are used
to retain the rubber boots. The same size ladder
clamp is used to retain the small-diameter end of the
inner and outer CV Joint rubber boots. Clamp Installer/Remover C-4124 is used to compress and
tighten the clamp (Fig. 23). Service replacement
clamps use a protective plastic strap over both inner
2 - 30
2 - 31
..........
with Gauge
..........
..........
..........
. . 35
. . 40
. . 37
. . 31
GENERAL INFORMATION
The 7 1/4 inch front axle consists of a cast iron differential housing with axle shaft tubes extending
from either side. The tubes are pressed into and
welded to the differential housing to form a one-piece
axle housing.
The integral type housing, hypoid gear design has
the centerline of the pinion set below the centerline
of the ring gear.
The axle has a fitting for a vent hose used to relieve internal pressure caused by lubricant vaporization and internal expansion.
The axle shafts are retained by C-clips in the differential side gears.
The cover provides a means for inspection and service of the differential without removing the axle.
The axles have the gear ratio listed on a tag. The
tag is attached to the housing cover.
The differential case is a one-piece design. The differential pinion mate shaft is retained with a
threaded roll pin. Differential bearing preload and
ring gear backlash is adjusted by the use of threaded
adjusters. The adjusters are located between the differential bearing cups and housing tubes. Pinion
bearing preload is set and maintained by the use of a
collapsible spacer.
PINION GEAR DEPTH MEASUREMENT WITH
GAUGE SET C-3715-B is used when;
The axle/differential housing is being replaced
The original pinion depth shim pack is lost or misplaced
Replacing the differential case
Replacing pinion and differential bearings
LUBRICANT SPECIFICATIONS
Multi-purpose, hypoid gear lubricant should be
used in the 7 1/4 inch axle. The lubricant should
have MIL-L-2105C and API GL 5 quality specifications. MOPARt Hypoid Gear Lubricant conforms to
both of these specifications.
The factory installed lubricant for the 7 1/4 inch
front axle is SAE 80W 90 gear lubricant
The factory installed lubricant quantity is 4861
fluid oz.
page
General Information . . . . . . . .
Lubricant Change . . . . . . . . . .
Lubricant Specifications . . . . . .
Pinion Gear Shaft Removal . . .
Pinion Shaft Seal Replacement
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31
33
31
38
34
2 - 32
2 - 33
LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle
has been recently driven.
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the differential housing cover.
(3) Remove the differential housing cover and
drain the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth. Do not use water,
steam, kerosene or gasoline for cleaning.
2 - 34
Install the housing cover within 5 minutes after applying the sealant. If not installed the
sealant must be removed and another bead applied.
(7) Install the cover and any identification tag.
Tighten the cover bolts in a criss-cross pattern to 47
Nzm (35 ft. lbs.) torque.
(8) Refill the differential with MOPARt Hypoid
Gear Lubricant within 13 mm (1/2 in.) below the fill
plug hole.
(9) Install the fill hole plug and lower the vehicle.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer C-4076-A
and Handle C-4735.
2 - 35
2 - 36
CAUTION: Inspect the housing bore for burrs. Remove them if they exist.
2 - 37
2 - 38
RING GEAR
Do not remove the ring gear from case unless
the runout must be measured.
(1) Clamp the case (with the ring gear bolts facing
upward). Use a vise equipped with soft jaws (brass).
(2) Remove and discard the ring gear bolts. The
bolts have left-hand threads. Use a hammer and a
brass drift to force the ring gear loose from the case
pilots. Remove the ring gear.
2 - 39
2 - 40
2 - 41
Depth shims are available in 0.001-inch increments from 0.020 inch to 0.038 inch.
(10) Note the etched number on the face of the
drive pinion gear. The numbers represent thousandsof-an-inch deviation from the standard. If the number is - (negative), add that value to the required
thickness of the depth shim(s). If the number is +
(positive), subtract that value from the thickness of
the depth shim(s). If the number is 0, no change is
necessary.
(11) Remove the tools from the differential housing.
(12) Position the depth shim(s) on the pinion gear.
Install the rear bearing with Installer C-3717 (Fig.
27). Be sure the contact surfaces are clean and without foreign particles.
(13) Lubricate the pinion gear front and rear bearings with gear lubricant.
(14) Install the pinion gear in the housing. Install
the new collapsible spacer at the end of the pinion
gear. Install the pinion gear front bearing.
(15) Install the pinion yoke with Remover/Installer
C-3718 and Wrench C-3281 (Fig. 28).
It is necessary to use the tools (above) to correctly seat the front bearing on the drive pinion gear shaft (Fig. 28).
CAUTION: Use care to prevent collapsing preload
collapsible spacer during installation of the yoke
and seating the front bearing.
(16) Remove yoke and tools from the pinion gear.
2 - 42
(20) Retain pinion yoke with Wrench C-3281. Initially tighten the drive pinion gear shaft nut enough
to remove the bearing end play. While tightening, rotate the pinion shaft to ensure the bearing rollers are
correctly seated (Fig. 28).
(21) Tighten the pinion nut to (Fig. 30) 285 Nzm
(210 ft. lbs.) torque (minimum).
(22) Remove the tools from the shaft. Rotate the
pinion several complete revolutions (both directions)
to additionally seat the bearing rollers.
2 - 43
load torque is 1 Nzm (10 in. lbs.) torque in addition to the torque measured and recorded
during disassembly.
2 - 44
2 - 45
2 - 46
2 - 47
AXLE SPECIFICATIONS
7 1/4 AXLE
Axle Type ................................Semi-floating, hypoid
Lubricant...............................................SAE 80W-90
Lube Capacity ..................................1.4 L (3.0 pts.)
Axle Ratio .........................................3.21, 3.55, 3.90
Differential
Case Clearance ...........................0.30 mm (0.012 in.)
TORQUE SPECIFICATIONS
FRONT SUSPENSION COMPONENTS2WD
DESCRIPTION ................................................TORQUE
Shock Absorber
Upper Nut....................................41 Nzm (30 ft. lbs.)
Lower Bolts ...............................23 Nzm (200 in. lbs.)
Lower Suspension Arm
Front Nut.................................176 Nzm (130 ft. lbs.)
Rear Nut ....................................108 Nzm (80 ft. lbs.)
Ball Stud Nut ..........................183 Nzm (135 ft. lbs.)
Upper Suspension Arm
Pivot Bar Nuts ........................210 Nzm (155 ft. lbs.)
Ball Stud Nut ..........................142 Nzm (105 ft. lbs.)
Stabilizer Bar
Clamp Bolt...................................54 Nzm (40 ft. lbs.)
Link Nut ......................................23 Nzm (17 ft. lbs.)
Support Bracket Bolts .............30 Nzm (22.5 ft. lbs.)
ft. lbs.)
ft.
ft.
ft.
ft.
lbs.)
lbs.)
lbs.)
lbs.)
CV DRIVE SHAFT
DESCRIPTION ................................................TORQUE
Axle Shaft
Flange Bolts.................................90 Nzm (65 ft. lbs.)
Axle Nut...................................258 Nzm (190 ft. lbs.)
7 1/4 AXLE
DESCRIPTION ................................................TORQUE
Diff. Cover Bolt ........................47 Nzm (35 ft. lbs.)
Bearing Cap Bolt .....................61 Nzm (45 ft. lbs.)
Ring Gear Bolt .........................95 Nzm (70 ft. lbs.)
3 - 1
page
GENERAL INFORMATION
SUSPENSION
Dakota rear suspensions are comprised of;
Drive axle
Leaf springs
Dual-action shock absorbers
Jounce bumpers (used to limit the travel of the
suspension)
The rear suspension design uses semi-elliptic
multi-leaf springs and a solid drive axle. The forward
end of the springs are mounted to the frame rail
hangers through rubber bushings. The bushings isolate road noise as the springs move. The rearward
end of the springs are attached to the frame by the
use of shackles. Again the spring and shackles use
rubber bushings to isolate road noise. The shackles
allow the springs to change their length as the vehicle moves over various road conditions. The spring
and axle travel is limited through the use of rubber
bumpers mounted on the frame.
Suspension components that use rubber bushings
should be tightened with the vehicle at the normal
height. Rubber bushings must never be lubricated.
The springs are attached to the axle pads with Ubolts and plates. The springs use a center bolt that
aligns and holds the spring leafs in position. The bolt
is also used to locate the spring assembly to the axle
pad which is welded to the axle shaft tubes.
Ride control is accomplished through the use of dual-action shock absorbers. The shocks dampen the
jounce and rebound as the vehicle travels over various road conditions. The top of the shock absorbers
are bolted to the frame crossmember. The bottom of
the shocks are bolted to the axle bracket.
The cover provides a means for inspection and service without removing the axle from the vehicle.
A small, gear ratio identification tag is attached to
the housing cover.
The rear wheel anti-lock (RWAL) brake speed sensor is attached to the top of the differential housing
(Fig. 1). A seal is located between the sensor and the
wire harness connector. The seal must be in-place
when the wire connector is connected to the
sensor. The RWAL brake exciter ring is press-fitted
onto the differential case against the flange.
AXLES
The 7 1/4 or 8 1/4 Inch axle housings consist of a
cast iron center section. They also have two steel axle
shaft tubes that are pressed into and welded to the
differential housing.
3 - 2
IDENTIFICATION
The diameter of the ring gear can be determined
from the size of the axle shaft tubes.
The 7 1/4 Inch axle has shaft tubes that are 2.5inch (63.5-mm) diameter at the inner end. The outer
end is 3.0-inch (76.2-mm) diameter
The 8 1/4 Inch axle has axle shaft tubes that have
a 3.0-inch (76.2-mm) diameter at both ends
The axle differential covers can be used for identification (Fig. 2, 3).
travel a greater distance than the inside wheel in order to complete a turn. This difference must be compensated for in order to prevent the wheels from
scuffing and skidding through the turn. To accomplish this, the differential becomes effective allowing
the axle shafts to turn at unequal speeds (Fig. 5). In
this instance, the input torque applied to the pinion
gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite direc-
3 - 3
3 - 4
SHOCK ABSORBER
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the shock absorber lower nut and bolt
from the axle bracket (Fig. 1, 2).
(3) Remove the shock absorber upper nuts and
bolts from the frame crossmember bracket (Fig. 1, 2).
Remove the shock absorber.
INSTALLATION
(1) Install the shock absorber and upper fasteners
on the frame bracket (Fig. 1, 2).
3 - 5
LEAF SPRINGS
CAUTION: The rear of the vehicle must be lifted
only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the
rear axle. Use care to avoid bending the side rail
flange.
REMOVAL
(1) Raise the vehicle at the frame.
(2) Use a hydraulic jack to relieve the axle weight.
(3) Remove the wheel and tire.
(4) Remove the nuts, the U-bolts and spring
bracket from the axle (Fig. 1, 2).
(5) Remove the nut and bolt that attaches the
spring rear eye to the shackle (Fig. 1, 2).
(6) Remove the nut and bolt from the spring front
eye (Fig. 1, 2).
(7) Remove the spring from the vehicle.
INSTALLATION
(1) If removed, install the spring shackle on the
spring finger tight (Fig. 1, 2).
(2) Position the spring on the rear axle pad. Make
sure the spring center bolt is inserted in the pad locating hole (Fig. 1, 2). If 2WD, ensure the parking
brake cable guide is properly positioned.
(3) Align the spring front eye with the bolt hole in
the rail front bracket. Install the spring eye bolt and
nut (Fig. 1, 2). Tighten the spring eye nut fingertight.
(4) Align the spring shackle eye with the bolt hole
in the rail rear bracket. Install the bolt and nut (Fig.
1, 2). Tighten the spring shackle eye nut finger-tight.
(5) Install the spring seat (2WD only), U-bolts,
spring bracket, replacement washers and nuts (Fig.
1, 2). Tighten the nuts until the washers are compressed against the spring bracket.
(6) Remove the support stands from under the
frame rails. Lower the vehicle until the springs are
supporting the weight of the vehicle. Tighten the Ubolt nuts (Fig. 1, 2):
2WD vehicles88 Nzm (65 ft. lbs.) torque
4WD vehicles149 Nzm (110 ft. lbs.) torque
(7) Tighten the spring eye pivot bolt nut and all
shackle nuts to 88 Nzm (65 ft. lbs.) torque (Fig. 1, 2).
(8) Install the wheel and tire.
3 - 6
3 - 7
3 - 8
Driveline Snap . . . . . .
Gear and Bearing Noise
General Information . .
Limited Slip Differential
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9
8
8
9
GENERAL INFORMATION
Axle bearing problem conditions are usually caused
by:
Insufficient or incorrect lubricant
Foreign matter/water contamination
Incorrect bearing preload torque adjustment
When serviced, the bearings must be cleaned thoroughly. They should be dried with lint-free shop towels. Never dry bearings with compressed air.
This will overheat them and brinell the bearing
surfaces. This will result in noisy operation after repair.
Axle gear problem conditions are usually the result
of:
Insufficient lubrication
Incorrect or contaminated lubricant
Overloading (excessive engine torque)
Incorrect clearance or backlash adjustment
Insufficient lubrication is usually the result of a
housing cover leak. It can also be from worn axle
shaft or pinion gear seals. Check for cracks or porous
areas in the housing or tubes.
Using the wrong lubricant or over filling will cause
overheating and gear failure. Gear tooth cracking
and bearing spalling are indicators of this.
Axle component breakage is most often the result
of:
Severe overloading
Insufficient lubricant
Incorrect lubricant
Improperly tightened components
Common causes of overloading is from full-throttle
acceleration. Overloading happens when towing
heavier-than-recommended loads. Component breakage can occur when the wheels are spun excessively.
Insufficient or incorrect lubricants contribute to
breakage through overheating. Loose differential
components can also cause breakage.
Incorrect bearing preload or gear backlash will not
result in component breakage. Mis-adjustment will
produce enough noise to cause service repair before a
failure occurs. If a mis-adjustment condition is not
corrected, component failure can result.
page
Low Speed Knock . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear Axle Alignment . . . . . . . . . . . . . . . . . . . . . . . . 9
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
Damaged drive shaft
Missing drive shaft balance weight
Worn, out-of-balance wheels
Loose wheel lug nuts
Worn U-joint
Loose spring clamp bolts
Loose/broken springs
Damaged axle shaft bearings
Loose pinion gear nut
Excessive pinion yoke run out
Bent axle shaft
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rear-end vibration. Do not overlook engine accessories, brackets
and drive belts.
All driveline components should be examined before starting any repair.
Refer to Group 22, Wheels and Tires for additional
information.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
High engine idle speed
Loose engine/transmission/transfer case mounts
Worn U-joints
Loose spring mounts
Loose pinion gear nut and yoke
Excessive ring gear backlash
Excessive differential side gear-to-case clearance
The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the vehicle on a hoist with the wheels free to rotate.
Instruct the helper to shift the transmission into
gear. Listen for the noise, a mechanics stethoscope is
helpful in isolating the source of a noise.
3 - 9
3 - 10
3 - 11
3 - 12
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15
19
12
12
15
GENERAL INFORMATION
The 7 1/4 inch and 8 1/4 inch rear axle consists of a
cast iron housing. Tubes are pressed into and welded
to the housing to form a one-piece axle housing.
The integral housing hypoid gear design, has the
pinion set below the centerline of the ring gear.
The axle uses a vent hose to relieve internal pressure caused by lubricant vaporization and expansion.
The axles are equipped with semi-floating axle
shafts, meaning that loads are supported by the axle
shaft and bearings. The axle shafts are retained by
C-clips in the differential side gears.
The axles are equipped with RWAL brake sensors.
The sensor is attached to the differential housing and
the exciter ring is pressed on the differential carrier.
Use care when removing the differential as NOT to
damage the sensor.
The removable cover provides a means for inspection and servicing the differential.
The axles have the gear ratio listed on a tag. The
tag is attached to the housing cover.
The differential case is a one-piece design. The differential pinion mate shaft is retained with a
threaded roll pin. Differential bearing preload and
ring gear backlash is adjusted by the use of threaded
adjusters. The adjusters are located between the differential bearing cups and housing tubes. Pinion
bearing preload is set and maintained by the use of a
collapsible spacer.
PINION GEAR DEPTH MEASUREMENT WITH
GAUGE SET C-3715-B is used when;
The axle/differential housing is being replaced
The original pinion depth shim pack is lost or misplaced
Replacing the differential case
Replacing pinion and differential bearings
LUBRICANT SPECIFICATIONS
Multi-purpose, hypoid gear lubricant should be
used for the 7 1/4 inch and 8 1/4 inch rear axles. The
lubricant should have MIL-L-2105C and API GL 5
quality specifications. Mopar Hypoid Gear Lubricant
conforms to both of these specifications.
page
Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . 12
Pinion Depth Measurement and Adjustment with
Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pinion Seal Replacement . . . . . . . . . . . . . . . . . . . 17
The factory installed lubricant for the 7 1/4 inch
and 8 1/4 inch rear axles is SAE 80W 90 gear lubricant
The factory installed lubricant quantity
7 1/4 inch, 4661 fluid oz..
8 1/4 Inch, 7061 fluid oz..
Refer to Group 0, Lubrication and Maintenance for
additional information.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
REMOVAL
(1) Raise the vehicle to a comfortable working
height that will permit support stands to be installed
at the front of the rear springs.
(2) Block the brake pedal in the up (non-depressed)
position with a wooden block.
(3) Remove the wheel and tire. Do not remove
the brake drum retaining clips or the drums.
(4) Disconnect the brake fluid tube fittings from
the wheel cylinders. Cap the fittings to prevent loss
of brake fluid.
(5) Remove the vent hose from the brake tee nipple.
(6) Remove the brake tee bolt. Carefully detach
the brake fluid tubes from the clips. Disconnect the
RWAL brake sensor.
(7) Disconnect the parking brake cables. Mark the
U-joint, pinion yoke, and pinion shaft for reference.
(8) Disconnect the drive shaft from the pinion
yoke. Secure the drive shaft in an upright position to
prevent damage to the rear U-joint.
(9) Remove the shock absorber lower nuts and
bolts. Remove the rear spring U-bolts and spring
brackets.
(10) Remove the axle assembly from the vehicle.
3 - 13
3 - 14
3 - 15
(11) Wash and clean the outer surface of the housing and axle shaft tubes. Use an appropriate cleaning
solution and dry the surface with compressed air.
INSTALLATION
(1) Support the vehicle at the front of the rear
springs. Position the spring pads on the parking
brake cable guides (2WD vehicles) or against the
spring center bolts (4WD vehicles).
Ensure the spring center bolts and holes in
the spring pads are correctly aligned.
(2) Install the spring U-bolts, brackets and nuts.
Install the shock absorber lower bolts and nuts.
2WD vehicles88 Nzm (65 ft. lbs.) torque
4WD vehicles149 Nzm (110 ft. lbs.) torque
(3) Tighten the spring U-bolt nuts finger-tight.
Tighten the shock absorber nuts to 81 Nzm (60 ft.
lbs.) torque.
(4) Connect the parking brake cables.
(5) Remove the block from the brake pedal.
(6) Connect the brake tube fittings to the wheel
cylinders, bleed and adjust the brakes.
(7) Attach the brake tubes to the clips.
(8) Install the brake tee bolt. Tighten it to 14 Nzm
(10 ft. lbs./125 in. lbs.) torque.
(9) Connect the vent hose to the brake tee nipple.
(10) Install the drive shaft with the installation
reference marks aligned. Tighten the U-joint yoke
clamp screws to 19 Nzm (14 ft. lbs./170 in. lbs.)
torque.
(11) Install the wheel and tire.
(12) Adjust the hoist so the vehicle is in a level position. Check the differential housing lubricant level.
If necessary, add Mopar Hypoid Gear Lubricant to
the correct level.
LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle
has been recently driven.
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the differential housing cover.
(3) Remove the differential housing cover and
drain the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth. Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the sealant from the housing and cover
surfaces. Use solvent to clean the mating surfaces.
(6) Apply a bead of Mopar Silicone Rubber Sealant
to the housing cover (Fig. 3). Allow the sealant to
cure for a few minutes.
Install the housing cover within 5 minutes after applying the sealant. If not installed the
sealant must be removed and another bead applied.
3 - 16
3 - 17
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the U-joint, pinion yoke, and pinion shaft
for reference.
(3) Disconnect the drive shaft from the pinion
yoke. Secure the drive shaft in an upright position to
prevent damage to the rear U-joint.
(4) Remove the rear wheels and tire and brake
drums to prevent any drag. The drag can cause a
possible false bearing preload torque measurement.
(5) Use a Newton-meter or an inch-pound torque
wrench to measure the pinion bearing preload. Rotate the pinion shaft several times with the torque
wrench. Note the indicated torque as the wrench is
moved through several revolutions.
This measurement is important because bearing preload torque must be carefully re-adjusted after the seal installation.
(6) Remove the pinion gear nut and washer. Use
Puller C-452 and Wrench C-3281 to remove the pinion gear yoke (Fig. 8).
INSTALLATION
(1) Examine the splines on the pinion shaft for
burrs or wear.
(2) Remove any burrs and clean the shaft.
(3) Inspect the pinion yoke for cracks, worn splines
and a worn seal contact surface. Repair or replace
the yoke as necessary.
The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of sealant is not required.
(4) Install the new pinion shaft seal (Fig. 10) with
Seal Installer C-4076-A and Handle C-4735.
The seal is correctly installed when the seal
3 - 18
3 - 19
3 - 20
3 - 21
3 - 22
3 - 23
3 - 24
3 - 25
3 - 26
CAUTION: Never loosen the pinion gear nut to decrease the pinion gear bearing preload torque. If the
specified preload torque is exceeded, a replacement
collapsible spacer must be installed. The torque sequence will have to be repeated.
(23) Measure the pinion bearing preload torque by
rotating pinion shaft with a Newton-meter or an
inch-pound torque wrench. The correct bearing preload torque is 1 to 2 Nzm (10 to 20 in. lbs.). This
torque value is with replacement bearings and pinion
nut tightened to a minimum of 285 Nzm (210 ft. lbs.)
torque (Fig. 32).
When using original pinion rear bearing and
a replacement front bearing. The correct preload torque is 1 Nzm (10 in. lbs.) plus the torque
measured during disassembly.
3 - 27
3 - 28
3 - 29
3 - 30
GENERAL INFORMATION
The Trac-Loc differential is an option available in
the 8 1/4 Inch rear axles (Fig. 1).
In a conventional differential, the torque applied to
the ring gear is transmitted to the axle shafts
through the differential gears. During normal operation, the torque transmitted to each wheel is equal at
all times. However, if one wheel spins, the opposite
wheel will generate only as much torque as the spinning wheel.
In the Trac-Lok differential, part of the ring gear
torque is transmitted through clutch packs. The
clutch packs contain multiple disc. The clutch will
have radial grooves on the plates, and concentric
grooves on the discs or bonded fiber material that is
smooth appearance.
In operation, the Trac-Lok clutches are engaged by
two concurrent forces. The first being preload force
exerted through Belleville spring washers. The second is from separating forces generated by the side
gears (Fig. 1).
The Trac-Lok design provides the normal differential action needed for turning corners. It also provides for the transmission of equal torque to both
wheels when driving straight ahead. When one wheel
loses traction, the clutch packs transfer torque to the
wheel having the most traction. Trac-Lok differentials resist wheel spin on bumpy roads. It also provides more pulling power when one wheel loses
traction. Pulling power is continuous until both
wheels lose traction. If both wheels slip due to unequal traction, Trac-Lok operation is normal. In extreme cases of differences of traction, the wheel with
the least traction may spin. This occurs after the
Trac-Lok has transferred as much torque as possible
to the non-spinning wheel.
NOISE DIAGNOSIS
If chatter occurs when turning corners, the most
probable cause is incorrect or contaminated lubricant. Before removing the Trac-Lok unit for repair,
drain, flush and refill the axle with the specified lubricant. Refer to Lubricant change in this Group.
A container of Trac-Lok Lubricant (friction modifier) should be added after.
Vehicles with a limited slip differential should be
road tested by making 10 to 12 slow figure-eight
turns. This maneuver will pump the lubricant
through the clutch discs.
Refer to Group 0, Lubrication and Maintenance for
additional information.
DIFFERENTIAL TEST
WARNING: WHEN SERVICING VEHICLES WITH A
LIMITED SLIP DIFFERENTIAL DO NOT USE THE EN-
3 - 31
DIFFERENTIAL OVERHAUL
The Trac-Lok differential components are illustrated in (Fig. 3). Refer to this illustration during repair service.
DISASSEMBLY
Service to the Trac-Lok differential requires the
use of Tool Set C-4487 (J-23781). Refer to Axle section in this Group for Differential Removal and Installation.
(1) Clamp one axle shaft in a vise equipped with
soft jaws (Fig. 4).
(2) Position the differential case on the axle shaft
(Fig. 5). Place shop towels under the differential to
avoid damage during removal of the ring gear (Fig.
5).
(3) Remove and discard the ring gear bolts. Tap
3 - 32
3 - 33
3 - 34
3 - 35
3 - 36
TORQUE SPECIFICATIONS
SUSPENSION COMPONENTS
DESCRIPTION ................................................TORQUE
Shock Absorber
Lower Bolt ...................................88 Nzm (65 ft. lbs.)
Upper Bolt ...................................27 Nzm (20 ft. lbs.)
Spring Clamp Nut
2WD ..............................................88 Nzm (65 ft. lbs.)
4WD ..........................................149 Nzm (110 ft. lbs.)
Spring
Spring Eye Nut ...........................88 Nzm (65 ft. lbs.)
Pivot Bolt Nut .............................88 Nzm (65 ft. lbs.)
DESCRIPTION ................................................TORQUE
Diff. Cover Bolt ........................47 Nzm (35 ft. lbs.)
Bearing Cap Bolt
7 1/4 Axle .....................................61 Nzm (45 ft. lbs.)
8 1/4 Axle .....................................95 Nzm (70 ft. lbs.)
Pinion Nut .............................285 Nzm (210 ft. lbs.)
Ring Gear Bolt .........................95 Nzm (70 ft. lbs.)
RWAL/ABS Sensor Bolt .........24 Nzm (18. ft. lbs.)
BRAKES
5 - 1
BRAKES
CONTENTS
page
page
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . 63
POWER BRAKE BOOSTERBRAKE PEDAL
STOPLAMP SWITCH . . . . . . . . . . . . . . . . . . . 17
RWAL BRAKE OPERATION AND SERVICE . . . . 44
SERVICE BRAKE DIAGNOSIS . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 68
GENERAL INFORMATION
INDEX
page
page
5 - 2
BRAKES
5 - 3
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6
4
6
4
3
6
DIAGNOSIS PROCEDURES
The diagnosis information in this section covers
service brake components only. Antilock brake component diagnosis is covered in the antilock brake diagnosis section.
Service brake components include front/rear brakeshoes, disc brake calipers, wheel cylinders, brake
drums, support plates, brakelines, master cylinder,
power brake booster, and parking brake components.
Brake diagnosis involves determining if the problem is related to a mechanical, hydraulic, vacuum, or
electrically operated component. A preliminary check,
road testing and component inspection can all be
used to determine a problem cause.
Road testing will either verify proper brake operation or confirm the existence of a problem. Component inspection will then identify the actual causal
part.
page
Power Booster Check Valve Test . . . . . .
Power Booster Vacuum Test . . . . . . . . .
Preliminary Brake Check . . . . . . . . . . . .
Road Testing . . . . . . . . . . . . . . . . . . . .
Service Brake Warning Light Illumination
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7
7
3
3
3
The next step in brake diagnosis should be a preliminary check. This involves inspecting fluid level,
parking brake action, wheel and tire condition, leak
checking and testing brake pedal response.
ROAD TESTING
5 - 4
COMPONENT INSPECTION
Fluid leak points and dragging brake units can
usually be located without removing any components.
The area around a leak point will be wet with fluid.
The components at a dragging brake unit (wheel,
tire, rotor) will be quite warm or hot to the touch.
Other brake problem conditions will require component removal for proper inspection. Raise the vehicle
and remove the necessary wheel brake components
for better visual access.
During component inspection, pay particular attention to heavily rusted/corroded brake components
(e.g. rotors, caliper pistons, brake return/holddown
springs, support plates, etc.).
Heavy accumulations of rust may be an indicator of
rust and corrosion damage to a brake component. It
is wise to remove surface rust in order to accurately
determine the depth of rust penetration and damage.
Light surface rust is fairly normal and not a major
concern (as long as it is removed). However, heavy
rust buildup, especially on high mileage vehicles,
may actually cover structural damage to such important components as: brakelines; rotors; support
plates; and brake booster.
A decrease in fluid level in the master cylinder reservoirs may only be the result of normal lining wear.
Fluid level will decrease in proportion to wear. It is a
result of the outward movement of caliper and wheel
cylinder pistons to compensate for normal wear. Top
off the reservoir fluid level and check brake operation
to verify proper operation.
SPONGY PEDAL
A spongy pedal is most often caused by air in the
system. Thin brake drums or substandard brake
lines and hoses can also cause a spongy pedal. The
proper course of action is to bleed the system and replace thin drums and suspect quality brake lines and
hoses.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or high pedal effort may be due to lining that is water soaked, contaminated, glazed, or
badly worn. The power booster or check valve could
also be faulty. Test the booster and valve as described
in this section.
BRAKE DRAG
Brake drag occurs when the lining is in constant
contact with the rotor or drum. Drag can occur at one
wheel, all wheels, fronts only, or rears only. It is a
product of incomplete brakeshoe release. Drag can be
minor or severe enough to overheat the linings, rotors and drums.
Brake drag also has a direct effect on fuel economy.
If undetected, minor brake drag can be misdiagnosed
as an engine or transmission/torque converter problem.
Minor drag will usually cause slight surface charring of the lining. It can also generate hard spots in
rotors and drums from the overheat-cool down process. In most cases, the rotors, drums, wheels and
tires are quite warm to the touch after the vehicle is
stopped.
Severe drag can char the brake lining all the way
through. It can also distort and score rotors and
drums to the point of replacement. The wheels, tires
and brake components will be extremely hot. In severe cases, the lining may generate smoke as it chars
from overheating.
Some common causes of brake drag are:
seized or improperly adjusted parking brake cables
loose or damaged wheel bearing
seized caliper or wheel cylinder piston
caliper binding on corroded bushings or rusted
slide surfaces
loose caliper mounting bracket
drum brakeshoes binding on worn-damaged support plates
misassembled components
5 - 5
BRAKE FADE
Brake fade is a product of overheating caused by
brake drag. Brake overheat and fade can also be
caused by riding the brake pedal, making repeated
high deceleration stops in a short time span, or constant braking on steep mountain roads. Refer to the
Brake Drag information in this section for causes.
BRAKE NOISE
PEDAL PULSATION
Pedal pulsation is caused by components that are
loose, or beyond tolerance limits.
Disc brake rotors with excessive lateral runout or
thickness variation, or out of round brake drums are
the primary causes of pulsation. Other causes are
loose wheel bearings or calipers and worn, damaged
tires.
PULL
A front pull condition could be the result of contaminated lining in one caliper, seized caliper piston,
binding caliper, loose caliper, loose or corroded slide
pins, improper brakeshoes, or a damaged rotor.
A worn, damaged wheel bearing or suspension component are further causes of pull. A damaged front
tire (bruised, ply separation) can also cause pull.
A common and frequently misdiagnosed pull condition is where direction of pull changes after a few
stops. The cause is a combination of brake drag followed by fade at one of the brake units.
As the dragging brake overheats, efficiency is so reduced that fade occurs. Since the opposite brake unit
is still functioning normally, its braking effect is
magnified. This causes pull to switch direction in favor of the normally functioning brake unit.
When diagnosing a change in pull condition, remember that pull will return to the original direction
if the dragging brake unit is allowed to cool down
(and is not seriously damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pull is usually caused by an improperly adjusted or seized parking brake cable, contaminated lining, bent or binding shoes and support
plates, or improperly assembled components. This is
particularly true when only one rear wheel is involved. However, when both rear wheels are affected,
the master cylinder or proportioning valve could be
at fault.
Squeak/Squeal
Brake squeak or squeal may be due to linings that
are wet or contaminated with brake fluid, grease, or
oil. Glazed linings and rotors with hard spots can
also contribute to squeak. Dirt and foreign material
embedded in the brake lining can also cause squeak/
squeal.
A very loud squeak or squeal is frequently a sign of
severely worn brake lining. If the lining has worn
through to the brakeshoes in spots, metal-to-metal
contact occurs. If the condition is allowed to continue,
rotors can become so scored that replacement is necessary.
Thump/Clunk
Thumping or clunk noises during braking are frequently not caused by brake components. In many
cases, such noises are caused by loose or damaged
steering, suspension, or engine components. However,
calipers that bind on the slide pins can generate a
thump or clunk noise. In addition, worn out, improperly adjusted, or improperly assembled rear brakeshoes can also produce noise a thump noise.
Chatter/Shudder
Brake chatter, or shudder is usually caused by
loose or worn components, or glazed/burned lining.
Rotors with hard spots can also contribute to chatter.
Additional causes of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes,
loose wheel bearings and contaminated brake lining.
BRAKELINING CONTAMINATION
Brakelining contamination is usually a product of
leaking calipers or wheel cylinders, driving through
deep water puddles, or lining that has become covered with grease and grit during repair.
WHEEL AND TIRE PROBLEMS
Some conditions attributed to brake components
may actually be caused by a wheel or tire problem.
A damaged wheel can cause shudder, vibration and
pull. A worn or damaged tire can also cause vibration
or pull.
Severely worn tires with very little tread left can
produce a grab-like condition as the tires lose and recover traction.
5 - 6
5 - 7
5 - 8
page
DIAGNOSIS PROCEDURES
ABS System
Antilock diagnosis involves checking only those
components that form the antilock system. Diagnosis
involves three basic steps which are:
observation of the warning light display
visual examination for low fluid, leaks, or damaged wires
circuit check with DRB scan tool
Visual examination includes a check of reservoir
fluid level and condition of the system components.
This includes inspection of the sensor wires and electrical connections. Things to look for are leaks, loose
connections, or obvious component damage.
Circuit checking involves using the DRB scan tool
to identify a faulty circuit or component.
RWAL System
An RWAL system malfunction will be indicated by
illumination of the amber warning lamp.
If a problem occurs, system diagnosis should begin
with a fluid level check followed by a visual examination of the system electrical and hydraulic connections. If obvious defects (low fluid, leaks, loose
connections, etc.) are not evident, road test the vehicle. A road test should help determine if a malfunction is actually related to an antilock component.
During the road test, note if other conditions are
evident such as a low pedal, pull, grab, or similar
condition. Remember that brake malfunctions such
as low fluid, system leaks, or parking brakes partially applied will affect antilock system operation.
The idea is to determine if a malfunction is actually
related to an antilock component.
If a visual inspection and road test do not indicate
the problem cause, check the system fault flash
codes. Refer to the system fault code information in
this section.
5 - 9
5 - 10
5 - 11
5 - 12
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13
14
12
12
12
page
Master Cylinder Bleeding . . . . . . . . . .
Master Cylinder Installation . . . . . . . . .
Master Cylinder Removal . . . . . . . . . .
Master Cylinder Reservoir Replacement
Recommended Brake Fluid . . . . . . . . .
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13
14
13
13
12
Use new brake fluid only, to top off the master cylinder or refill the system. Never use reclaimed fluid, unmarked or unspecified fluid,
fluid not meeting SAE/DOT standards, fluid
marked 70R1, or fluid from a container that has
been left open for any length of time. Using non
recommended or unspecified fluid can result in
brake failure after hard prolonged braking.
5 - 13
(4) Note or mark position of reservoir before removal. Side of reservoir with fluid level information
on it goes toward driver side of engine compartment.
(5) Remove reservoir by firmly rocking it from side
to side (Fig. 4). Continue rocking until reservoir
comes out of grommets.
5 - 14
5 - 15
5 - 16
5 - 17
page
5 - 18
5 - 19
(7) Work switch and bracket up toward pedal support and connect harness wires to switch.
(8) Position switch and bracket in support. Install
bracket retaining nut and washer. Tighten nut to 7
Nzm (60 in. lbs.) torque. Be sure bracket tang is
seated in support.
(9) Check switch operation before proceeding any
further. If brakelights fail to illuminate or remain on,
switch bracket is not seated, switch is not fully engaged in mounting bracket, switch plunger is not
aligned with striker, or wire harness is not fully connected. Reposition switch, bracket or striker as
needed.
(10) Align and install air duct and steering column
cover.
5 - 20
DRUM BRAKES
DRUM BRAKES
INDEX
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23
22
22
20
23
23
23
21
page
Brakeshoe Removal . . . . . .
Cleaning and Inspection . . .
General Information . . . . . .
Rear Drum Brake Adjustment
Wheel Cylinder Installation .
Wheel Cylinder Overhaul . . .
Wheel Cylinder Removal . . .
Wheel Nut Tightening . . . . .
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20
21
20
24
24
24
24
25
GENERAL INFORMATION
The drum brake units used for all applications are
dual shoe, internal expanding units with an automatic self adjusting mechanism (Figs. 1 and 2). Nine
inch brakes are used on standard models. Ten inch
brakes are used on models with heavy duty option
packages.
Cast wheel cylinders are used for all applications.
The cylinders are serviceable components and can be
overhauled. The cylinder bores can be lightly
polished with crocus cloth but must not be
honed.
BRAKESHOE REMOVAL
(1) Remove rear wheel and brake drum.
(2) Remove shoe return springs with Brake Spring
Plier Tool C-3785 (Fig. 3).
(3) Remove adjuster cable. Slide cable eye off anchor pin. Then unhook and remove cable from adjuster lever.
DRUM BRAKES
5 - 21
BRAKESHOE INSTALLATION
(1) Lubricate anchor pin and brakeshoe contact
surfaces of support plate (Fig. 6). Use Mopar multipurpose grease, bearing grease, or Lubriplate.
(2) Lubricate adjuster screw socket, nut, button
and screw thread surfaces with Mopar spray lube or
Lubriplate.
5 - 22
DRUM BRAKES
marked L (left) and R (right) for identification (Fig.
8). The passenger side adjuster screw has left hand
threads and the driver side screw has right hand
threads.
DRUM BRAKES
drum outer edge (Fig. 9). Generally, a nine inch drum
can be machined to a maximum of 230.1 mm (9.060
in.) and a ten inch drum to 255.5 mm (10.060 in.). Always replace the drum if machining would cause
drum diameter to exceed indicated size limit.
5 - 23
5 - 24
DRUM BRAKES
The rear drum brakes are equipped with a self adjusting mechanism. Under normal circumstances, the
only time adjustment is required is when the brakeshoes are replaced, removed for access to other parts,
or when one or both drums are replaced.
Adjustment can be performed with a standard
brake gauge, or with Adjusting Tool C-3784. Both
methods are described in the following procedures.
DRUM BRAKES
5 - 25
5 - 26
DRUM BRAKES
5 - 27
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29
28
32
31
GENERAL INFORMATION
Two-wheel drive AN models are equipped with single piston disc brake calipers. The calipers move laterally on pins that attach the caliper to the mounting
adapter. Abutment surfaces machined in the brakeshoes and mounting adapter maintain fore and aft
alignment. The calipers are fully serviceable components and can be overhauled when necessary.
Non metallic caliper pistons are used for all applications. The pistons are made of a phenolic resin material.
Two-wheel drive models are equipped with a disc
brake rotor and hub assembly. The rotor hub is supported on the steering knuckle spindle by the wheel
bearings. The rotor braking surfaces are ventilated
and can be machined to restore surface finish when
necessary.
The disc brakeshoes are held in position by retaining springs. The inboard shoe spring is an integral
part of the shoe. The outboard shoe is spring is removable. Two slide pins secure the caliper to the caliper adapter. The adapter, which is also removable, is
attached to the steering knuckle (Fig. 1).
page
Caliper Disassembly
Caliper Installation .
Caliper Removal . . .
General Information
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32
30
27
5 - 28
BRAKESHOE REMOVAL
(1) Clean master cylinder reservoir and filler caps.
(2) Remove filler caps and drain approximately 1/4
of fluid from reservoir. Use clean suction gun or similar device to remove fluid.
(3) Raise and support front of vehicle.
(4) Remove front wheel and tire assemblies.
(5) Remove outboard retaining spring from caliper
(Fig. 3). Push spring ends downward and pull spring
ends out of caliper to remove.
(9) Support caliper on box, mechanics stool, or secure it to chassis with wire. Do not allow brake hose
to support caliper weight.
(10) Remove outboard shoe from adapter or from
caliper (Fig. 6).
(11) Remove inboard shoe from caliper (Fig. 7). Tilt
shoe outward until retainer springs clear piston and
remove shoe.
5 - 29
BRAKESHOE INSTALLATION
(1) Clean and lubricate slide surfaces of caliper
mounting adapter (Fig. 11). Use wire brush to clean
surfaces. Then apply coating of Mopar multi mileage
grease to slide surfaces and to threads of slide pin
holes.
(2) Clean caliper slide pins with brake cleaner or
brake fluid. Then apply coating of silicone grease to
pins. Minor rust or corrosion can be polished
from pins with crocus cloth. However, replace
5 - 30
CALIPER REMOVAL
Fig. 11 Caliper Adapter Slide Surfaces
the pins if severely rusted, or corroded.
(3) Install caliper slide pin bushings and boots if
removed (Fig. 10).
(4) Install inboard shoe (Fig. 7). Be sure spring is
fully seated in caliper piston.
(5) Install outboard shoe in caliper mounting
adapter.
(6) Carefully lower caliper into place over rotor
and outboard brakeshoe.
(7) Align caliper in adapter and start caliper slide
pins by hand. Do not cross thread pins.
(8) Check position of brakeshoes (Fig. 12). Verify
that shoe tabs are squarely seated on ledge surfaces
of caliper adapter.
(9) Final-tighten caliper slide pins to 25-35 Nzm
(18-26 ft. lbs.).
CALIPER DISASSEMBLY
5 - 31
5 - 32
CALIPER ASSEMBLY
(1) Lubricate slide pin boots and bushings with
GE, or Dow silicone grease. Then install boots and
bushings in caliper.
(2) Coat caliper piston bore, piston and new piston
seal with fresh brake fluid.
(3) Install new piston seal in caliper bore. Press
seal into groove with finger (Fig. 19). Lubricate seal
and caliper bore with additional, fresh brake fluid after seal installation.
CALIPER INSTALLATION
(1) Install brake shoes in caliper.
5 - 33
5 - 34
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35
36
35
38
37
GENERAL INFORMATION
Four-wheel drive AN models are equipped with single piston, slider type disc brake calipers. The calipers slide laterally on pins that attach the caliper to
the steering knuckle (Fig. 1).
The brakeshoes ride on ledges machined in the
steering knuckle. The shoe mounting ears are
notched to seat on these ledges. The notched ears
also maintain fore and aft position of the shoes. A retainer spring on each brakeshoe maintains shoe position in the caliper.
The single piston used in each caliper is non-metallic. The pistons are made of a phenolic resin material.
Ventilated, disc brake rotors are used for all applications. The rotors are serviceable and can be machined to restore the surface finish when necessary.
The calipers are fully serviceable components and
can be overhauled when necessary. The brakeshoes
page
Caliper Disassembly
Caliper Installation .
Caliper Removal . . .
General Information
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37
40
37
34
are replaceable components but must be replaced on both front wheels at the same time to
maintain braking balance. Never replace the
shoes on only one side.
5 - 35
BRAKESHOE REMOVAL
(1) Clean master cylinder reservoir and filler caps.
(2) Remove reservoir filler caps and drain approximately 1/4 of fluid from reservoir. Use clean suction
gun or similar device to drain fluid.
(3) Raise and support vehicle.
(4) Remove front wheel and tire assemblies.
(5) Bottom caliper pistons in bores with large
C-clamp. Position clamp frame on rear of caliper and
clamp screw on outboard brakeshoe.
(6) Remove caliper slide pins.
(7) Remove caliper and brakeshoes (Fig. 3).
5 - 36
BRAKESHOE INSTALLATION
(1) Clean slide surfaces of adapter ledges with a
wire brush. Then lubricate surfaces with Mopar
multi mileage grease.
(2) Install new slide pin boots and sleeves if necessary.
5 - 37
CALIPER REMOVAL
(1) Raise and support vehicle.
(2) Remove front wheel and tire assemblies.
(3) Disconnect brake hose at caliper. Discard hose
fitting washers if worn, or damaged (Fig. 11).
CALIPER DISASSEMBLY
(1) Remove brakeshoes from caliper (Figs. 4 and
5). Discard shoes if worn, or damaged.
(2) Drain old brake fluid out of caliper into drain
pan.
(3) Remove piston dust boot (Fig. 12). Use screwdriver to push boot out of groove.
(4) Pad outboard shoe side of caliper interior with
a minimum 1 inch thickness of shop towels (Fig. 13).
Towels will prevent piston damage when piston is
comes out of bore.
(5) Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet
port of caliper (Fig. 13).
CAUTION: Do not blow the piston out of the caliper.
This procedure will usually result in severe piston
damage. Use only enough air pressure to ease the
piston out of the bore. In addition, never attempt to
catch the piston as it leaves the caliper bore. This
practice will result in personal injury.
5 - 38
CALIPER ASSEMBLY
5 - 39
5 - 40
CALIPER INSTALLATION
(1) Install brake shoes in caliper.
(2) Install caliper and shoes over rotor and into
ledges in steering knuckle. Be sure ends of brakeshoes are properly seated on slide surfaces of ledges.
(3) Align caliper in adapter and start caliper slide
pins into adapter by hand.
(4) Tighten caliper slide pins to 30 Nzm (22 ft. lbs.)
torque.
(5) Connect brake hose to caliper. Use new washers to attach hose fitting if original washers are
scored, worn, or damaged.
(6) Fill and bleed brake hydraulic system.
(7) Install wheel and tire assemblies.
(8) Remove supports and lower vehicle.
(9) Pump brake pedal to seat shoes and verify firm
pedal before moving vehicle.
(10) Check master cylinder fluid level again and
top off if necessary.
5 - 41
Installation . . . . . . .
Minimum Thickness
Refinishing . . . . . .
Removal . . . . . . . .
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41
42
42
41
page
Rotor Runout . . . . . . . . . . . . . . . .
Rotor Thickness Variation and Taper
Rotor Types . . . . . . . . . . . . . . . . .
Wheel Nut Tightening . . . . . . . . . .
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42
43
41
43
ROTOR TYPES
A disc brake rotor is used for 4-wheel drive applications (Fig. 1). A disc brake rotor and hub assembly
is used for 2-wheel drive applications (Fig. 1). Both
rotor types are cast metal with built in ventilating
ribs between the rotor braking surfaces.
The rotor braking surfaces on both rotor types can be
sanded, or machined to restore surface finish when necessary. However, a rotor should be replaced if machining
would cause rotor thickness to fall below usable minimum.
On 2-wheel drive models with ABS brakes, the tone
wheel for the front speed sensor is pressed onto the
rotor hub. Because the tone wheel is only serviced as
part of the complete rotor and hub assembly, extra
care will be required in handling to avoid damage.
Refer to the rotor removal and installation procedures in this section.
ROTOR REMOVAL
(1) Raise vehicle.
(2) Remove wheel cover and wheel and tire assembly.
(3) Remove caliper and brakeshoe assembly but do
not disconnect brake line. Support caliper on stool, or
box. Do not allow brake hose to support caliper
weight.
(4) On 2-wheel drive models, remove grease cap,
cotter pin, nut lock,nut, thrust washer and outer
wheel bearing. Then remove rotor and hub assembly
(Fig. 1).
CAUTION: On 2-wheel drive models with ABS
brakes, the tone wheel for the front wheel sensor is
located on the rotor hub (Fig. 2). Exercise care
when handling the rotor during service. The entire
rotor and hub assembly will have to be replaced if
the tone wheel becomes damaged during handling.
(5) On 4-wheel drive models, remove stamped rotor
retainer nuts or clips and remove rotor (Fig. 1).
(6) On 2-wheel drive models, if rotor will be refinished, remove wheel bearings from rotor hub so rotor
can be mounted on brake lathe arbor.
ROTOR INSTALLATION
(1) On 4-wheel drive models:
(a) Install rotor on wheel studs.
5 - 42
ROTOR REFINISHING
Rotor braking surfaces can be refinished by sanding and/or machining in a disc brake lathe. The lathe
must be capable of machining both rotor surfaces simultaneously with dual cutter heads (Fig. 2). Equipment capable of machining only one side at a time
will produce a tapered rotor. The lathe should also be
equipped with a grinder attachment or dual sanding
discs for final cleanup or light refinishing (Fig. 3).
If the rotor surfaces only need minor cleanup of rust,
scale, or minor scoring, use abrasive discs to clean up
the rotor surfaces. However, when a rotor is scored or
worn, machining with cutting tools will be required.
CAUTION: Do not refinish a rotor if machining
would cause the rotor to fall below minimum allowable thickness.
The final finish on the rotor should be a non-directional, cross hatch pattern (Fig. 4). Sanding discs will
produce this finish.
ROTOR RUNOUT
Check rotor lateral runout with a dial indicator (Fig.
6). Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brakeshoes.
Maximum allowable rotor runout for all models is
0.102 mm (0.004 inch).
5 - 43
5 - 44
....
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47
46
47
48
48
44
47
page
Rear Antilock Valve Removal . . . . . . . . . . . . . . .
RWAL System Brake Bleeding . . . . . . . . . . . . . .
RWAL System Components . . . . . . . . . . . . . . .
RWAL System Manual Brake Bleeding Procedure
RWAL System Operation . . . . . . . . . . . . . . . . . .
Speed Sensor Installation . . . . . . . . . . . . . . . . .
Speed Sensor Removal . . . . . . . . . . . . . . . . . .
. . 46
. . 48
. . 44
. 49
. . 45
. . 48
. . 48
GENERAL INFORMATION
The RWAL brake system is standard on all AN
models. The system is controlled by a separate electronic control module.
The RWAL system retards rear wheel lockup during periods of high wheel slip and deceleration. Retarding lockup is accomplished by modulating fluid
pressure to the rear brake units.
Rear brake fluid pressure is modulated according
to wheel speed, degree of wheel slip and rate of deceleration. A sensor in the rear axle housing converts
differential rotating speed into electronic signals. The
signals are transmitted to the electronic control module for processing. The control module determines
rate of deceleration and wheel slip from these signals.
5 - 45
5 - 46
5 - 47
5 - 48
Bleeding Equipment
RWAL system bleeding can be performed manually,
or with vacuum/pressure equipment. Refer to the
vacuum and pressure bleeding information in this
section.
Brake Bleeding Precautions
Observe the following precautions while brake
bleeding:
Use recommended brake fluid meeting SAE
J1703-F and DOT 3 standards only. Use fresh, clean
fluid from a sealed container at all times.
Do not pump brake pedal at any time while bleeding. Air in system will be compressed into small bub-
5 - 49
VACUUM BLEEDING
If vacuum bleeding equipment is being used, it is
not necessary to hold the front brake metering valve
open. Simply bleed the brakes following the bleed
equipment manufacturers instructions.
PRESSURE BLEEDING
If pressure bleeding equipment will be used, the
front brake metering valve will have to be held open
to bleed the front brakes. The valve stem is located
5 - 50
Do pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage,
or drawing air back into the system.
Fill the bleeder tank with recommended fluid and
purge air from the tank lines before bleeding.
Do not exceed the tank manufacturers pressure
recommendations. In most cases, a tank pressure of
15-20 psi is more than sufficient for bleeding purposes.
5 - 51
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60
51
59
59
60
54
57
55
57
55
55
page
Front Brake Speed Sensor Installation (4-Wheel
Drive Models) . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Brake Speed Sensor Removal (2-Wheel Drive
Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Brake Speed Sensor Removal (4-Wheel Drive
Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Antilock Valve Installation . . . . . . . . . . . . . . .
Rear Antilock Valve Removal . . . . . . . . . . . . . . . . .
Rear Brake Speed Sensor Installation . . . . . . . . . .
Rear Brake Speed Sensor Removal (All) . . . . . . . .
Tone Wheel Service . . . . . . . . . . . . . . . . . . . . . . .
59
58
59
57
56
59
59
58
. . . 58
ABS COMPONENTS
The optionally available ABS system is an allwheel antilock brake system (Fig. 1). ABS system
components include:
rear antilock valve
rear wheel speed sensor and exciter ring
front wheel speed sensors and tone rings
front antilock valve
electronic control module
electrical harnesses
combination valve
diagnostic connector
Front Antilock Valve
The front antilock valve consists of a solenoid valve
body and pump/motor unit combined into a single assembly (Fig. 2).
5 - 52
5 - 53
5 - 54
ABS OPERATION
The all-wheel ABS system is a three channel design. The front wheel brakes are controlled individually and the rear wheel brakes in tandem (Fig. 9).
The ABS system is designed to retard wheel lockup
during periods of high wheel slip when braking. Retarding wheel lockup is accomplished by modulating
fluid pressure to the wheel brake units.
The antilock electrical system is separate from
other electrical circuits in the vehicle. A specially programmed electronic control module is used to operate
the system components.
The front and rear antilock valves contain electrically operated solenoid valves. The solenoid valves
5 - 55
5 - 56
5 - 57
5 - 58
5 - 59
Position module in mounting bracket and inmodule attaching screws (Fig. 21).
Connect main harness connector to module.
connector in module retaining lugs and start
5 - 60
combination valve
rear antilock valve
front antilock valve
left rear wheel
right rear wheel
right front wheel
left front wheel
Use Mopar brake fluid, or an equivalent meeting
SAE J1703-F and DOT 3 standards, to fill and bleed
the system.
Bleed only one brake component at a time.
Clean the master cylinder filler caps and reservoir
before adding fluid.
Use a bleed hose at each caliper/cylinder bleed
screw. Attach one end of the hose to the screw and
insert the opposite end in glass container partially
filled with brake fluid (Fig. 22). A glass container
makes it easier to see air bubbles as they exit the
bleed hose.
Be sure the end of the bleed hose remains immersed in fluid. This prevents air from being drawn
back into the system.
Be sure to tighten each brakeline fitting, or bleed
screw once bleeding is completed. Loose fittings and
bleed screws allow air to re-enter the system.
Do not allow the master cylinder to run out of
fluid when bleeding the brakes. An empty cylinder
will allow air to be drawn back into the system.
Check fluid level frequently during bleeding operations.
5 - 61
VACUUM BLEEDING
If vacuum bleeding equipment is being used, it is
not necessary to hold the front brake metering valve
open. Simply bleed the brakes following the equipment manufacturers instructions.
PRESSURE BLEEDING
If pressure bleeding equipment will be used, the
front brake metering valve will have to be held open
to bleed the front brakes. The valve stem is located
in the forward end of the combination valve. The
stem must either be pressed inward, or held outward
slightly. a spring clip tool or helper is needed to hold
the valve stem in position.
Follow the manufacturers instructions carefully
when using pressure equipment.
Make sure the front brake metering valve in the
combination is held open. A spring clip tool is best for
securing the valve stem in an open position.
Do pressure bleed without a proper master cylinder
adapter. The wrong adapter can lead to leakage, or
drawing air back into the system.
5 - 62
PARKING BRAKES
5 - 63
PARKING BRAKES
INDEX
page
Front Cable Installation . . . . .
Front Cable Removal . . . . . .
General Information . . . . . . .
Intermediate Cable Installation
Intermediate Cable Removal .
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63
63
63
66
66
page
Parking Brake Cable Tensioner Adjustment
Parking Brake Pedal Installation . . . . . . .
Parking Brake Pedal Removal . . . . . . . . .
Rear Cable Installation . . . . . . . . . . . . . .
Rear Cable Removal . . . . . . . . . . . . . . . .
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67
66
66
66
66
GENERAL INFORMATION
The parking brakes are operated by a system of cables and levers attached to the rear brake secondary
shoes. A foot pedal, cable tensioner, and four cables form
the control system.
The rear drum brakeshoes serve as the parking
brakes. The shoes are moved into contact with the
brake drum surface by a cable and lever mechanism
attached to the trailing brakeshoe. A strut installed
between the primary and secondary shoes maintains
shoe position when the parking brakes are applied.
The front parking brake cable is connected to the
parking brake pedal and to an intermediate cable.
The intermediate cable connects the front cable to
the rear cables.
The parking brake pedal assembly is mounted on
the driver side cowl panel (Fig. 1). The front cable is
directly attached to the assembly. The pedal assembly contains a spring loaded, ratchet-type mechanism
to hold the pedal in the applied position. A cable and
spring are used to release the ratchet mechanism
and return the pedal to normal position.
Parking brake cable adjustment is controlled by
the cable tensioner. The tensioner, once adjusted at
the factory, will not need further adjustment under
normal circumstances. There are only two instances when adjustment is required. The first is
when a new tensioner, or cables have been installed. And the second, is when the tensioner and
cables are disconnected for access to other brake
components.
5 - 64
PARKING BRAKES
PARKING BRAKES
5 - 65
5 - 66
PARKING BRAKES
PARKING BRAKES
PARKING BRAKE CABLE TENSIONER ADJUSTMENT
Tensioner adjustment is only necessary when
the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is
necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty parking brake operation.
(1) Raise vehicle.
(2) Back off cable tensioner adjusting nut at equalizer to create slack in cables.
(3) Remove rear wheel/tire assemblies. Then remove brake drums.
(4) Check rear brakeshoe adjustment with standard brake gauge. Also check condition of brake parts
as follows:
(a) Replace worn parts if necessary. Excessive
shoe-to-drum clearance, or worn components
will result in faulty parking brake adjustment
and operation.
(b) Verify that parking brake cables operate
freely and are not binding, or seized. Replace faulty
cables, before proceeding.
(c) Adjust rear brakeshoes to drums.
(d) Install drums and verify that drums rotate
freely without drag.
(5) Reinstall wheel/tire assemblies after brakeshoe
adjustment is complete.
(6) Lower vehicle enough for access to parking
brake foot pedal. Then fully apply parking
brakes. Leave brakes applied until adjustment
is complete.
(7) Raise vehicle again.
5 - 67
5 - 68
PARKING BRAKES
SPECIFICATIONS
TORQUE SPECIFICATIONS
CLUTCH
6 - 1
CLUTCH
CONTENTS
page
page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL INFORMATION
INDEX
page
page
Clutch Components . . . . . . . . . . . . . . . . . . . . . . . . 1
Clutch Disc Application . . . . . . . . . . . . . . . . . . . . . . 1
Clutch Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . 1
Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clutch Pedal Position Switch . . . . . . . . . . . . . . . . . . 2
Hydraulic Clutch Linkage . . . . . . . . . . . . . . . . . . . . . 1
CLUTCH COMPONENTS
6 - 2
CLUTCH
CLUTCH LUBRICATION
Proper clutch component lubrication is important
to satisfactory operation. Using the correct lubricant
and avoiding over lubrication are also equally important.
During service, apply recommended lubricant sparingly. Do not overlubricate as this could result in
clutch disc and pressure plate contamination.
Clutch and transmission components requiring lubrication are:
pilot bearing
release lever pivot ball stud
release lever pivot surfaces
release bearing bore
clutch pedal pivot bore and bushings.
transmission input shaft splines and pilot hub
release bearing slide surface of front bearing retainer
CLUTCH
6 - 3
CLUTCH DIAGNOSIS
INDEX
page
Clutch
Clutch
Clutch
Clutch
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4
4
3
3
GENERAL INFORMATION
Problem diagnosis will generally require a road
test to determine the type of fault. Component inspection will then determine the problem cause after
road testing.
Drive the vehicle at normal speeds during the road
test. Shift the transmission through all gear ranges
and observe clutch action.
If chatter, grab, slip, or improper release is experienced, remove and inspect the clutch components.
However, if the problem is noise or hard shifting, further diagnosis may be needed. The transmission or
another driveline component may actually be at
fault. Careful observation during the test will help
narrow the problem area.
page
Flywheel Misalignment . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . .
Improper Clutch Release or Engagement
Inspection and Diagnosis Charts . . . . . .
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3
3
3
4
Grease contamination is usually a product of excessive lubrication during clutch service. Apply only a
small amount of grease to the input shaft splines,
bearing retainer, pilot bearing, release fork and pivot
stud. Excess grease can be thrown off during operation and contaminate the disc.
CLUTCH MISALIGNMENT
Clutch components must be in proper alignment
with the crankshaft and transmission input shaft.
Misalignment caused by excessive runout or warpage
of any clutch component will cause grab, chatter and
improper clutch release.
FLYWHEEL MISALIGNMENT
Common causes of misalignment are heat warping,
mounting the flywheel on a dirty crankshaft flange,
incorrect bolt tightening, improper seating on the
crankshaft flange shoulder, or loose crankshaft or flywheel bolts.
6 - 4
CLUTCH
CLUTCH
CLUTCH INSPECTION CHART
6 - 5
6 - 6
CLUTCH
CLUTCH SLIPS
CLUTCH
IMPROPER CLUTCH RELEASE
6 - 7
6 - 8
CLUTCH
CLUTCH GRAB/CHATTER
CLUTCH
CLUTCH NOISE
6 - 9
6 - 10
CLUTCH
CLUTCH COMPONENT SERVICE
INDEX
page
Clutch
Clutch
Clutch
Clutch
Clutch
...........
...........
..........
...........
...........
10
10
11
13
12
page
Clutch Pedal Installation . . . .
Clutch Pedal Removal . . . . . .
Flywheel Service . . . . . . . . . .
Pilot Bearing Replacement . .
Release Bearing Replacement
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13
13
13
12
12
CLUTCH
6 - 11
6 - 12
CLUTCH
essary followed by a wax and grease remover, or similar solvent. Also clean engine block surface as well.
(5) Position replacement clutch housing on transmission and install housing attaching bolts. Tighten
bolts to 38 Nzm (28 ft. lbs.) torque.
(6) Transfer release fork pivot ball stud to replacement housing if necessary.
(7) Lubricate release bearing bore, release fork
contact surfaces and release fork pivot stud with Mopar high temperature bearing grease. Also lubricate
transmission input shaft splines, pilot hub and bearing retainer slide surface with light coat of same
grease.
(8) Install release fork and bearing in housing. Be
sure release fork boot is properly seated in housing.
(9) Install transmission as described in Group 21.
CLUTCH
(7) Remove retaining ring, flat washer and wave
washer that attach clutch master cylinder push rod
to clutch pedal (Fig. 8).
(8) Slide clutch master cylinder push rod off clutch
pedal pin.
(9) Inspect condition of bushing on clutch pedal
pin. Remove and replace bushing if worn or damaged.
(10) Verify that cap on clutch master cylinder reservoir is tight. This is necessary to avoid undue spillage during removal.
(11) Remove screws attaching clutch fluid reservoir
to dash panel.
(12) Pull clutch master cylinder rubber seal from
dash panel (Fig. 8).
(13) Rotate clutch master cylinder 45 counterclockwise to unlock it. Then remove cylinder from
dash panel.
(14) Remove hydraulic linkage components from
vehicle.
6 - 13
(3) Inspect bushing on the clutch pedal pin. Replace bushing if worn or damaged.
(4) Remove snap ring and washer attaching clutch
pedal to the pivot shaft.
(5) Slide pedal off pivot shaft and remove pedal.
(6) Remove and inspect bushings in pedal bore. Replace bushings if worn or cracked.
FLYWHEEL SERVICE
Inspect the flywheel whenever the clutch disc and
cover are removed for service. Check condition of the
flywheel face, hub, starter ring gear teeth, and flywheel bolts.
Minor scratches, burrs, or glazing on the flywheel
face can be reduced with 120/180 grit emery cloth.
However, the flywheel should be replaced if the disc
contact surface is severely scored, heat checked,
cracked, or obviously worn.
Cleanup of minor flywheel scoring should be performed with surface grinding equipment. Remove
only enough material to reduce scoring (approximately 0.001 - 0.003 in.).
Heavy stock removal is not recommended.
The flywheel surface is manufactured with a
unique contour which can be damaged by machining. Replace the flywheel if scoring is severe and deeper than 0.076 mm (0.003 in.).
Excessive stock removal can also result in flywheel cracking or warpage after installation. It
can also weaken the flywheel and interfere
with proper clutch release.
Check flywheel runout if misalignment is suspected. Runout should not exceed 0.08 mm (0.003
in.). Measure runout at the outer edge of the flywheel face with a dial indicator. Mount the dial indicator on a stud installed in place of one of the
flywheel attaching bolts.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing runout.
Check condition of the flywheel hub and attaching
bolts. Replace the flywheel if the hub exhibits cracks
in the area of the attaching bolt holes.
Install new attaching bolts whenever the flywheel
is replaced. Apply Mopar Lock-N-Seal, or Loctite 242
on the replacement bolt threads before installation.
6 - 14
CLUTCH
closed heating device should be used. Temperature required for uniform expansion is 149177C (300-350F).
CAUTION: Never use an oxy/acetylene torch to remove the old ring gear, or to heat and expand a replacement gear. The high temperature of the torch
flame will cause localized heating and damage the
flywheel. In addition, using the torch to heat a replacement gear will cause uneven heating and expansion. The torch flame will also anneal the gear
teeth resulting in rapid wear and damage after installation.
(e) Be sure to wear eye and hand protection.
Heat resistent gloves and protective goggles are
needed for personal safety. Also use metal tongs,
vise grips, or similar tools to position the gear as
necessary for installation.
(f) Allow the flywheel and ring gear assembly to
cool down before installation. Set the assembly on a
workbench and let it cool to shop air temperature.
CAUTION: Do not use water, or compressed air to
cool the ring gear or flywheel. The rapid cooling
produced by water or compressed air will distort, or
crack the gear and flywheel.
CLUTCH
SPECIFICATIONS
TORQUE SPECIFICATIONS
6 - 15
COOLING SYSTEM
7 - 1
COOLING SYSTEM
CONTENTS
page
page
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . . 39
ENGINE BLOCK HEATERS . . . . . . . . . . . . . . . . . 47
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 48
GENERAL INFORMATION
Throughout this group, references are made to particular vehicle models by alphabetical designation or
by the particular vehicle nameplate. A chart showing
a breakdown of alphabetical designations is included
in the Introduction section at the beginning of this
manual.
COOLING SYSTEM
The cooling system regulates engine operating temperature. It allows the engine to reach normal oper-
7 - 2
COOLING SYSTEM
7 - 3
DIAGNOSIS
INDEX
page
page
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . 4
7 - 4
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as
the following may be the cause:
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page
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Pressure Cap . . . . . . . . . . . . . . . .
Refilling Cooling System . . . . . . . . . . . . . . .
Testing Cooling System for Leaks . . . . . . . .
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . .
Viscous Fan Drive3.9L/5.2L Engine . . . . .
Water Pump Bypass Hose3.9L/5.2L Engine
Water PumpsGeneral Information . . . . . . .
Water PumpsRemoval/Installation . . . . . .
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12
WATER PUMPSREMOVAL/INSTALLATION
The water pump on all models can be removed
without discharging the air conditioning system (if
equipped).
7 - 13
7 - 14
CAUTION: The solid mount accessory bracket fasteners must be tightened in following sequence.
(e) Tighten bolt 1 (Fig. 2) to 3 Nzm (30 in. lbs.)
torque.
(f) Tighten nut 2 and bolt 3 (Fig. 2) to 54 Nzm
(40 ft. lbs.) torque.
(g) Tighten bolts 1, 4 and 5 (Fig. 2) to 54 Nzm (40
ft. lbs.) torque.
(h) Tighten bolts 6 and 7 (Fig. 2) to 54 Nzm (40
ft. lbs.) torque.
(i) Install air conditioning compressor. Tighten
mounting bolts to 54 Nzm (40 ft. lbs.) torque.
(3) Install generator. Refer to Group 8B, Battery/
Starter/ Generator Service.
(4) Install accessory drive belts. Refer to the Engine Accessory Drive Belt section of this group for installation procedure and belt tension specifications.
(5) Fill cooling system with coolant. Refer to the
Refilling Cooling System section in this group.
(6) Start and warm the engine. Check for leaks.
3.9L/5.2L ENGINE
The water pump on 3.9L and 5.2L engines is bolted
directly to the engine timing chain case/cover.
A gasket is used as a seal between the water pump
and timing chain case/cover.
If water pump is replaced because of bearing/shaft
damage, or leaking shaft seal, the mechanical cooling
fan assembly should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan if
any of these conditions are found. Also check condition of the thermal Viscous Fan Drive. Refer to Viscous Fan Drive in this group.
7 - 15
REMOVAL
The water pump can be removed and installed
without discharging the air conditioning system (if
equipped).
(1) Disconnect negative battery cable from battery.
(2) Drain cooling system. Refer to Draining Cooling
System in this group.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
(3) Remove throttle cable at top of fan shroud.
(4) Unsnap coolant overflow tank (up and out)
from fan shroud and lay aside. Do not disconnect
hose or drain coolant from tank.
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. 3). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING
CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 4). If replacement is necessary, use only an original equipment clamp with matching number or letter.
(5) Remove upper radiator hose clamp (Fig. 3) and
hose at radiator.
(6) The thermal viscous fan drive is attached
(threaded) to the water pump hub shaft (Fig. 6). Remove fan/viscous fan drive assembly from water
pump by turning mounting nut counterclockwise as
viewed from front. Threads on viscous fan drive are
RIGHT HAND. A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummins Diesel Tool
Set number 2017DSP) can be used. Place a bar or
screwdriver between water pump pulley bolts (Fig. 6)
to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at
this time.
If water pump is being replaced, do not unbolt fan
blade assembly (Fig. 6) from thermal viscous fan
drive.
(7) Remove fan shroud attaching hardware (two
bolts at bottom-two clips at top).
(8) Remove fan shroud and fan blade/viscous fan
drive assembly from vehicle as a complete unit.
After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in
viscous fan drive could drain into its bearing assembly and contaminate lubricant.
Do not remove water pump pulley bolts at this
time.
7 - 16
7 - 17
placement is necessary, use only an original equipment clamp with matching number or letter.
7 - 18
7 - 19
THERMOSTAT
GENERAL INFORMATIONALL ENGINES
On 2.5L 4-cylinder engines, the thermostat is located inside the water box at front of engine on radiator side (Fig. 18). This thermostat does not have an
air bleed notch.
On 3.9L and 5.2L engines, the thermostat is located beneath the thermostat housing at front of intake manifold (Fig. 19). This thermostat has an air
bleed notch.
All thermostats (2.5L, 3.9L and 5.2L engines) are of
the wax-pellet-driven, reverse-poppet-choke-type. The
wax pellet is located in a sealed container at spring
end of thermostat. When heated, the pellet expands,
overcoming closing spring tension and water pump
pressure to force valve to open. Coolant leakage into
pellet container will cause thermostat to fail in open
position. Do not attempt to free a sticking thermostat
with a prying device.
The thermostat controls the operating temperature
of the engine by controlling the amount of coolant
flow to radiator. On all engines (2.5L, 3.9L and 5.2L),
thermostat is closed below 88C (192F). When cool-
7 - 20
WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
If thermostat is being replaced, be sure that replacement is the specified thermostat for vehicle
model and engine type.
(1) Disconnect negative battery cable from battery.
(2) Drain cooling system until coolant level is below thermostat. Refer to Draining Cooling System in
this group.
7 - 21
If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model
and engine type.
Factory installed thermostat housings on 3.9L/5.2L
engines are installed on a gasket with an anti-stick
coating. This will aid in gasket removal and clean-up.
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system until coolant level is below thermostat. Refer to Draining Cooling System in
this group.
(3) Air Conditioned vehicles: Remove support
bracket (generator mounting bracket-to-intake manifold) located near rear of generator (Fig. 20).
(3) Remove radiator hose clamp (Fig. 12) and radiator hose at thermostat housing.
(4) Remove ignition coil/coil mounting bracket assembly. Do not remove coil from mounting bracket.
(5) Remove thermostat housing stud/bolts, thermostat housing, gasket and thermostat (Fig. 18). Discard old gasket.
(6) Clean gasket mating surfaces.
INSTALLATION2.5L ENGINE
If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model
and engine type.
(1) Dip replacement gasket in water and position
on water box (Fig. 18).
(2) Assemble the thermostat and thermostat housing as shown in (Fig. 18). Be sure the thermostat is
centered into thermostat housing and that spring
side is installed towards cylinder head.
CAUTION: Tightening housing unevenly or without
thermostat centered, may result in a cracked housing.
(3) Install housing stud/bolts. Tighten housing
stud/bolts to 23 Nzm (200 in. lbs.) torque.
(4) Install ignition coil/coil mounting bracket assembly.
(5) Install upper radiator hose to thermostat housing.
(6) Connect negative battery cable to battery.
(7) Fill cooling system. Refer to Refilling Cooling
System in this group.
REMOVAL3.9L/5.2L ENGINE
WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
7 - 22
front of vehicle. The housing is slightly angled forward after installation to intake manifold.
INSTALLATION3.9L/5.2L ENGINE
(1) Clean mating areas of intake manifold and
thermostat housing.
(2) Install thermostat (spring side down) into recessed machined groove on intake manifold (Fig. 22).
(3) Install gasket on intake manifold and over
thermostat (Fig. 22).
(4) Position thermostat housing to intake manifold.
Note the word FRONT stamped on housing (Fig. 23).
For adequate clearance, this must be placed towards
COOLANT
The cooling system is designed around the coolant.
Coolant flows through the engine water jackets absorbing heat produced during engine operation. The
7 - 23
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mixtures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
100% Ethylene-Glycol-The corrosion inhibiting
additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing
temperature to rise to as high as 149C (300F). This
temperature is hot enough to melt plastic and soften
solder. The increased temperature can result in engine detonation. In addition, 100 percent ethyleneglycol freezes at -22C (-8F).
50/50 Ethylene-Glycol and Water-Is the recommended mixture, it provides protection against freezing to -37C (-35F). The antifreeze concentration
must always be a minimum of 44 percent, yearround in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7C (-90F). A higher percentage will
freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethylene-glycol.
COOLANT SELECTION-ADDITIVES
Coolant should be maintained at the specified level
with a mixture of ethylene glycol-based antifreeze
and low mineral content water. Only use an antifreeze containing ALUGARD 340-2 .
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
COOLANT SERVICE
It is recommended that the cooling system be
drained and flushed at 84,000 kilometers (52,500
7 - 24
DEAERATION
As the engine operates, any air trapped in cooling
system gathers under the radiator cap. The next time
the engine is operated, thermal expansion of coolant
will push any trapped air past radiator cap into the
coolant reserve/overflow tank. Here it escapes to the
atmosphere into the tank. When the engine cools
down the coolant, it will be drawn from the reserve/
overflow tank into the radiator to replace any removed air.
7 - 25
CHEMICAL CLEANING
In some instances, use a radiator cleaner (Mopar
Radiator Kleen or equivalent) before flushing. This
will soften scale and other deposits and aid flushing
operation.
CAUTION: Follow manufacturers instructions when
using these products.
Aluminum Hydroxide Deposition is a type of corrosion encountered in cooling system of engines that
are of an aluminum composition. This would be on a
2.5L engine with aluminum cylinder head. It appears
as dark grey when wet, but, when dry it is white.
This type of corrosion can usually be removed with a
commercially available two part cleaner (oxcilac acid
and neutralizer). Follow manufacturers directions for
use. However, it is recommended that engine be operated one extra hour if acid is in coolant.
7 - 26
gauge pointer and determine condition of cooling system according to following criteria:
Holds Steady: If pointer remains steady for two
minutes, serious coolant leaks are not present in system. However, there could be an internal leak that
does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks cannot be detected, inspect for interior leakage or perform Internal Leakage Test.
Drops Slowly: Indicates a small leak or seepage is
occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
hoses, gasket edges and heater. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system again with pressure applied.
Drops Quickly: Indicates that serious leakage is
occurring. Examine system for external leakage. If
leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
reputable radiator repair shop.
7 - 27
vides a convenient and safe method for checking coolant level and adjusting level at atmospheric
pressure. This is done without removing the radiator
pressure cap. The system also provides some reserve
coolant to the radiator to cover minor leaks and
evaporation or boiling losses.
As the engine cools, a vacuum is formed in the
cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator.
TANK REMOVAL
(1) Remove overflow hose at reserve/overflow tank.
(2) Unsnap the coolant reserve/overflow tank from
fan shroud. Lift straight up. The fan shroud is
equipped with T-shaped slots to attach the tank.
TANK INSTALLATION
(1) Snap tank into fan shroud.
(2) Install overflow hose to tank.
7 - 28
7 - 29
INSPECTION
Hold cap at eye level, right side up. The vent valve
(Fig. 29) at bottom of cap should open. If rubber gasket has swollen and prevents vent valve from opening, replace cap.
Hold cap at eye level, upside down. If any light can
be seen between vent valve and rubber gasket, replace cap. Do not use a replacement cap that has
a spring to hold vent shut. A replacement cap
must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm
spring and a rubber gasket. This gasket is used to
seal to radiator filler neck top surface. Use of proper
cap will allow coolant return to radiator.
RADIATOR
The radiators used in these models are of the
down-flow type (vertical tubes) and have plastic
tanks. The radiator supplies sufficient heat transfer
to cool engine.
CAUTION: Although plastic radiator tanks are stronger than brass, they are more susceptible to damage from impact or excessive hose clamp torque.
In the event of damage to a plastic radiator tank,
replacement tanks and o-ring seals (Fig. 31) are
available through the parts department. Tank repair
should be performed by qualified personnel using
proper equipment.
7 - 30
7 - 31
7 - 32
RADIATOR CLEANING
The radiator and air conditioning fins should be
cleaned when an accumulation of bugs, leaves etc.
has occurred. Clean radiator fins are necessary for
good heat transfer. With the engine cold, apply cold
water and compressed air to the back (engine side) of
the radiator to flush the radiator and/or A/C condenser of debris.
7 - 33
7 - 34
7 - 35
7 - 36
REMOVAL
(1) Disconnect negative battery cable from battery.
(2) Remove throttle cable at top of fan shroud.
(3) Unsnap coolant reserve/overflow tank from fan
shroud and lay aside. The tank is held to shroud
with T-shaped slots. Do not disconnect hose or drain
coolant from tank.
(4) The thermal viscous fan drive/fan blade assembly is attached (threaded) to water pump hub shaft
(Fig. 48). Remove fan blade/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on
viscous fan drive are RIGHT HAND. A Snap-On 36
MM Fan Wrench (number SP346 from Snap-On
Cummins Diesel Tool Set number 2017DSP) can be
used. Place a bar or screwdriver between water
pump pulley bolts (Fig. 48) to prevent pulley from rotating.
Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
INSPECTION
The fan blades cannot be repaired. If fan is damaged, it must be replaced. Inspect fan as follows:
(1) Remove fan blade and viscous fan drive as an
assembly from the engine. Refer to preceding Removal procedure.
(2) Remove fan blade assembly from viscous fan
drive unit (four bolts).
(3) Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface, replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
7 - 37
INSTALLATION
(1) Install fan blade assembly to viscous fan drive.
Tighten bolts (Fig. 48) to 23 Nzm (17 ft. lbs.) torque.
(2) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(3) Install fan shroud.
(4) Install fan blade/viscous fan drive assembly to
water pump shaft (Fig. 48).
(5) Install coolant reserve/overflow tank to fan
shroud. Snaps into position.
(6) Install throttle cable to fan shroud.
(7) Connect negative battery cable.
7 - 38
CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
NOISE
It is normal for fan noise to be louder (roaring) when:
The underhood temperature is above the engagement point for the viscous drive coupling. This may
occur when ambient (outside air temperature) is very
high.
Engine loads and temperatures are high such as
when towing a trailer.
Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged
(warm) position. This can occur during the first 15
seconds to one minute after engine start-up on a cold
engine.
LEAKS
Viscous fan drive operation is not affected by small
oil stains near the drive bearing. If leakage appears
excessive, replace the fan drive unit.
TESTING
If the fan assembly free-wheels without drag (the
fan blades will revolve more than five turns when
spun by hand), replace the fan drive. This spin test
must be performed when the engine is cool.
For the following test, the cooling system must be
in good condition. It also will ensure against excessively high coolant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Drill a 3.18-mm (1/8-in) diameter hole in the
top center of the fan shroud.
(2) Obtain a dial thermometer with an 8 inch stem
(or equivalent). It should have a range of -18-to-
7 - 39
page
Belt Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
BELT DIAGNOSIS
V-BELT DIAGNOSIS2.5L 4-CYLINDER
ENGINE ONLY
Refer to the V-Belt diagnosis chart.
SERPENTINE DRIVE BELT DIAGNOSISALL
ENGINES
When diagnosing serpentine drive belts, small
cracks that run across ribbed surface of belt from rib
to rib (Fig. 1), are considered normal. These are not a
reason to replace belt. However, cracks running along
a rib (not across) are not normal. Any belt with
cracks running along a rib must be replaced (Fig. 1).
Also replace belt if it has excessive wear, frayed cords
or severe glazing.
Refer to the Serpentine Drive Belt Diagnosis charts
for further belt diagnosis. Also refer to Automatic
Belt Tensioner3.9L/5.2L Engine, proceeding in this
group.
7 - 40
7 - 41
7 - 42
7 - 43
BELT SCHEMATICS
Models are available with either a 2.5L four-cylinder engine, a 3.9L six-cylinder (V-6) engine or a 5.2L
eight-cylinder (V-8) engine. Refer to Figs. 2, 3 or 4 for
accessory drive belt routing.
BELT TENSION
ALL ENGINES
Correct accessory drive belt tension is required to
be sure of optimum performance of belt driven engine
accessories. If specified tension is not maintained,
belt slippage may cause; engine overheating, lack of
BELT REMOVAL/INSTALLATION
GENERATOR BELT2.5L ENGINE
REMOVAL
(1) Disconnect negative battery cable from battery.
(2) Loosen generator mounting bolt (Fig. 6).
7 - 44
7 - 45
7 - 46
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 Nzm (45 ft. lbs.).
(2) Install tensioner assembly to mounting bracket.
An indexing tab is located on back of tensioner. Align
this tab to slot in mounting bracket. Tighten nut to
67 Nzm (50 ft. lbs.).
(3) Connect all wiring to ignition coil.
(4) Install coil to coil bracket. If nuts and bolts are
used to secure coil to coil bracket, tighten to 11 Nzm
(100 in. lbs.) torque. If coil mounting bracket has
been tapped for coil mounting bolts, tighten bolts to 5
Nzm (50 in. lbs.) torque.
Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator)
A pulley on an engine accessory being loose
Misalignment of an engine accessory
Belt incorrectly routed. Refer to (Fig. 4)
A used belt should be replaced if tensioner indexing
arrow has moved beyond point A (Fig. 10).
REMOVAL
(1) Attach a socket/wrench to mounting bolt of automatic tensioner pulley bolt (Fig. 9).
(2) Rotate tensioner assembly clockwise (as viewed
from front) until tension has been relieved from belt.
(3) Remove belt from idler pulley first.
(4) Remove belt from other pulleys.
(5) Disconnect wiring and secondary cable from ignition coil.
7 - 47
REMOVAL
(1) Disconnect negative battery cable from battery.
(2) Drain coolant from radiator and cylinder block.
Refer to Draining Cooling System in this group.
(3) Remove power cord from block heater (Fig. 1).
(4) Loosen screw at center of block heater. Remove
heater assembly.
INSTALLATION
(1) Thoroughly clean cylinder block core hole and
block heater seat.
(2) Insert block heater assembly with element loop
pointing down.
(3) With block heater fully seated, tighten center
screw to 2 Nzm (17 in. lbs.) torque.
(4) Fill cooling system with recommended coolant.
Refer to Filling Cooling System section in this group.
(5) Start and warm the engine. Check for leaks.
7 - 48
GENERAL INFORMATION
The following specifications are published from the
latest information available at the time of publication. If anything differs between the specifications found on the Vehicle Emission Control
Information (VECI) label and the following
specifications, use specifications on VECI label.
The VECI label is located in the engine compartment. Refer to Group 25, Emission System for more
information on the VECI label.
COOLANT CAPACITIES
TORQUE
ELECTRICAL
8A - 1
ELECTRICAL
GROUP INDEX
Group
AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY/STARTER/GENERATOR SERVICE . . . .
BATTERY/STARTING/CHARGING SYSTEMS
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . .
CHIME/BUZZER WARNING SYSTEMS . . . . . . . .
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL AND GAUGES . . . . . . . . .
LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . .
8F
8B
8A
8U
8G
8D
8E
8L
8C
Group
POWER LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . 8P
POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . 8T
POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . . 8S
RESTRAINT SYSTEMS . . . . . . . . . . . . . . . . . . . 8M
TURN SIGNAL AND HAZARD WARNING
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J
VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . 8H
WIPER AND WASHER SYSTEMS . . . . . . . . . . . . 8K
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 8W
page
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . 17
IGNITION-OFF DRAW . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 22
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 11
USING ON-BOARD DIAGNOSTIC SYSTEM . . . . 21
GENERAL INFORMATION
The battery, starting, and charging systems operate
with one another; therefore, they must be tested as a
complete system. In order for the vehicle to start and
charge properly, all of the components involved in
these systems must perform within specifications.
Group 8A covers battery, starting (Fig. 1) and
charging (Fig. 2) system diagnostic procedures. These
procedures include the most basic conventional diag-
8A - 2
8A - 3
BATTERY
GENERAL INFORMATION
The storage battery is a device used to store electrical
energy potential in a chemical form. When an electrical
load is applied to the battery terminals, an electrochemical reaction occurs within the battery. This reaction
causes the battery to discharge electrical current.
The battery is made up of 6 individual cells that
are connected in series. Each cell contains positively
charged plate groups made of lead oxide, and negatively charged plate groups made of sponge lead.
These dissimilar metal plates are submerged in a
sulfuric acid and water solution called electrolyte.
As the battery discharges, a gradual chemical change
takes place within each cell. The sulfuric acid in the
electrolyte combines with the plate materials, causing
both plates to change to lead sulfate. At the same time,
oxygen from the positive plate material combines with
hydrogen from the sulfuric acid, causing the electrolyte
to become mainly water.
The chemical changes within the battery are caused
by movement of excess or free electrons between the
positive and negative plate groups. This movement of
electrons produces a flow of electrical current through
the load device attached to the battery terminals.
As the plate materials become more similar chemically, and the electrolyte becomes less acid, the voltage potential of each cell is reduced. However, by
charging the battery with a voltage higher than that
of the battery, the process is reversed.
Charging the battery gradually changes the sulfated
lead plates back into sponge lead and lead oxide, and
the water back into sulfuric acid. This action restores
the difference in electron charges deposited on the
plates, and the voltage potential of the battery cells.
For a battery to remain useful, it must be able to
produce high-amperage current over an extended period. A battery must also be able to accept a charge,
so that its voltage potential may be restored.
In addition to producing and storing electrical energy, the battery serves as a capacitor or voltage stabilizer for the vehicle electrical system. It absorbs
abnormal or transient voltages caused by switching
of any of the vehicles electrical components.
The battery is vented to release excess gas that is
created when the battery is being charged or discharged. However, even with these vents, hydrogen
gas can collect in or around the battery. If hydrogen
gas is exposed to flame or sparks, it can ignite.
If the electrolyte level is low, the battery could arc internally and explode. If the battery is equipped with removable cell caps, add distilled water whenever the
electrolyte level is below the top of the plates. If the battery cell caps cannot be removed, the battery must be
replaced if the electrolyte level is low.
BATTERY RATINGS
Currently, there are 2 commonly accepted methods for
rating and comparing battery performance. These ratings are called Cold Cranking Amperage (CCA), and Reserve Capacity (RC). Be certain that a replacement
battery has CCA and RC ratings that equal or exceed
the original equipment specification for the vehicle being serviced. See Battery Classifications and Ratings
charts in Specifications at the back of this group.
COLD CRANKING AMPERAGE
The Cold Cranking Amperage (CCA) rating specifies how much current (in amperes) the battery can
deliver for 30 seconds at -17.7C (0F). Terminal voltage must not fall below 7.2 volts during or after the
30 second discharge. The CCA required is generally
higher as engine displacement increases, depending
also upon the starter current draw requirements.
RESERVE CAPACITY
The Reserve Capacity (RC) rating specifies the
time (in minutes) it takes for battery terminal voltage to fall below 10.2 volts at a discharge rate of 25
amps. RC is determined with the battery fullycharged at 26.7C (80F). This rating estimates how
long the battery might last after a charging system
failure, under minimum electrical load.
DIAGNOSIS
The battery must be completely charged and the
top, posts, and terminal clamps should be properly
cleaned before diagnostic procedures are performed.
Refer to Group 8B - Battery/Starter/Generator Service for more information.
The condition of a battery is determined by two criteria:
(1) State-Of-Charge This can be determined by
viewing the built-in test indicator, by checking specific gravity of the electrolyte (hydrometer test), or by
checking battery voltage (open circuit voltage test).
(2) Cranking Capacity This can be determined by
performing a battery load test, which measures the ability of the battery to supply high-amperage current.
If the battery has a built-in test indicator, use this
test first. If it has no test indicator, but has removable cell caps, perform the hydrometer test first. If
cell caps are not removable, or a hydrometer is not
available, perform the open circuit voltage test first.
The battery must be charged before proceeding
with a load test if:
8A - 4
8A - 5
8A - 6
HYDROMETER TEST
The hydrometer test reveals the battery state-ofcharge by measuring the specific gravity of the electrolyte. This test cannot be performed on batteries
with non-removable cell caps. If battery has non-removable cell caps, see Built-In Test Indicator or Open
Circuit Voltage Test.
Specific gravity is a comparison of the density of
the electrolyte to the density of pure water. Pure water has a specific gravity of 1.000, and sulfuric acid
has a specific gravity of 1.835. Sulfuric acid makes
up approximately 35% of the electrolyte by weight, or
24% by volume.
In a fully-charged battery the electrolyte will have
a temperature corrected specific gravity of 1.260 to
1.290. However, a specific gravity of 1.235 or above is
satisfactory for battery load testing and/or return to
service.
Before testing, visually inspect battery for any
damage (cracked case or cover, loose posts, etc.) that
would cause the battery to be faulty. Then remove
cell caps and check electrolyte level. Add distilled water if electrolyte level is below the top of the battery
plates.
To use the hydrometer correctly, hold it with the
top surface of the electrolyte at eye level. Refer to the
hydrometer manufacturers instructions for correct
use of hydrometer. Remove only enough electrolyte
from the battery so the float is off the bottom of the
hydrometer barrel with pressure on the bulb released.
Exercise care when inserting the tip of the hydrometer into a cell to avoid damaging the plate separators. Damaged plate separators can cause premature
battery failure.
Hydrometer floats are generally calibrated to indicate the specific gravity correctly only at 26.7C
(80F). When testing the specific gravity at any other
temperature, a correction factor is required.
The correction factor is approximately a specific
gravity value of 0.004, referred to as 4 points of specific gravity. For each 5.5C above 26.7C (10F above
80F), add 4 points. For each 5.5C below 26.7C
(10F below 80F), subtract 4 points. Always correct
the specific gravity for temperature variation. Test
the specific gravity of the electrolyte in each battery
cell.
Example: A battery is tested at -12.2C (10F) and
has a specific gravity of 1.240. Determine the actual
specific gravity as follows:
(1) Determine the number of degrees above or below 26.7C (80F):
26.6C - -12.2C = 38.8C (80F - 10F = 70F)
(2) Divide the result from step 1 by 5.5 (10):
38.8C/5.5 = 7 (70F/10 = 7)
(3) Multiply the result from step 2 by the temperature correction factor (0.004):
7 x 0.004 = 0.028
(4) The temperature at testing was below 26.7C
(80F); therefore, the temperature correction is subtracted:
1.240 - 0.028 = 1.212
The corrected specific gravity of the battery in this
example is 1.212.
If the specific gravity of all cells is above 1.235, but
variation between cells is more than 50 points
(0.050), the battery should be replaced.
If the specific gravity of one or more cells is less
than 1.235, charge the battery at a rate of approximately 5 amperes. Continue charging until 3 consecutive specific gravity tests, taken at 1-hour intervals,
are constant. If the cell specific gravity variation is
more than 50 points (0.050) at the end of the charge
period, replace the battery.
When the specific gravity of all cells is above 1.235,
and cell variation is less than 50 points (0.050), the
battery may be load tested.
8A - 7
See Open Circuit Voltage chart. This voltage reading will indicate state-of-charge, but will not reveal
cranking capacity. If a battery has an open circuit
voltage reading of 12.4 volts or greater, it may be
load tested. A battery that will not endure a load test
is faulty and must be replaced.
LOAD TEST
A battery load test will verify battery cranking capacity. The test is based on the Cold Cranking Amperage (CCA) rating of the battery. See Battery
Classifications and Ratings chart in Specifications, at
the back of this group.
WARNING: IF BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, OR LOW ELECTROLYTE LEVEL, DO NOT LOAD TEST. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
Before performing load test, the battery must
be FULLY-CHARGED.
(1) Remove both battery cables, negative first. Battery top and posts should be clean.
(2) Connect a suitable volt-ammeter-load tester
(Fig. 4) to the battery posts (Fig. 5). Refer to operating instructions provided with the tester being used.
Check the open circuit voltage (no load) of the battery. Open circuit voltage must be 12.4 volts or
greater.
8A - 8
(6) Voltage drop will vary with battery temperature at the time of the load test. Battery temperature
can be estimated by the ambient temperature over
the past several hours. If the battery has been
charged, boosted, or loaded a few minutes prior to
test, the battery will be somewhat warmer. See Load
Test Temperature chart for proper loaded voltage
reading.
(7) If the voltmeter reading falls below 9.6 volts, at
a minimum battery temperature of 21C (70F), replace the battery.
BATTERY CHARGING
A battery is fully-charged when:
all cells are gassing freely during charging
a green color is visible in sight glass of built-in
test indicator
three corrected specific gravity tests, taken at
1-hour intervals, indicate no increase in specific gravity
open circuit voltage is 12.4 volts or above.
WARNING: DO NOT ASSIST BOOST OR CHARGE A
BATTERY THAT HAS LOW ELECTROLYTE LEVEL
OR IS FROZEN. BATTERY MAY ARC INTERNALLY
AND EXPLODE.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR BATTERY.
WARNING: POISONOUS AND CAUSTIC. BATTERY
CONTAINS SULFURIC ACID. AVOID CONTACT WITH
SKIN, EYES, OR CLOTHING. IN EVENT OF CONTACT, FLUSH WITH WATER AND CALL PHYSICIAN
IMMEDIATELY. KEEP OUT OF REACH OF CHILDREN.
CAUTION: Always disconnect the battery negative
cable before charging battery to avoid damage to
8A - 9
CHARGE RATE
8A - 10
GENERAL INFORMATION
Ignition-Off Draw (IOD) refers to power being
drained from the battery with the ignition switch
turned OFF. A normal vehicle electrical system will
draw from 5 to 20 milliamps (0.005 - 0.020 amps).
This is with the ignition switch in the OFF position,
and all non-ignition controlled circuits in proper
working order. The 20 milliamps are needed to supply PCM memory, digital clock memory, and electronically-tuned radio memory.
A vehicle that has not been operated for approximately 20 days, may discharge the battery to an inadequate level. When a vehicle will not be used for
20 days or more (stored), remove the IOD fuse in the
Power Distribution Center (PDC). This will reduce
battery discharging.
Excessive battery drain can be caused by:
electrical items left on
faulty or improperly adjusted switches
internally shorted generator
intermittent shorts in the wiring.
If the IOD is over 20 milliamps, the problem must
be found and corrected before replacing a battery. In
most cases, the battery can be charged and returned
to service.
DIAGNOSIS
Testing for high-amperage IOD must be performed first to prevent damage to most milliamp meters.
(1) Verify that all electrical accessories are off.
Turn off all lamps, remove ignition key, and close all
doors. If the vehicle is equipped with illuminated entry or electronically-tuned radio, allow the systems to
automatically shut off (time out). This may take up
to 3 minutes.
(2) Determine that the underhood lamp is operating properly, then disconnect or remove bulb.
(3) Disconnect negative cable from battery.
(4) Connect a typical 12-volt test lamp (low-wattage bulb) between the negative cable clamp and the
battery negative terminal. Make sure that the doors
remain closed so that illuminated entry is not activated.
The test lamp may light brightly for up to 3 minutes, or may not light at all, depending upon the vehicles electrical equipment. The term brightly, as
used throughout the following tests, implies the
brightness of the test lamp will be the same as if it
were connected across the battery.
The test lamp must be securely clamped to the negative cable clamp and battery negative terminal. If
the test lamp becomes disconnected during any part
of the IOD test, the electronic timer function will be
activated and all tests must be repeated.
(5) After 3 minutes the test lamp should turn off
or be dimly lit, depending upon the vehicles electrical equipment. If the test lamp remains brightly lit,
do not disconnect it. Remove each fuse or circuit
breaker (refer to Group 8W - Wiring Diagrams) until
test lamp is either off or dimly lit. This will isolate
each circuit and identify the source of the high-amperage draw.
If the test lamp is still brightly lit after disconnecting each fuse and circuit breaker, disconnect the wiring harness from the generator. If test lamp now
turns off or is dimly lit, see Charging System in this
group to diagnose faulty generator. Do not disconnect
the test lamp.
After high-amperage IOD has been corrected, lowamperage IOD may be checked. It is now safe to install a milliamp meter to check for low-amperage
IOD.
(6) With test lamp still connected securely, clamp a
milliamp meter between battery negative terminal
and negative cable clamp.
Do not open any doors or turn on any electrical accessories with the test lamp disconnected
or the milliamp meter may be damaged.
(7) Disconnect test lamp. Observe milliamp meter.
The current draw should not exceed 0.020 amp. If
draw exceeds 20 milliamps, isolate each circuit by removing circuit breakers and fuses. The milliamp
meter reading will drop when the source of the draw
is disconnected. Repair this circuit as necessary,
whether a wiring short, incorrect switch adjustment
or a component failure is found.
8A - 11
STARTING SYSTEM
GENERAL INFORMATION
The starting system (Fig. 1) consists of:
ignition switch
starter relay
park/neutral position switch (automatic transmission)
clutch pedal position switch (manual transmission)
wiring harness and connections
battery
starter with an integral solenoid.
DIAGNOSIS
Before removing any unit from the starting system
for repair, perform the following inspections:
INSPECTION
BATTERY INSPECTION
To determine condition of the battery, see Battery
in this group.
8A - 12
WIRING INSPECTION
Inspect wiring for damage. Inspect all connections
at:
starter solenoid
park/neutral position switch (automatic transmission)
clutch pedal position switch (manual transmission)
ignition switch
starter relay
battery (including all ground connections).
Clean, tighten and repair all connections as required.
SOLENOID, RELAY AND SWITCH INSPECTIONS
Inspect the solenoid, relay and ignition switch to
determine their condition. Also, if equipped with automatic transmission, inspect condition of the park/
neutral position switch. If equipped with manual
transmission, inspect condition of the clutch pedal
position switch. Testing information can be found in
the following pages.
8A - 13
8A - 14
8A - 15
RELAY TEST
The starter relay is in the Power Distribution Center (PDC)(Fig. 11). Refer to the underside of the PDC
cover for relay location.
Remove starter relay from PDC to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to next step. If not OK, replace faulty relay.
(2) Resistance between terminals 85 and 86 (electromagnet) should be 7565 ohms. If OK, go to next
step. If not OK, replace faulty relay.
(3) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, go to Relay Circuit Test. If not OK,
replace faulty relay.
8A - 16
8A - 17
CHARGING SYSTEM
GENERAL INFORMATION
The charging system consists of:
generator
voltage regulator circuitry (within PCM)
ignition switch
battery
voltmeter
wiring harness and connections.
Following is a general description of the major
charging system components. Refer to Group 8W Wiring Diagrams for complete circuit descriptions
and diagrams.
The charging system is turned on and off with the
ignition switch. When the ignition switch is turned to
the ON position, battery voltage is applied to the
generator rotor through one of the two field terminals to produce a magnetic field. The generator is
driven by the engine through a serpentine belt and
pulley arrangement.
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor.
The wye (Y) type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes,
rectified DC current is delivered to the vehicle electrical system through the generator battery and
ground terminals.
The amount of DC current produced by the generator is controlled by the generator voltage regulator
(field control) circuitry, contained within the Powertrain Control Module (PCM)(Fig. 1). This circuitry is
connected in series with the second rotor field terminal and ground.
Voltage is regulated by cycling the ground path to
control the strength of the rotor magnetic field. The
generator voltage regulator circuitry monitors system
line voltage and ambient temperature. It then compensates and regulates generator current output accordingly.
The generator is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. The generator
voltage regulator (field control) circuitry can be serviced only by replacing the entire PCM.
All vehicles are equipped with On-Board Diagnostics (OBD). All OBD-sensed systems, including the
generator voltage regulator (field control) circuitry,
are monitored by the PCM. Each monitored circuit is
assigned a Diagnostic Trouble Code (DTC). The PCM
will store a DTC in electronic memory for any failure
it detects. See Using On-Board Diagnostic System in
this group for more information.
DIAGNOSIS
When the ignition switch is turned to the ON position, battery potential will register on the voltmeter.
During engine cranking a lower voltage will appear on
the meter. With the engine running, a voltage reading
higher than the first reading (ignition in ON) should
register.
The following procedures may be used to diagnose
the charging system if:
the voltmeter does not operate properly
an undercharged or overcharged battery condition occurs.
Remember that an undercharged battery is often
caused by:
accessories being left on with the engine not running
a faulty or improperly adjusted switch that allows a
lamp to stay on (see Ignition-Off Draw in this group).
INSPECTION
(1) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter solenoid and relay. They should be clean and tight. Repair as required.
(2) Inspect all fuses in the fuseblock module and
Power Distribution Center (PDC) for tightness in re-
8A - 18
8A - 19
RESULTS
If a higher voltage drop is indicated, inspect, clean and
tighten all connections. This includes any connection between generator battery output terminal and battery positive post. A voltage drop test may be performed at each
connection to locate the connection with excessive resistance. If resistance tests satisfactorily, reduce engine speed,
turn OFF carbon pile and turn OFF ignition switch.
(1) Disconnect negative cable from battery.
(2) Remove test ammeter, voltmeter, carbon pile,
and tachometer.
(3) Remove jumper wire.
(4) Connect generator output wire to generator
battery output terminal. Tighten nut to 8.561.5 Nzm
(75615 in. lbs.).
(5) Connect negative cable to battery.
(6) Use DRB scan tool to erase DTC.
8A - 20
(2) Adjust carbon pile and engine speed in increments until a speed of 1250 rpm and voltmeter reading of 15 volts is obtained.
CAUTION: Do not allow voltage meter to read above
16 volts.
(3) The ammeter reading must be within limits
shown in Generator Output Voltage Specifications.
RESULTS
(1) If reading is less than specified and generator
output wire resistance is not excessive, generator
should be replaced. Refer to Group 8B - Battery/
Starter/Generator Service.
(2) After current output test is completed, reduce
engine speed, turn OFF carbon pile and turn OFF ignition switch.
(3) Disconnect negative cable from battery.
(4) Remove test ammeter, voltmeter, tachometer
and carbon pile.
(5) Remove jumper wire (Fig. 3).
(6) Connect generator output wire to generator
battery output terminal. Tighten nut to 8.561.5 Nzm
(75615 in. lbs.).
(7) Connect negative cable to battery.
(8) Use DRB scan tool to erase DTC.
8A - 21
to be set. Therefore, it is important that the test procedures be followed in sequence, to understand what
caused a DTC to be set.
See Generator Diagnostic Trouble Code chart for
DTCs which apply to the charging system. Refer to
the Powertrain Diagnostic Procedures manual to diagnose an on-board diagnostic system trouble code.
8A - 22
BATTERY SPECIFICATIONS
BATTERY CLASSIFICATIONS AND RATINGS
8A - 23
BATTERY/STARTER/GENERATOR SERVICE
8B - 1
BATTERY/STARTER/GENERATOR SERVICE
CONTENTS
page
page
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 9
STARTER AND STARTER RELAY . . . . . . . . . . . . . 4
GENERAL INFORMATION
Group 8B covers battery, starter and generator service procedures. For diagnosis of these components
and their related systems, refer to Group 8A - Bat-
GENERAL INFORMATION
BATTERY
BATTERY REMOVE/INSTALL
(1) Turn ignition switch to OFF position. Make
sure all electrical accessories are off.
(2) Loosen the cable terminal clamps and remove
both battery cables, negative cable first. If necessary,
use a puller to remove terminal clamps from battery
posts (Fig. 2).
(3) Inspect the cable terminals for corrosion and damage. Remove corrosion using a wire brush or post and
terminal cleaning tool, and a sodium bicarbonate (baking soda) and warm water cleaning solution (Fig. 3). Replace cables that have damaged or deformed terminals.
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOVING A BATTERY BY HAND. SAFETY GLASSES
SHOULD ALSO BE WORN. IF THE BATTERY IS
CRACKED OR LEAKING, THE ELECTROLYTE CAN
BURN THE SKIN AND EYES.
8B - 2
BATTERY/STARTER/GENERATOR SERVICE
BATTERY/STARTER/GENERATOR SERVICE
8B - 3
8B - 4
BATTERY/STARTER/GENERATOR SERVICE
STARTER AND STARTER RELAY
GENERAL INFORMATION
This section covers starter and starter relay service
procedures only. For diagnostic procedures, refer to
Group 8A - Battery/Starting/Charging Systems Diagnostics. Service procedures for other starting system
components can be found as follows:
battery - see Battery, in this group
ignition switch - refer to Group 8D - Ignition Systems
clutch pedal position switch - refer to Group 6 Clutch
park/neutral position switch (automatic transmission) - refer to Group 21 - Transmission and Transfer
Case.
wiring harness and connectors - refer to Group 8W
- Wiring Diagrams.
STARTER
The starter motor incorporates several features to
create a reliable, efficient, compact and lightweight
unit. A planetary gear system (intermediate transmission) is used between the electric motor and pinion gear. This feature makes it possible to reduce the
dimensions of the starter. At the same time, it allows
higher armature rotational speed and delivers increased torque through the pinion gear to the flywheel or drive plate ring gear.
The use of a permanent magnet field on 2.5L engine starters also reduces size and weight. This field
contains high-strength permanent magnets. The
magnets are aligned according to their polarity and
are permanently fixed in the starter field frame.
The starter motors for all engines are activated by
a solenoid mounted to the overrunning clutch housing. However, the starter motor/solenoid are serviced
only as a complete assembly. If either component
fails, the entire assembly must be replaced.
Permanent magnet starters are highly sensitive to
hammering, shocks and external pressure.
CAUTION: The 2.5L engine starter motor MUST NOT
BE CLAMPED in a vise by the starter field frame.
Doing so may damage the magnets. Starter may be
clamped by the mounting flange ONLY.
CAUTION: Do not connect 2.5L engine starter motor
incorrectly when tests are being performed. The
permanent magnets may be damaged and rendered
unserviceable.
STARTER RELAY
The starter relay is an International Standards Organization (ISO) type relay. It is located in the Power
STARTER REMOVE/INSTALL2.5L
(1) Disconnect battery negative cable. Raise and
support vehicle.
(2) Remove starter heat shield clamp and heat
shield (Fig. 1).
STARTER REMOVE/INSTALL3.9L/5.2L
TWO-WHEEL DRIVE MODELS
(1) Disconnect battery negative cable. Raise and
support vehicle.
BATTERY/STARTER/GENERATOR SERVICE
8B - 5
8B - 6
BATTERY/STARTER/GENERATOR SERVICE
BATTERY/STARTER/GENERATOR SERVICE
8B - 7
GENERATOR
GENERAL INFORMATION
This section covers generator service procedures
only. For generator or charging system diagnosis, refer to Group 8A - Battery/Starting/Charging Systems
Diagnostics.
The generator is belt-driven by the engine. All engines use serpentine drive. The generator is serviced
only as a complete assembly. If the generator fails for
any reason, the entire assembly must be replaced.
Three generator output ratings are available on
this vehicle, depending upon optional equipment. Be
certain that the replacement generator has the same
output rating as the original unit. Refer to Group 8A
- Battery/Starting/Charging Systems Diagnostics and
see Specifications.
The generator field control (voltage regulator) circuitry is internal to the Powertrain Control Module
(PCM). If faulty, the entire PCM must be replaced.
Refer to Group 14 - Fuel System for PCM service
procedure.
GENERATOR REMOVE/INSTALL2.5L
GENERATOR REMOVE/INSTALL3.9L/5.2L
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.
(1) Disconnect battery negative cable.
8B - 8
BATTERY/STARTER/GENERATOR SERVICE
(4) Remove nuts from harness holddown, battery
terminal, ground terminal and 2 field terminals (Fig.
5). Remove wire connectors.
BATTERY/STARTER/GENERATOR SERVICE
SPECIFICATIONS
BATTERY SPECIFICATIONS
BATTERY CLASSIFICATIONS AND RATINGS
8B - 9
8B - 10
BATTERY/STARTER/GENERATOR SERVICE
OVERHEAD CONSOLE
8C - 1
OVERHEAD CONSOLE
CONTENTS
page
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 5
GENERAL INFORMATION
Following are general descriptions of major components used in the Dakota overhead console. Refer to
Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
THERMOMETER
The thermometer displays the outside ambient
temperature. The temperature displayed can be
changed from Fahrenheit to Celsius using the US/
METRIC button. The displayed temperature is not
an instant reading of conditions, but an average temperature. It may take the unit several minutes to react to a major temperature change such as driving
out of a heated garage into winter temperatures.
When the ignition switch is turned OFF, the last
displayed temperature reading stays in memory.
When the ignition switch is turned ON again, the
thermometer will display the memory temperature
for one minute; then update the display to the current average temperature reading within five minutes.
COMPASS
The compass will display the direction in which the
vehicle is pointed using the eight major compass
headings (Examples: north is N, northeast is NE). It
does not display the headings in actual degrees. The
display is turned on or off using the COMP/TEMP
button to the left of the display.
The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may
prove necessary is to drive the vehicle in 3 complete
8C - 2
OVERHEAD CONSOLE
SUNGLASSES STORAGE
A flocked storage compartment for sunglasses is included in the overhead console. This compartment
features a push/push-type latch and a viscous dampening system for a fluid opening motion.
DIAGNOSIS
COMPASS/DISPLAY SELF-DIAGNOSTIC TEST
This self-diagnostic test is used to determine that
the compass and all of its display segments are operating properly electrically. There are three self-diagnostic tests available. They are:
(1) A magnetic field strength test that shows the
strength of the magnetic fields being received at the
compass unit fluxgate.
(2) An internal electronics test that checks the internal electronic circuitry of the compass unit.
(3) A walking segment test that checks the operation of each of the segments used in the electronic
display.
Initiate the self-diagnostic test as follows:
(1) With the ignition switch in the OFF position,
depress and hold the COMP/TEMP button. While
still holding the COMP/TEMP button depressed, turn
the ignition switch to the ON position. The display
will show d0 to indicate the unit is in the diagnostics mode.
(2) Before beginning the magnetic field strength
test, get a pencil and a piece of paper. To begin this
test, momentarily depress and release the US/METRIC button one time. The following will occur:
The letter N will be shown in the compass portion
of the display. A number that equals the magnetic
field strength in the north/south direction appears in
the temperature portion of the display. Note this
number on your paper.
The letter W will be shown in the compass portion
of the display. A number that equals the magnetic
field strength in the east/west direction appears in
the temperature portion of the display. Note this
number on your paper.
The display will read d1 to indicate the first diagnostic test is completed.
For proper compass operation, the numbers shown
should be between 1 and 14. A number of 7 or 8 is
ideal (no vehicle magnetism present). Numbers closer
to 1 or 14 show that the vehicle is highly magnetic. If
the test shows the vehicle is highly magnetic, the vehicle needs to be demagnetized. See Compass Demagnetizing in this group.
(3) To begin the internal electronic circuitry test,
momentarily depress and release the US/METRIC
button one time. The display will go blank as the test
begins. If the test is passed, the display will read
d2. If the display reads f2, the unit is faulty and
must be replaced.
(4) To begin the walking segment test, momentarily depress and release the US/METRIC button
one time. The display will illuminate each direction
and number until all segments have been used. The
display will read d3 when the test is complete. If
any segment should fail to light during the test, the
unit is faulty and requires replacement.
(5) Momentarily depress and release the US/METRIC button one time, or turn the ignition switch to
OFF to exit the self-diagnostic mode and return to
normal operation.
If the compass functions, but accuracy is suspect, it may be necessary to perform a variation
adjustment. This procedure allows the unit to
accommodate variations in the earths magnetic field strength based on geographic location. See Compass Variation Adjustment, in this
group.
If the compass display has blanked out and
only CAL appears, demagnetizing may be necessary to remove excessive residual magnetic
fields from the vehicle. See Compass Demagnetizing, in this group.
OVERHEAD CONSOLE
COMPASS/THERMOMETER DIAGNOSIS
8C - 3
8C - 4
OVERHEAD CONSOLE
THERMOMETER DIAGNOSIS
The thermometer function is supported by a temperature sensor, a wiring circuit and a portion of the
overhead console display. The sensor is mounted at
the center of the vehicle on the support brace, behind
the grille (Fig. 1).
SENSOR TEST
(1) Turn the ignition switch to OFF. Unplug sensor
connector.
(2) Measure resistance of sensor. At -40F the resistance is 336K ohms. At 140F the resistance is
2.488K ohms. Sensor resistance should read between
these two values. If OK, go to Sensor Circuit Test. If
not OK, replace the sensor.
SENSOR CIRCUIT TEST
(1) Turn ignition switch to OFF. Unplug sensor
connector.
(2) Short the pins on the body half of connector using a jumper wire.
(3) Remove the overhead console as described in
Service Procedures.
(4) Check continuity between cavities 6 and 8 of
overhead console harness connector (Fig. 2). There
should be continuity. If OK, go to next step. If not
OK, repair open circuit as required.
OVERHEAD CONSOLE
8C - 5
SERVICE PROCEDURES
COMPASS VARIATION ADJUSTMENT
Variance is the difference between magnetic north
and geographic north. In some areas, the difference
between magnetic and geographic north is great
enough to cause the compass to give false readings. If
this occurs, the variance must be set.
To set the variance:
(1) Using the map in Fig. 1, find your geographic
location and note the zone number.
COMPASS CALIBRATION
CAUTION: DO NOT place any external magnets
such as magnetic roof mount antennas, in the vicin-
COMPASS DEMAGNETIZING
The tool used to degauss or demagnetize the roof
panel is the Miller Tool 6029. Equivalent units must
be rated as continuous duty for 110/115 volts and
60Hz. They must also have a field strength of over
350 gauss at 1/4-inch beyond the tip of the probe.
The degaussing tool is used to demagnetize the roof
panel, as follows:
(1) Be sure the ignition switch is in the OFF position before you begin the demagnetizing procedure.
(2) Place an 8-1/2 X 11 inch piece of paper, oriented
lengthwise from front to rear, on the center line of
the roof at the windshield header (Fig. 2). The purpose of the paper is to protect the roof panel from
scratches and define the area to be demagnetized.
(3) Plug in the degaussing tool, while keeping the
tool at least 2 feet away from the compass unit.
8C - 6
OVERHEAD CONSOLE
OVERHEAD CONSOLE
(4) Push front of compass/thermometer module
back to release forward mounting tabs (Fig. 6).
8C - 7
8C - 8
OVERHEAD CONSOLE
READING/COURTESY LAMPS
OVERHEAD CONSOLE
8C - 9
IGNITION SYSTEMS
8D - 1
IGNITION SYSTEMS
CONTENTS
page
page
COMPONENT IDENTIFICATION/SYSTEM
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COMPONENT REMOVAL/INSTALLATION . . . . . . 18
DIAGNOSTICS/SERVICE PROCEDURES . . . . . . . 6
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . 27
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 29
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1
2
2
3
4
1
4
4
GENERAL INFORMATION
Throughout this group, references are made to particular vehicle models by alphabetical designation or
by the particular vehicle nameplate. A chart showing
a breakdown of alphabetical designations is included
in the Introduction group at the beginning of this
manual.
This section of the group, Component Identification/System Operation, will discuss ignition system
operation and will identify ignition system components.
For diagnostic procedures and adjustments, refer to
the Diagnostics/Service Procedures section of this
group.
For removal and installation of ignition system
components, refer to the Component Removal/Installation section of this group.
For other useful information, refer to On-Board Diagnostics in the General Diagnosis sections of Group
14, Fuel System in this manual.
For operation of the DRB Scan Tool, refer to the
appropriate Powertrain Diagnostic Procedures service manual.
An Ignition specifications section is included at the
end of this group. A general Maintenance Schedule
(mileage intervals) for ignition related items can be
found in Group 0, Lubrication and Maintenance. This
schedule can also be found in the Owners Manual.
page
Intake Manifold Air Temperature Sensor3.9L/5.2L
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor . . . . . . .
Oxygen (O2S) Sensor . . . . . . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . . . . . . . . .
Throttle Body Temperature Sensor2.5L Engine . .
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . .
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5
5
5
5
5
5
IGNITION SYSTEMS
Two different ignition operating systems are used.
One system is used on the 2.5L 4-cylinder engine.
The other is used on the 3.9L V-6 and 5.2L V-8 engine. Similarities and differences between the two
systems will be discussed.
A single-port, fuel injection system is used on the
2.5L 4-cylinder engine.
A multi-port, fuel injection system is used on the
3.9L/5.2L engine.
The ignition system is controlled by the powertrain
control module (PCM) on all engines. The PCM was
formerly referred to as the SBEC or engine controller.
The ignition system consists of:
Spark Plugs
Ignition Coil
Secondary Ignition Cables
Distributor2.5L engine. Contains rotor and hall
effect switch
Distributor3.9L/5.2L engine. Contains rotor and
camshaft position sensor
Powertrain Control Module (PCM)
Crankshaft Position Sensor3.9L/5.2L engine only
8D - 2
IGNITION SYSTEMS
IGNITION SYSTEMS
8D - 3
2.5L ENGINE
The 2.5L 4-cylinder engine is equipped with a mechanical distributor containing a shaft driven distributor rotor. It is driven by the timing belt through an
intermediate shaft.
The distributor uses a hall effect pick-up (Fig. 6).
This supplies engine piston position and rpm information to the powertrain control module (PCM). Refer to Hall Effect Pick-Up in this section for
additional information.
DISTRIBUTORS
For component testing, refer to the Diagnostics/Service Procedures section of this group.
8D - 4
IGNITION SYSTEMS
3.9L/5.2L ENGINES
All 3.9L V-6 and 5.2L V-8 engines are equipped
with a camshaft driven mechanical distributor, containing a shaft driven distributor rotor. They are
equipped with an internal camshaft position (fuel
sync) sensor. This sensor provides fuel injection synchronization and cylinder identification.
The distributors on the 3.9L/5.2L engines do not
have built in centrifugal or vacuum assisted advance.
Base ignition timing and all timing advance is controlled by the powertrain control module (PCM). Because ignition timing is controlled by the PCM, base
ignition timing is not adjustable on any of these
engines.
The distributor is held to the engine in the conventional method using a holddown clamp and bolt. Although the distributor on the 3.9L/5.2L engine
can be rotated, it will have no effect on ignition
timing.
All distributors contain an internal oil seal that
prevents oil from entering the distributor housing.
The seal is not serviceable.
For removal and installation of this component, refer to the Component Removal/Installation section of
this group.
IGNITION COIL
Battery voltage is supplied to the ignition coil positive terminal from the ASD relay.
The powertrain control module (PCM) opens and
closes the ignition coil ground circuit for ignition coil
operation.
Base ignition timing is not adjustable on the
3.9L/5.2L engine. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet
changing engine operating conditions.
The ignition coil is not oil filled. The windings are
embedded in an epoxy compound. This provides heat
and vibration resistance that allows the ignition coil
to be mounted on the engine.
2.5L engine: The coil is mounted on a bracket, to
the thermostat housing, in front of the coolant temperature sensor (Fig. 7).
3.9L or 5.2L engines: The coil is mounted to a
bracket that is bolted to the front of the right engine
cylinder head (Fig. 8). This bracket is also used to
mount the automatic belt tensioner.
For component testing, refer to the Diagnostics/Service Procedures section of this group.
For removal and installation of this component, refer to the Component Removal/Installation section of
this group.
IGNITION SYSTEMS
8D - 5
For an operational description, diagnosis and removal/installation procedures, refer to the 3.9L/5.2L
Engine sections of Group 14, Fuel System.
For an operational description, diagnosis and removal/installation procedures, refer to Group 14,
Fuel System.
For an operational description, diagnosis and removal/installation procedures, refer to Group 14,
Fuel System.
The PCM (formerly called the SBEC or engine controller) is located on the right inner fender in the engine compartment (Fig. 10).
For an operational description, diagnosis and removal/installation procedures, refer to Group 14,
Fuel System.
8D - 6
IGNITION SYSTEMS
DIAGNOSTICS/SERVICE PROCEDURES
INDEX
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6
6
7
7
7
8
8
6
8
9
GENERAL INFORMATION
This section of the group, Diagnostics/Service Procedures, will discuss basic ignition system diagnostics
and service adjustments.
For system operation and component identification,
refer to the Component Identification/System Operation section of this group.
For removal or installation of ignition system components, refer to the Component Removal/Installation section of this group.
For other useful information, refer to On-Board Diagnostics in the General Diagnosis sections of Group
14, Fuel System in this manual.
For operation of the DRB Scan Tool, refer to the
appropriate Powertrain Diagnostic Procedures service manual.
page
Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold Air Temperature Sensor Test . . . . .
Manifold Absolute Pressure (MAP) Sensor Test . . .
On-Board Diagnostics . . . . . . . . . . . . . . . . . . . . . .
Oxygen Sensor (O2S) Tests . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . . . . . . . . .
Spark Plug Secondary Cables . . . . . . . . . . . . . . . .
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor Test . . . . . . . . . . . . . . . . .
11
12
12
16
16
12
15
12
16
IGNITION SYSTEMS
8D - 7
DISTRIBUTOR CAP
INSPECTION
Remove the distributor cap and wipe it clean with
a dry lint free cloth. Visually inspect the cap for
cracks, carbon paths, broken towers, or damaged rotor button (Figs. 3 and 4). Also check for white depos-
DISTRIBUTOR ROTOR
Visually inspect the rotor (Fig. 5) for cracks, evidence of corrosion, or the effects of arcing on the
metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal on
the end of the metal tip. The silicone-dielectric-varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred.
This is normal. Do not remove the charred compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse
conditions.
8D - 8
IGNITION SYSTEMS
IGNITION COIL
To perform a complete test of the ignition coil and
its circuitry, refer to the DRB scan tool. Also refer to
the appropriate Powertrain Diagnostics Procedures
manual. To test the coil only, refer to the following:
The ignition coil (Figs. 6 or 7) is designed to operate without an external ballast resistor.
Inspect the ignition coil for arcing. Test the coil according to coil tester manufacturers instructions.
Test the coil primary and secondary resistance. Replace any coil that does not meet specifications. Refer
to the Ignition Coil Resistance chart.
IGNITION SYSTEMS
8D - 9
8D - 10
IGNITION SYSTEMS
that the ignition secondary system is operating correctly. (note that if the ignition coil cable is removed for this test, instead of a spark plug
cable, the spark intensity will be much higher.)
If steady arcing occurs at the spark plug cables, but
the engine will not start, connect the DRB scan tool.
Refer to the Powertrain Diagnostic Procedures service manual.
IGNITION SYSTEMS
IGNITION TIMING
8D - 11
high resistance. In addition, breaking the rubber insulation may permit secondary current to arc to
ground.
(3) Turn selector switch to the appropriate cylinder
position.
(4) Start engine and run until normal operating
temperature is obtained.
(a) If using the DRB scan tool: Connect the DRB
tool. Refer to the appropriate Powertrain Diagnostic Procedures service manual.
(b) If not using the DRB tool: Disconnect the
coolant temperature sensor (Fig. 16). When the
sensor is disconnected, the radiator (electrical) cooling fan should operate and the malfunction indicator lamp (displayed on the instrument panel as the
CHECK ENGINE lampfigure 17) should be lit.
2.5L ENGINE
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING IGNITION
TIMING ADJUSTMENT, OR ANY TESTS WITH A
RUNNING ENGINE.
Proper ignition timing is required to obtain optimum engine performance. The distributor must be
correctly indexed to provide correct initial ignition
timing.
(1) Set the gearshift selector in park or neutral
and apply the parking brake. All lights and accessories must be off.
(2) If a magnetic timing unit is being used, insert
the pickup probe into the open receptacle on the
transmission bell housing. This is located next to the
upper, left mounting bolt. If a magnetic timing unit
is not available, use a conventional timing light connected to the number one cylinder spark plug cable.
Use the timing scale on the transmission dust cover
(Fig. 15).
8D - 12
IGNITION SYSTEMS
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
TEST
For an operational description, diagnosis or removal/ installation procedures, refer to Group 14, Fuel
Systems.
SPARK PLUGS
For spark plug removal, cleaning, gap adjustment
and installation, refer to the Component Removal/Installation section of this group.
3.9L/5.2L Engine: Spark plug cable boot heat
shields are pressed into the cylinder head to surround each cable boot and spark plug (Fig. 20). These
shields protect the spark plug boots from damage
(due to intense engine heat generated by the exhaust
manifolds) and should not be removed. After the
spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the
heat shield (Fig. 20).
Faulty carbon and/or gas fouled plugs generally
cause hard starting, but they will clean up at higher
IGNITION SYSTEMS
8D - 13
CONDITION
NORMAL OPERATING
The few deposits present on the spark plug will
probably be light tan or slightly gray in color. This is
evident with most grades of commercial gasoline
(Fig. 21). There will not be evidence of electrode
burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000
miles) of operation. Spark plugs that have normal
wear can usually be cleaned, have the electrodes
filed, have the gap set and then be installed.
Some fuel refiners in several areas of the United
States have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with MMT
causes the entire tip of the spark plug to be coated
with a rust colored deposit. This rust color can be
misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits.
8D - 14
IGNITION SYSTEMS
this is a normal condition caused by chemical additives in certain fuels. These additives are designed to
change the chemical nature of deposits and decrease
spark plug misfire tendencies. Notice that accumulation on the ground electrode and shell area may be
heavy, but the deposits are easily removed. Spark
plugs with scavenger deposits can be considered normal in condition and can be cleaned using standard
procedures.
PREIGNITION DAMAGE
Preignition damage is usually caused by excessive
combustion chamber temperature. The center electrode dissolves first and the ground electrode dissolves somewhat latter (Fig. 26). Insulators appear
relatively deposit free. Determine if the spark plug
has the correct heat range rating for the engine. Determine if ignition timing is over advanced, or if
other operating conditions are causing engine overheating. (The heat range rating refers to the operating temperature of a particular type spark plug.
Spark plugs are designed to operate within specific
temperature ranges. This depends upon the thickness and length of the center electrodes porcelain insulator.)
IGNITION SYSTEMS
8D - 15
TESTING
Spark plug cables are sometimes referred to as secondary ignition cables or secondary wires. The cables
transfer electrical current from the distributor to in-
8D - 16
IGNITION SYSTEMS
ON-BOARD DIAGNOSTICS
FOR CERTAIN IGNITION SYSTEM
COMPONENTS
The powertrain control module (PCM) performs an
On-Board Diagnostic (OBD) check for certain ignition
system components on all vehicles. This is done by
setting a diagnostic trouble code (DTC).
A DTC can be obtained in two different ways. One
of the ways is by connecting the DRB scan tool to the
data link connector. This connector is located in the
engine compartment (Fig. 30). Refer to the appropriate Powertrain Diagnostic Procedures service manual
for operation of the DRB scan tool. The other way is
to cycle the ignition key and observe the malfunction
indicator lamp (MIL). The MIL lamp is displayed on
the instrument panel as the CHECK ENGINE lamp
(Fig. 31). This lamp will flash a numeric code. If a
numeric code number 11 (for the crankshaft position
sensor) or 42 (for the ASD relay) is observed, a problem has been found in the ignition system.
Note that the CHECK ENGINE lamp will illuminate initially for approximately two seconds each
time the ignition key is turned to the ON position.
This is done for a bulb test.
IGNITION SYSTEMS
8D - 17
8D - 18
IGNITION SYSTEMS
COMPONENT REMOVAL/INSTALLATION
INDEX
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18
18
19
20
21
20
18
23
page
Ignition Coil . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold Air Temperature Sensor . .
Manifold Absolute Pressure (MAP) Sensor
Oxygen (O2S) Sensor . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . .
Spark Plug Secondary Cables . . . . . . . . .
Spark Plugs . . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor (TPS) . . . . . . . .
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22
23
24
24
24
25
24
26
GENERAL INFORMATION
This section of the group, Component Removal/Installation, will discuss the removal and installation
of ignition system components.
For basic ignition system diagnostics and service
adjustments, refer to the Diagnostics/Service Procedures section of this group.
For system operation and component identification,
refer to the Component Identification/System Operation section of this group.
REMOVAL3.9L/5.2L ENGINE
Distributor removal is not necessary to remove
camshaft position sensor.
(1) Disconnect negative battery cable at battery.
(2) Remove distributor cap from distributor (two
screws).
(3) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.
The ASD relay is installed in the power distribution center (PDC) (Fig. 1). Relay location is printed
on the PDC cover.
INSTALLATION
(1) Install camshaft position sensor to distributor.
Align sensor into notch on distributor housing.
(2) Connect wiring harness.
(3) Install rotor.
(4) Install distributor cap. Tighten mounting screws.
IGNITION SYSTEMS
8D - 19
INSTALLATION
(1) Position crankshaft position sensor to engine
and install mounting bolts. Tighten bolts to 8 N!m
(70 in. lbs.) torque.
(2) Connect main harness electrical connector to
sensor.
(3) Clean the EGR tube and exhaust manifold (at
EGR tube mounting point) of any old gasket material.
(4) Install a new gasket to exhaust manifold end of
EGR tube and install EGR tube to both manifolds.
Tighten mounting nut at intake manifold. Tighten 2
mounting bolts at exhaust manifold to 23 N!m (204
in. lbs.) torque.
(5) Coat the threads of the oil pressure sending
unit with thread sealant. Do not allow any of the
thread sealant to get into the sending unit opening,
or the opening at the engine. Install sending unit to
engine and tighten to 14 N!m (130 in. lbs.) torque. Install electrical connector to sending unit.
(6) Clean the intake manifold and EGR valve of
any old gasket material.
(7) Install a new EGR valve gasket at intake manifold.
(8) Install EGR valve to intake manifold. Tighten 2
bolts to 23 N!m (200 in. lbs.) torque.
(9) Position EGR valve control and install its electrical connector. Connect hoses between EGR valve
and EGR valve control. Connect hose between main
vacuum harness and control valve.
(10) Install spark plug cable loom and spark plug
cables to valve cover mounting stud.
8D - 20
IGNITION SYSTEMS
DISTRIBUTOR2.5L ENGINE
Also refer to Hall Effect Pick-Up in this section for
removal and installation.
REMOVAL
(1) Disconnect distributor pick-up lead wire at wiring harness connector (Fig. 5).
INSTALLATION
(1) Position distributor in engine. Make certain
that the O-ring is properly seated on distributor. If
O-ring is cracked or nicked, replace O-ring.
(2) Carefully engage distributor drive with auxiliary shaft drive. When distributor is installed properly, rotor will be pointing toward cylinder block. If
engine has been cranked while distributor is removed, it will be necessary to establish proper relationship between the distributor shaft and number
one piston position as follows:
(a) Rotate the crankshaft until number one piston is at top of compression stroke. Pointer on
IGNITION SYSTEMS
8D - 21
Before distributor is removed, the number-one cylinder must be brought to the top dead center (TDC)
firing position.
(4) Attach a socket to the Crankshaft Vibration
Damper mounting bolt.
(5) Slowly rotate engine clockwise, as viewed from
front, until indicating mark on crankshaft vibration
damper is aligned to 0 degree (TDC) mark on timing
chain cover (Fig. 10).
DISTRIBUTOR3.9L/5.2L ENGINE
REMOVAL
CAUTION: Base ignition timing is not adjustable on
any 3.9L V-6 or 5.2L V-8 engine. Distributors do not
have built in centrifugal or vacuum assisted advance. Base ignition timing and timing advance are
controlled by the powertrain control module (PCM).
Because a conventional timing light can not be
used to adjust distributor position after installation,
note position of distributor before removal.
(1) Disconnect negative battery cable at battery.
(2) Remove distributor cap from distributor (two
screws).
(3) Mark the position of distributor housing in
relationship to engine or dash panel. This is done
to aid in installation.
8D - 22
IGNITION SYSTEMS
CHECKING DISTRIBUTOR POSITION
To verify correct distributor rotational position,
connect the DRB scan tool to the data link connector.
The data link connector is located in the engine compartment. Gain access to the SET SYNC screen on
the DRB.
WARNING: WHEN PERFORMING THE FOLLOWING
TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
INSTALLATION
If engine has been cranked while distributor is removed, establish the relationship between distributor
shaft and number one piston position as follows:
Rotate crankshaft in a clockwise direction, as
viewed from front, until number-one cylinder piston
is at top of compression stroke (compression should
be felt on finger with number one spark removed).
Then continue to slowly rotate engine clockwise until
indicating mark (Fig. 10) is aligned to 0 degree
(TDC) mark on timing chain cover.
(1) Clean top of cylinder block for a good seal between distributor base and block.
(2) Lightly oil the rubber O-ring seal on the distributor housing.
(3) Install rotor to distributor shaft.
(4) Position distributor into engine to its original
position. Engage tongue of distributor shaft with slot
in distributor oil pump drive gear. Position rotor to
the number one spark plug cable position.
(5) Install distributor holddown clamp and clamp
bolt. Do not tighten bolt at this time.
(6) Rotate the distributor housing until rotor is
aligned to CYL. NO. 1 alignment mark on the camshaft position sensor (Fig. 11).
(7) Tighten clamp holddown bolt (Fig. 12) to 22.5
N!m (200 in. lbs.) torque.
(8) Connect camshaft position sensor wiring harness to main engine harness.
(9) Install distributor cap. Tighten mounting
screws.
(10) Refer to the following Checking Distributor
Position.
IGNITION COIL
The ignition coil is an epoxy filled type. If the coil
is replaced, it must be replaced with the same type.
REMOVAL2.5L ENGINE
The coil is mounted on a bracket, to the thermostat
housing, in front of the coolant temperature sensor
(Fig. 13).
(1) Disconnect the ignition coil secondary cable
from ignition coil (Fig. 13).
(2) Disconnect engine harness connector from ignition coil.
(3) Remove ignition coil mounting screws. Remove
coil.
INSTALLATION2.5L ENGINE
(1) Install ignition coil to bracket on cylinder block
with mounting screws.
(2) Connect engine harness connector to coil.
(3) Connect ignition coil cable to ignition coil.
REMOVAL3.9L/5.2L ENGINE
The ignition coil is mounted to a bracket near the
front of the right engine cylinder head on 3.9L/5.2L
engines (Fig. 14).
IGNITION SYSTEMS
8D - 23
INSTALLATION3.9L/5.2L ENGINE
(1) Install the ignition coil to coil bracket. If nuts
and bolts are used to secure coil to coil bracket,
tighten to 11 N!m (100 in. lbs.) torque. If the coil
mounting bracket has been tapped for coil mounting
bolts, tighten bolts to 5 N!m (50 in. lbs.) torque.
(2) Connect all wiring to ignition coil.
REMOVAL
(1) Remove shield and distributor cap. Refer to
Distributor Removal2.5L Engine.
(2) Remove rotor from shaft (Fig. 15).
INSTALLATION
(1) Place hall effect pick-up assembly into distributor housing (Fig. 16).
CAUTION: The hall effect pick-up assembly leads
may be damaged if not properly installed (Fig. 16).
(2) Install rotor (Fig. 15).
(3) Install cap and splash shield. Refer to Distributor Installation2.5L Engine.
8D - 24
IGNITION SYSTEMS
INSTALLATION
(1) Check pins in 60-way PCM connector for damage. Repair as necessary.
(2) Connect 60-Way electrical connector to the
PCM (Fig. 17).
(3) Mount PCM to inside right front fender (Fig.
17). Tighten screws to 4 N!m (35 in. lbs.) torque.
(4) Install air cleaner duct to the PCM (2.5L only).
(5) Connect negative battery cable to battery.
SPARK PLUGS
PLUG REMOVAL
(1) Always remove spark plug or ignition coil cables by grasping at the cable boot (Fig. 19). Turn the
cable boot 1/2 turn and pull straight back in a steady
motion. Never pull directly on the cable. Internal
damage to cable will result.
(2) Prior to removing the spark plug, spray compressed air around the spark plug hole and the area
around the spark plug. This will help prevent foreign
material from entering the combustion chamber.
(3) Remove the spark plug using a quality socket
with a rubber or foam insert.
IGNITION SYSTEMS
8D - 25
PLUG CLEANING
The plugs may be cleaned using commercially
available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point
file or jewelers file before adjusting gap.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause
plug misfire.
8D - 26
IGNITION SYSTEMS
spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the
heat shield (Fig. 24).
IGNITION SYSTEMS
8D - 27
1995 AN Dakota
Publication No. 81-370-5110
TSB 23-44-94 June 3, 1994
IGNITION SWITCH
INDEX
General Information
page
page
. . . . . . . . . . . . . . . . . . . . . . . 27
GENERAL INFORMATION
The ignition switch is located in the steering column. The Key-In- Switch and Halo Light are integral
with the ignition switch. Refer to Group 8U for KeyIn-Switch and Halo Light diagnosis.
8D - 28
IGNITION SYSTEMS
1995 AN Dakota
Publication No. 81-370-5110
TSB 23-44-94 June 3, 1994
INSTALLATION TYPE I
If the vehicle has floor mounted gear shifter, place
the selector in the Park position.
(1) Connect electrical connectors to the ignition
switch. Make sure that the switch locking tabs are
fully seated in the wiring connectors.
(2) Before attaching the ignition switch to a tilt steering
column, the transaxle shifter must be in the Park position.
Also the park lock dowel pin and the column lock flag must be
properly indexed before installing the switch (Fig. 8).
(a) Place the transaxle shifter in the PARK position.
IGNITION SYSTEMS
8D - 28A
1995 AN Dakota
Publication No. 81-370-5110
TSB 23-44-94 June 3, 1994
INSTALLATION TYPE II
(1) Connect electrical connectors to the ignition
switch. Make sure that the switch locking tabs are
fully seated in the wiring connectors.
(2) Before attaching the ignition switch to a tilt
steering column, the transmission shifter must be in
the Park position. Also the park lock dowel pin and
the column lock flag must be properly indexed before
installing the switch (Fig. 8).
(a) Place the transmission shifter in the PARK
position.
(b) Place the ignition switch in the lock position.
The switch is in the lock position when the column
lock flag is parallel to the ignition switch terminals
(Fig. 8).
(c) Position ignition switch park lock dowel pin
so it will engage the steering column park lock
slider linkage (Fig. 9).
(d) Apply a light coating of grease to the column
lock flag and the park lock dowel pin.
(3) Place the ignition switch against the lock housing opening on the steering column. Ensure that the
ignition switch park lock dowel pin enters the slot in
the park lock slider linkage in the steering column.
(4) Install retaining bracket and ignition switch
mounting screws. Tighten screws to 3!5 N!m (26!4
in. lbs.) torque.
(5) Install ignition lock cylinder:
(a) With the lock cylinder and the ignition switch
in the Lock position, insert the lock cylinder into
the ignition switch until it bottoms.
(b) Insert ignition key into lock cylinder. While
gently pushing the lock cylinder in toward the ignition switch, rotate the ignition key to the end of
travel.
(6) Install retaining screw into bracket and lock
cylinder. Tighten screw to 3!5 N!m (26!4 in. lbs.)
torque.
(7) Install steering column covers. Tighten screws
to 2 N!m (17 in. lbs.) torque.
(8) If vehicle is equipped with a tilt steering column, install tilt lever.
(9) Connect negative cable to battery.
(10) Check for proper operation of the halo light,
shift lock (if applicable), and column lock. Also check
for proper operation of the ignition switch accessory,
lock, off, run, and start positions.
IGNITION SYSTEMS
8D - 29
SPECIFICATIONS
GENERAL INFORMATION
The following specifications are published from the
latest information available at the time of publication. If anything differs between the specifications found on the Vehicle Emission Control
Information (VECI) label and the following
specifications, use specifications on VECI label.
The VECI label is located in the engine compart-
8D - 30
IGNITION SYSTEMS
SPARK PLUGS
SENSOR
TORQUE
8E - 1
page
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . 15
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 24
GENERAL INFORMATION
Following are general descriptions of major instrument panel components. Refer to Group 8W - Wiring
Diagrams for complete circuit descriptions and diagrams.
INSTRUMENT PANEL
Modular instrument panel construction allows all
gauges and controls to be serviced from the front of
the panel. In addition, most instrument panel wiring
or heater and air conditioning components can be accessed without complete instrument panel removal. If
necessary, the instrument panel can be rolled-down
and removed from the vehicle as an assembly.
Removal of the instrument cluster bezel allows access to the cluster assembly, switches, the climate
controls, and the radio. Removal of the cluster assembly allows access to the individual gauges, illumination and indicator lamp bulbs, printed circuits, and
most wiring.
Removal of the lower instrument panel allows access to heater and air conditioning components, and
other wiring and electrical components. Removal of
the steering column cover provides access to the
steering column mounts, the intermittent wipe module, and the gear selector (auto trans) indicator cable.
Models equipped with a drivers-side airbag restraint
have a knee blocker and reinforcement behind the
steering column cover.
INSTRUMENT CLUSTERS
Two basic instrument cluster options are offered on
Dakota models. One is referred to as a standard cluster (Fig. 1), and the other is referred to as a optional
cluster (Fig. 2). Each cluster is served by a printed
circuit and two wiring connectors. Some variations of
each cluster exist due to optional equipment and regulatory requirements.
The standard cluster includes the following gauges:
coolant temperature gauge
fuel gauge
gear selector indicator (auto trans)
oil pressure gauge
speedometer/odometer
trip odometer
8E - 2
GAUGES
With the ignition switch in the ON or START position, voltage is supplied to all gauges through the instrument cluster printed circuit. With the ignition
switch in the OFF position, voltage is not supplied to
the gauges. A gauge pointer may remain within the
gauge scale after the ignition switch is OFF. However, the gauges do not accurately indicate any vehicle condition unless the ignition switch is ON.
All gauges except the odometer are air core magnetic units. Two fixed electromagnetic coils are located within the gauge. These coils are wrapped at
right angles to each other around a movable permanent magnet. The movable magnet is suspended
within the coils on one end of a shaft. The gauge needle is attached to the other end of the shaft.
One of the coils has a fixed current flowing through
it to maintain a constant magnetic field strength.
Current flow through the second coil changes, which
causes changes in its magnetic field strength. The
current flowing through the second coil can be
changed by:
a variable resistor-type sending unit (fuel level,
coolant temperature, or oil pressure)
changes in electrical system voltage (voltmeter)
electronic control circuitry (speedometer/odometer,
tachometer).
The gauge needle moves as the movable permanent
magnet aligns itself to the changing magnetic fields
created around it by the electromagnets.
FUEL GAUGE
The fuel gauge gives an indication of the level of
fuel in the fuel tank. The fuel gauge sending unit has
a float attached to a swing-arm in the fuel tank. The
float moves up or down within the fuel tank as fuel
level changes. As the float moves, an electrical contact on the swing-arm wipes across a resistor coil,
which changes sending unit resistance. High sending
unit resistance causes low fuel level readings. Low
resistance causes high fuel level readings. Sending
unit resistance values are shown in a chart in Specifications.
GEAR SELECTOR INDICATOR
The gear selector indicator is used on models with
an automatic transmission to show the position of
the transmission gear selector lever. The indicator is
mechanically actuated by a cable connected to the
PRNDL driver of the gear selector lever mechanism
on the steering column. Refer to Group 21 - Transmission and Transfer Case for diagnosis, service, and
adjustment of this component.
OIL PRESSURE GAUGE
The oil pressure gauge gives an indication of engine oil pressure. The combination oil pressure sending unit contains a flexible diaphragm. The
diaphragm moves in response to changes in engine
oil pressure. As the diaphragm moves, resistance increases or decreases. High resistance on the gauge
side of the sending unit causes low oil pressure readings. Low resistance causes high oil pressure readings. Sending unit resistance values are shown in a
chart in Specifications.
SPEEDOMETER/ODOMETER
The speedometer/odometer gives an indication of
vehicle speed and travel distance. The speedometer
receives a vehicle speed pulse signal from the Vehicle
Speed Sensor (VSS). An electronic integrated circuit
contained within the speedometer reads and analyzes
the pulse signal. It then adjusts the ground path resistance of one electromagnet in the gauge to control
needle movement. It also sends signals to an electric
stepper motor to control movement of the odometer
number rolls. Frequency values for the pulse signal
are shown in a chart in Specifications.
The VSS is mounted to an adapter near the transmission (two-wheel drive) or transfer case (four-wheel
drive) output shaft. The sensor is driven through the
adapter by a speedometer pinion gear. The adapter
and pinion vary with transmission, transfer case,
axle ratio and tire size. Refer to Group 21 - Transmission and Transfer Case for more information.
TACHOMETER
The tachometer gives an indication of engine speed
in Revolutions-Per-Minute (RPM). With the engine
TRIP ODOMETER
The trip odometer is driven by the same electronic
integrated circuit as the speedometer/odometer. However, by depressing the trip odometer reset knob on
the face of the speedometer, the trip odometer can be
reset to zero. The trip odometer is serviced only as a
part of the speedometer/odometer gauge assembly.
VOLTMETER
The voltmeter is connected in parallel with the battery. With the ignition switch ON, the voltmeter indicates battery or generator output voltage,
whichever is greater.
INDICATOR LAMPS
Indicator lamps are located in several areas of the
cluster and instrument panel, depending upon equipment. Those lamps within the cluster area are served
by the cluster printed circuit and cluster connectors.
8E - 3
8E - 4
DIAGNOSIS
GAUGES
If an individual gauge is inoperative, see the diagnostic procedure under the heading for that gauge. If
more than one gauge is inoperative, perform the following:
(1) Check fuse 14 in the fuseblock module. If OK,
go to next step. If not OK, replace fuse.
(2) Check for battery voltage at fuse 14 with ignition switch in ON position. If OK, go to next step. If
not OK, repair open in circuit from ignition switch
and/or refer to Group 8D - Ignition Systems for testing of ignition switch.
8E - 5
FUEL GAUGE
The diagnosis found here addresses an inoperative
gauge condition. If the problem being diagnosed is related to gauge accuracy, be certain to confirm that
problem is with gauge and not with fuel tank. Inspect fuel tank for signs of damage or distortion that
could affect sending unit performance before you proceed with gauge diagnosis. Refer to Group 14 - Fuel
System for more information.
(1) Turn ignition switch to ON. Disconnect fuel
gauge sending unit connector. Connector is located on
top of the fuel tank. The gauge needle should move
to low end of gauge scale. If OK, go to next step. If
not OK, go to step 4.
(2) Connect a jumper wire between sending unit
ground cavity and fuel sensor input cavity in the
body half of the fuel gauge sending unit connector
(Fig. 3). The gauge needle should move to high end of
gauge scale. If OK, refer to Group 14 - Fuel System
for procedure to replace sending unit. If not OK, remove jumper wire and go to next step.
8E - 6
SPEEDOMETER/ODOMETER
The diagnosis found here addresses an inoperative
gauge condition. If the problem being diagnosed is related to gauge accuracy, be certain to confirm that
problem is with gauge and not with incorrect speedometer pinion, axle ratio or tire size. Refer to Group
21 - Transmission and Transfer Case for more information.
(1) Perform vehicle speed sensor test as described
in the appropriate Powertrain Diagnostic Procedures
manual. If OK, go to next step. If not OK, replace vehicle speed sensor.
(2) Disconnect battery negative cable. Unplug vehi-
8E - 7
8E - 8
8E - 9
8E - 10
INDICATOR LAMPS
If an individual indicator lamp is inoperative, see
the diagnostic procedure under the heading for that
lamp. If more than one indicator lamp or a combination of lamps and gauges in the instrument cluster is
inoperative, see Gauges in this section for diagnosis.
8E - 11
8E - 12
8E - 13
8E - 14
8E - 15
SERVICE PROCEDURES
CLUSTER BEZEL REMOVE/INSTALL
(1) Disconnect battery negative cable.
(2) Remove screws along bottom edge of knee
blocker (Fig. 1).
8E - 16
GAUGES REMOVE/INSTALL
When removing gauge assemblies from cluster, gauge must be pulled straight out, not
twisted, or damage to gauge pins may result.
(1) Remove cluster lens and mask as described in
Cluster Lens and Mask Remove/Install.
(2) Remove retaining screws from gauge (Figs. 5, 6
and 7) and pull gauge straight out.
8E - 17
8E - 18
8E - 19
8E - 20
8E - 21
8E - 22
8E - 23
(11) On vehicles with automatic transmissions, disconnect gear selector indicator cable from column.
(12) Remove steering column support nuts, lower
steering column, then remove steering column attaching studs.
(13) Disconnect wiring at ignition switch and headlamp dimmer switch on steering column.
(14) Remove windshield pillar and cowl side trim
panels.
(15) Loosen the instrument panel pivot bolts (Fig
28).
(16) Remove 5 screws at base of windshield and
roll panel down. Attach a hook from fence line to center panel mount to hold instrument panel in position.
(17) Disconnect wiring for stereo speakers, door
switches and A/C-heater blower motor.
(18) Disconnect radio antenna cable, A/C-heater
control vacuum harness and temperature control cable.
(19) Disconnect demister hoses at A/C-heater unit.
(20) Remove instrument panel from vehicle.
(21) Reverse removal procedures to install.
8E - 24
AUDIO SYSTEMS
8F - 1
AUDIO SYSTEMS
CONTENTS
page
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 7
GENERAL INFORMATION
Following are general descriptions of major components used in Dakota audio systems. Refer to Group
8W - Wiring Diagrams for complete circuit descriptions and diagrams.
RADIOS
Radio options for the Dakota models include an
AM/FM, an AM/FM/cassette, an AM/FM/CD, or an
AM/FM/cassette with graphic equalizer. All receivers
are stereo Electronically-Tuned Radios (ETR) and include a clock function. For more information on radio
features, setting procedures, and control functions refer to the Sound System manual. The Sound System
manual is included with the owners manual in the
vehicle glove box.
SPEAKERS
Speaker system options include two or four speaker
locations. On two-speaker systems, one full range
speaker is located in each door. Four-speaker systems
add one full range speaker in each B pillar.
The premium speaker option upgrades all the
speakers in the above locations to Infinity bi-amplified models. Each Infinity speaker features an integral amplifier and frequency filter unit. The
amplifier of the radio is used to drive the tweeters at
each speaker location. The speaker-mounted amplifiers drive the woofers at each speaker location.
ANTENNA
All models use a fixed-length stainless steel rodtype antenna mast, installed at the right front fender
of the vehicle. The antenna mast is connected to the
center wire of the coaxial antenna cable and is not
grounded to any part of the vehicle.
To eliminate static, the antenna base must have a
good ground. The coaxial antenna cable shield (the
outer wire mesh of the cable) is grounded to the antenna base and the radio chassis.
The factory installed ETRs automatically compensate for radio antenna trim. Therefore, no antenna
trimmer adjustment is required or possible when replacing the receiver or the antenna.
8F - 2
AUDIO SYSTEMS
Fleet vehicles are available with an extra-cost RFIsuppressed Powertrain Control Module (PCM). This
unit reduces interference generated by the PCM on
some radio frequencies used in two-way radio com-
munications. However, this unit will not resolve complaints of RFI in the commercial AM or FM radio
frequency ranges.
DIAGNOSIS
RADIO
(1) Check fuse 12 in fuseblock module and fuse F2
in Power Distribution Center (PDC). If OK, go to
next step. If not OK, replace fuse.
(2) Check for battery voltage at fuse F2 in PDC. If
OK, go to next step. If not OK, repair circuit to cartridge fuse F2 in PDC.
(3) Turn ignition switch to ON position. Check for
battery voltage at fuse 12. If OK, go to next step. If
not OK, repair circuit to ignition switch as required.
(4) Turn ignition switch to OFF position. Disconnect battery negative cable. Remove instrument cluster bezel. Remove radio, but do not unplug any
AUDIO SYSTEMS
RADIO DIAGNOSIS CHART
8F - 3
8F - 4
AUDIO SYSTEMS
RADIO AND SPEAKER CONNECTORS
AUDIO SYSTEMS
SPEAKERS
(1) Turn radio on and adjust balance and fader
controls to check performance of each individual
speaker. Note the speaker locations that are not performing correctly. Go to next step.
If vehicle has Infinity premium speaker package and all speakers lack bass or low frequency
response, see Filter Choke/Speaker Relay diagnosis.
(2) Turn radio off. Disconnect battery negative cable. Remove instrument cluster bezel and remove radio. See Radio and Speaker Connector chart. Check
both the speaker feed and return cavities at radio for
continuity to a good ground. There should be no continuity. If OK, go to next step. If not OK, repair wiring circuit as required.
(3) Check resistance between speaker feed and return cavities. Meter should read between 3 and 8
ohms (speaker impedance). If OK with Infinity
speakers, go to next step. If OK without Infinity
speakers, see diagnosis for Radio. If not OK, go to
step 5.
(4) Install a known good radio. Connect battery
negative cable. Turn on radio and test speaker operation. If OK, see diagnosis for Radio. If not OK, disconnect battery negative cable, remove radio and go
to next step.
(5) Unplug speaker wiring connector. Check for
continuity between speaker feed cavity at radio and
at speaker. Repeat check between speaker return
cavity at radio and at speaker. There should be continuity. If OK with Infinity speakers, go to next step.
If OK without Infinity speakers, replace speaker. If
not OK, repair wiring circuit as required.
(6) Check for continuity between cavity 1 of
speaker connector and a good ground. There should
be continuity. If OK, go to next step. If not OK, repair wiring circuit to ground as required.
(7) Install radio. Connect battery negative cable.
Turn radio on. Check for battery voltage at cavity 4
of speaker connector. If OK, replace speaker. If not
OK, repair circuit to filter choke/speaker relay as required.
ANTENNA
The following four tests are used to diagnose the
antenna with an ohmmeter:
mast to ground test (Test 1)
tip-of-mast to tip-of-conductor test (Test 2)
body ground to battery ground test (Test 3)
body ground to coaxial shield test (Test 4).
Ohmmeter test lead connections for each test are
shown in Figure 1.
8F - 5
8F - 6
AUDIO SYSTEMS
TEST 1
Test 1 determines if the antenna mast is insulated
from the base. Proceed as follows:
(1) Disconnect antenna cable lead from radio chassis and isolate.
(2) Connect one ohmmeter lead to tip of antenna
mast and the other lead to the antenna base. Check
for continuity.
(3) There should be no continuity. If continuity is
found, replace defective or damaged antenna base
and cable assembly.
TEST 2
Test 2 checks the antenna for an open circuit as follows:
(1) Disconnect the antenna cable lead from the radio chassis.
(2) Connect one ohmmeter test lead to tip of antenna mast. Connect remaining lead to tip of antenna cable lead (the part inserted into the radio).
(3) Continuity should exist (ohmmeter should only
register a fraction of an ohm). High or infinite resistance indicates damage to the base and cable assembly. Replace if required.
TEST 3
Test 3 checks condition of the vehicle body ground
connection as follows:
(1) Connect one ohmmeter test lead to the vehicle
fender and the other lead to the battery negative
post.
(2) Resistance should be less than one ohm.
(3) If resistance is more than one ohm, check the
braided ground strap connected to the engine and vehicle body for being loose, corroded, or damaged. Repair as necessary.
TEST 4
Test 4 checks condition of the ground between the
antenna base and vehicle body as follows:
(1) Connect one ohmmeter test lead to the fender
and the other lead to the crimp on the coaxial antenna cable shield.
(2) Resistance should be less then one ohm.
(3) If resistance is more then one ohm, clean
and/or tighten antenna base to fender mounting
hardware.
AUDIO SYSTEMS
8F - 7
SERVICE PROCEDURES
RADIO REMOVE/INSTALL
(1) Disconnect battery negative cable.
(2) Remove 2 screws at bottom edge of knee
blocker (Fig. 2).
SPEAKERS REMOVE/INSTALL
FRONT DOOR
(1) Unscrew door lock knob.
(2) Remove window regulator handle (if equipped).
(3) Squeeze the ends of the power switch housing
while pulling the switch housing away from the door
trim panel.
(4) Remove 2 screws from the power switch bezel.
(5) Remove trim plug at top of trim panel.
8F - 8
AUDIO SYSTEMS
AUDIO SYSTEMS
(13) Move module rearward and down until there
is room over top of module to remove wiring harness
trough attaching screws (Fig. 10).
8F - 9
ANTENNA REMOVE/INSTALL
(1) Disconnect battery negative cable.
(2) Remove glove box.
(3) Reach behind instrument panel and unplug antenna cable from radio (Fig. 13).
(7) Remove cap nut from antenna body while holding antenna mast with Antenna Nut Wrench (Special
Tool C-4816).
(8) Lower antenna assembly down far enough to
gain access to antenna body.
(9) While holding antenna body remove antenna mast.
(10) Pull antenna body and cable assembly from
fender area and remove.
(11) Reverse removal procedures to install.
HORN
8G - 1
HORN
CONTENTS
page
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 3
GENERAL INFORMATION
Following are general descriptions of the major
components in the Dakota horn system. Refer to
Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
HORN SWITCH
Two horn switches are installed in the steering
wheel, one on each side of the center-mounted drivers airbag module. When either switch is depressed
it completes a circuit to ground for the coil side of the
horn relay. The steering wheel and steering column
must be properly grounded for the horn switches to
function. The horn switches are only serviced as a set
with their wiring. If either switch should fail, both
switches must be replaced.
HORN RELAY
The horn relay is installed in the fuseblock module
under the instrument panel and left of the steering
HORN
The single, lo-note, diaphragm-type horn is located
in the engine compartment on the upper left corner
of the radiator closure panel just forward of the battery. It is grounded to the closure panel and receives
battery feed through the closed contacts of the horn
relay.
8G - 2
HORN
DIAGNOSIS
WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO GROUP 8M - RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE PROPER PRECAUTIONS COULD RESULT
IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
HORN RELAY
RELAY TESTS
(1) Remove horn relay from fuseblock module. The
de-energized relay should have continuity between
terminals 1 and 3 (Fig. 1). There should be no continuity between terminals 2 and 3. If OK, go to next
step. If not OK, replace faulty relay.
(2) Connect relay terminal 1 to a good ground and
terminal 3 to a battery feed. There should now be
battery voltage at terminal 2. If OK, go to Circuit
Test. If not OK, replace faulty relay.
HORN SWITCH
(1) Disconnect battery negative cable. Remove
knee blocker. Check for continuity between metal
steering column jacket and a good ground. There
should be continuity. If OK, go to next step. If not
OK, refer to Group 19 - Steering and check for proper
installation of steering column ground clip.
(2) Remove horn relay from fuseblock module. Access horn switch wire connector as described in Horn
Switch Remove/Install. Unplug horn wire connector.
Check for continuity between steering column half of
horn wire connector and a good ground. There should
be no continuity. If OK, go to next step. If not OK,
repair short circuit as required.
(3) Check for continuity between steering column
half of horn wire connector and horn relay cavity 1.
There should be continuity. If OK, go to next step. If
not OK, repair open circuit as required.
(4) Check for continuity between horn switch half
of horn wire connector and a good ground. There
should be no continuity. If OK, go to next step. If not
OK, replace faulty horn switches.
(5) Depress one horn switch and check for continuity between horn switch half of horn wire connector
and a good ground. There should be continuity. Repeat test for other horn switch. If either switch is not
OK, replace faulty horn switches.
HORN
(1) Measure resistance between the horn mounting
bracket and a good ground. There should be zero
ohms. If not OK, repair horn ground.
(2) Disconnect horn connector. Depress horn
switch. There should be battery voltage at the horn
connector. If OK, replace horn. If not OK, repair open
circuit to horn relay.
HORN
8G - 3
SERVICE PROCEDURES
HORN SWITCH REMOVE/INSTALL
WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT REMOVAL OR INSTALLATION, REMOVE
AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE
AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT
IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
INJURY. WAIT 2 MINUTES FOR THE RESERVE CAPACITOR TO DISCHARGE BEFORE REMOVING OR WORKING
ON ANY AIRBAG SYSTEM COMPONENTS.
(1) Disconnect negative cable from battery.
(2) From underside of steering wheel, remove speed
control switch or trim bar mounting screws (Fig. 2).
8G - 4
HORN
HORN REMOVE/INSTALL
(1) Raise and support the hood.
(2) Make sure ignition switch is in OFF position
and all battery feed accessories are OFF.
(3) Disconnect and remove battery cables at battery, negative cable first.
HORN
CAUTION: The horn connector is a self locking connector. To remove it, grasp and pull the insulator
only. DO NOT pull on the wire.
8G - 5
8H - 1
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 8
GENERAL INFORMATION
The vehicle speed control system (Fig. 1) is an available option on Dakota models equipped with a 3.9L or
5.2L engine. The system is electronically controlled and
vacuum operated. Following are general descriptions of
the major components in the Dakota speed control system. Refer to Group 8W - Wiring Diagrams for complete
circuit descriptions and diagrams.
SERVO CABLE
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle control linkage. This cable causes the throttle
control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm.
VACUUM RESERVOIR
The vacuum reservoir is mounted to the speed control servo mounting bracket on the passenger side
dash panel in the engine compartment. The reservoir
contains a one-way check valve to trap engine vacuum in the reservoir. When engine vacuum drops, as
in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed
control operation. The vacuum reservoir cannot be
repaired and must be replaced if faulty.
8H - 2
8H - 3
DIAGNOSIS
Before beginning diagnosis, perform a vehicle road
test to verify reports of speed control system malfunction. The road test should include attention to
the speedometer. Speedometer operation should be
smooth and without flutter at all speeds.
Flutter in the speedometer indicates a problem
which might cause surging in the speed control system. The cause of any speedometer problems should
be corrected before proceeding. Refer to Group 8E Instrument Panel and Gauges for speedometer diagnosis.
If a road test verifies a system problem and the
speedometer operates properly, check for:
(1) Loose or corroded electrical connections at the
servo. Corrosion should be removed from electrical
terminals and a light coating of Mopar MultiPurpose
Grease, or equivalent, applied.
(2) Correct installation of the vacuum check valve
in the hose from servo to vacuum source. The word
VAC on the valve must point toward the vacuum
source.
(3) Loose or leaking vacuum hoses or connections.
(4) Secure attachment of both ends of the speed
control servo cable.
CAUTION: When test probing for voltage or continuity 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.
8H - 4
8H - 5
8H - 6
(1) Disconnect battery negative cable. Wait 2 minutes for airbag system capacitor to discharge. Remove speed control switch from steering wheel.
(2) Check speed control switch continuity as shown
in chart (Fig. 2). If OK, reinstall switch. If not OK,
replace switch.
8H - 7
8H - 8
SERVICE PROCEDURES
SPEED CONTROL SERVO REMOVE/INSTALL
(1) Disconnect vacuum hose at servo.
(2) Unplug electrical connector at servo.
(3) Remove 2 nuts from cable sleeve (Fig. 8).
WARNING: TO AVOID AN ACCIDENTAL AIRBAG DEPLOYMENT ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE PERFORMING
SERVICE PROCEDURES.
(2) From underside of steering wheel, remove
speed control switch mounting screws (Fig. 9).
8H - 9
8J - 1
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 4
GENERAL INFORMATION
Following are general descriptions of the major
components in the Dakota turn signal and hazard
warning systems. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
The standard flasher is designed to handle the current flow requirements of the factory installed lighting. If supplemental lighting is added to the turn
signal circuits such as when towing a trailer with
lights, the current flow through the flasher increases.
This causes the flash rate to increase. It is recommended that the standard flasher be replaced with a
heavy-duty (hazard warning) flasher when supplemental lighting is added.
However, when a turn signal bulb fails with a standard flasher, the remaining bulbs in that circuit will
light, but not flash. This will give the driver an indication to check the turn signal bulbs. Because a
heavy-duty flasher has different internal circuitry, a
failed bulb will not prevent the remaining bulbs in
the circuit from flashing. Therefore, it is recommended that an occasional visual inspection of exterior turn signal lamp operation be performed when a
heavy-duty flasher is installed.
8J - 2
DIAGNOSIS
When diagnosing the turn signal or hazard warning circuits, remember that high generator output
can burn out bulbs rapidly and repeatedly. If this is a
problem on the vehicle being diagnosed, refer to
Group 8A - Battery/Starting/Charging Systems Diagnostics to test charging system.
WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO GROUP 8M - RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE PROPER PRECAUTIONS COULD RESULT
IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
TURN SIGNAL
(1) Turn ignition switch to ON position. Move turn
signal lever down for left turn signal problem, or up
for right turn signal problem. Observe the turn indicator lamp in the instrument cluster. If the lamp
HAZARD WARNING
(1) Check fuse F1 in power distribution center. If
OK, go to next step. If not OK, replace fuse.
(2) Check for battery voltage at the fuse side of the
hazard warning flasher (L9 circuit). If OK, go to next
step. If not OK, repair open circuit between fuse and
flasher.
(3) Replace hazard flasher with known good unit of
the same rating. The lamps should flash. If OK, dis-
8J - 3
MULTI-FUNCTION SWITCH
(1) Access multi-function switch connector and remove. See service procedures for Multi-Function
Switch, in this group.
(2) Using an ohmmeter, perform switch continuity
checks at the switch terminals as shown in the chart
(Fig. 3).
8J - 4
WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO GROUP 8M - RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE PROPER PRECAUTIONS COULD RESULT
IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
8K - 1
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 7
GENERAL INFORMATION
Following are general descriptions of the major
components in the Dakota wiper and washer systems. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
8K - 2
WIPER/WASHER SWITCH
Controls for the windshield wiper and washer systems are contained in the multi-function switch control lever. The multi-function switch is mounted on
the left side of the steering column between the
steering wheel and the instrument panel. This switch
also controls many other functions. The multi-function switch can not be repaired. If any function of the
switch is faulty, the entire switch must be replaced.
INTERMITTENT WIPE MODULE
In addition to low and high speed, the intermittent
wipe system has a delay mode. The delay mode has a
range of 2 to 15 seconds. The length of the delay is
selected with a variable resistor in the wiper switch
and is accomplished by electronic circuitry within the
intermittent wipe module. If the washer knob is depressed while the wiper switch is in the OFF position, the intermittent wipe module will operate the
wiper motor for approximately 2 wipes and automatically turn the motor off. The intermittent wipe module is mounted to the instrument panel, behind the
knee blocker and to the right of the steering column.
The module can not be repaired.
WASHER NOZZLES
The two fluidic washer nozzles are snap-fit into
openings in the cowl grille panel below the windshield and are not adjustable. Washer fluid is fed to
the nozzles through hoses clipped to the underside of
the cowl grille panel. The nozzles can not be repaired
and, if faulty, should be replaced.
WASHER RESERVOIR
The washer solvent reservoir is mounted to the left
front inner fender shield near the cowl panel. It has
a provision for a low washer fluid level sensor. Refer
to Group 8E - Instrument Panel and Gauges for diagnosis and service of the sensor. The reservoir and
filler cap are available for service.
WASHER PUMP
The washer pump and motor are press-fit into a
rubber grommet near the bottom of the washer reservoir. A permanently lubricated and sealed motor is
coupled to a rotor-type pump. Washer fluid is gravity
fed from the reservoir to the pump. The pump then
pressurizes the fluid and forces it through the plumbing to the nozzles when the motor is energized. The
pump and motor can not be repaired. If faulty, the
entire assembly must be replaced.
8K - 3
DIAGNOSIS
WIPER MOTOR
The following are wiper motor system problems,
tests to be performed to locate the faulty part, and
the proper action to be taken. If the malfunction involves only the delay mode, switch, or wiring, see the
diagnosis for Intermittent Wipe Module and Wiper/
Washer Switch.
CONDITION
Motor will not run in any wiper/washer
switch position.
PROCEDURE
(1) Check fuse 10 in the fuseblock module. If OK,
go to step 3. If not OK, replace fuse and go to next
step.
(2) Check motor operation in all wiper/washer
switch positions. If not OK and fuse blows, go to step
5. If not OK and fuse is OK, go to next step.
(3) Place wiper/washer switch in LOW position and
listen to motor. If you cannot hear it running, go to
next step. If motor is running, check motor output
shaft. If output shaft is not turning, replace motor
assembly. If it is turning, drive link to output shaft
or linkage is not properly connected. Replace worn
parts and/or properly connect drive link to the motor
output shaft.
(4) Connect a voltmeter between motor terminal L
and ground strap (Fig. 1). If there is little or no voltage (less than 1 volt), move negative test lead from
the ground strap to battery negative terminal. If an
increase in voltage is noticed, the problem is a bad
ground circuit. Make sure the motor mounting is free
of paint and that mounting fasteners are tight. If
there is still no indication of voltage, the problem is
an open in wiring or faulty wiper/washer switch. If a
small increase (greater than 3 volts) in voltage is observed, the problem is a faulty motor assembly.
CONDITION
Motor runs slowly at all speeds.
PROCEDURE
(1) Disconnect wiring harness connector at motor.
Remove wiper arms and blades. Connect an ammeter
between battery and terminal L on motor (Fig. 2). If
motor runs and average ammeter reading is more
than 6 amps, continue to next step. If motor runs
and average ammeter reading is less than 6 amps, go
to step 3.
CONDITION
Motor will run at high speed, but not at low
speed.
Motor will run at low speed, but not at high speed.
8K - 4
8K - 5
CONDITION
Motor will stop wherever it is, when wiper/
washer switch is put in OFF position. (Wipers
do not continue running to park position.)
PROCEDURE
(1) Remove motor wiring connector and clean terminals. Reconnect connector and test motor. If not
OK, go to step 2.
(2) Put wiper/washer switch in OFF position. Disconnect motor wiring connector. Connect a voltmeter
or test lamp to the motor ground strap. Connect the
other lead to terminal P1 of wiring connector. If voltage is not present, check for an open circuit in the
wiring harness or wiper/washer switch. If voltage is
present, go to next step.
(3) Connect an ohmmeter or continuity tester between terminals L and P2 (Fig. 5). If there is continuity between these terminals, the problem is a
defective motor. If there is no continuity, the problem
is an open in wiring or a faulty wiper/washer switch.
CONDITION
Motor will keep running with wiper/washer
switch in OFF position.
PROCEDURE
(1) Disconnect wiring harness connector at motor.
Connect jumper from terminal P2 to terminal L of
wiper motor (Fig. 4).
8K - 6
WIPER/WASHER SWITCH
Use an ohmmeter to test for continuity (no resistance) between the terminals of the switch as shown
in the Multi-Function Switch Continuity chart (Fig.
6).
CONDITION
In DELAY mode wipers run continually when
wash is operated, but do not provide an extra
wipe when the washer switch is released.
PROCEDURE
Replace the intermittent wipe module.
CONDITION
Wipers start erratically during DELAY mode.
CONDITION
Excessive delay (more than 30 seconds) or inadequate variation in delay.
PROCEDURE
Variations in delay should be as follows:
(1) Minimum delay (wiper/washer switch to extreme counter-clockwise position before LOW detent)
1/2 to 2 seconds.
(2) Maximum delay (wiper/washer switch to extreme clockwise position before OFF detent) 10 to 30
seconds.
PROCEDURE
(1) Verify that the ground connection at the instrument panel is making good connection (free from
paint) and is tight.
(2) Verify that the motor ground strap is making
good contact and that the motor mounting bolts are
tight.
(3) Verify that the wiring ground connections for
the intermittent wipe module and the wiper/washer
switch are tight.
(4) If condition is not corrected, replace intermittent wipe module.
WASHER PUMP
(1) Check for continuity between black wire of
pump connector and a good ground. There should be
continuity. If OK, go to next step. If not OK, repair
ground circuit as required.
(2) Turn ignition switch to ON position. Check for
battery voltage at brown wire of pump connector
with washer switch depressed. If OK, replace pump.
If not OK, see diagnosis for Wiper/Washer Switch in
this group. If switch tests OK, repair wiring between
switch and pump as required.
8K - 7
SERVICE PROCEDURES
WIPER BLADES OR ELEMENTS REMOVE/INSTALL
There are two types of wiper blade assemblies. The
assemblies are identified as Type A (Fig. 8) and Type
B (Figs. 9 and 10).
WIPER MOTOR
(1) Disconnect battery negative cable.
8K - 8
LINKAGE REMOVE/INSTALL
(1) Remove wiper arms as described in Wiper Arms
Remove/Install.
(2) Remove cowl grille panel mounting screws (Fig.
13). There is a screw in the center of the grille to the
right of right pivot assembly.
(3) Disengage rear of cowl panel from windshield
weatherstrip by pulling forward and remove cowl
grille panel.
(4) Remove screen by carefully prying up clips.
(5) Remove crank arm from drive link by prying
retainer bushing from crank arm pin with a suitable
size screwdriver.
(6) Remove pivot mounting screws.
(7) Working through access holes, remove linkage
and pivots as an assembly.
(8) Remove drive link from pivots by prying retainer bushing from pivot pin with a suitable size
screwdriver.
(9) Reverse removal procedures to install. Use
channel-lock pliers to reinstall linkage retainer bushings on pivot and crank pins. Tighten pivot mounting
screws to 7 Nzm (60 in. lbs.) torque.
8K - 9
8K - 10
LAMPS
8L - 1
LAMPS
CONTENTS
page
BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . 13
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 6
GENERAL INFORMATION
Each vehicle is equipped with various lamp assemblies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush and coat the inside of the socket lightly with
Mopar Multi-Purpose Grease or equivalent.
Aero headlamps use a replaceable bulb that is
mounted in a molded plastic lens.
DIAGNOSTIC PROCEDURES
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
8L - 2
LAMPS
HEADLAMP DIAGNOSIS
LAMPS
FOG/OFF ROAD LAMP DIAGNOSIS
8L - 3
8L - 4
LAMPS
SWITCH TEST
(1) Disconnect battery negative cable.
LAMPS
(10) Use an ohmmeter to test for continuity between the terminals of the switch as shown in the
continuity chart (Fig. 5).
(11) Refer to Service Procedures for assembly.
8L - 5
8L - 6
LAMPS
SERVICE PROCEDURES
INDEX
page
page
HEADLAMP ALIGNMENT
LAMPS
8L - 7
8L - 8
LAMPS
FOG LAMPS
Fog lamps are turned OFF by the circuit relay
when the high beam driving lamps are turned ON.
Fog lamps may be operated ONLY when low beam
headlamps are ON. If the headlamps are switched to
high beam, the low beam lamps and fog lamps will
LAMPS
8L - 9
8L - 10
LAMPS
HEADLAMP SWITCH
To remove or replace the headlamp switch. Refer to
Group 8E, Instrument Panel and Gauges.
LAMPS
8L - 11
UNDERHOOD LAMP
When equipped, the underhood lamp is installed on
the hood left, rear panel for all Dakota vehicles (Fig.
15). The lamp is illuminated when the hood is
opened via the liquid ON/OFF switch that is integral
with the lamp base (Fig. 14).
8L - 12
LAMPS
LAMPS
8L - 13
BULB APPLICATION
GENERAL INFORMATION
16The following Bulb Application Table lists the
lamp title on the left side of the column and trade
number or part number on the right.
CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
oily surfaces. Bulb life will be reduced.
EXTERIOR LAMPS
Back-up .................................................................1156
Center High Mounted Stoplamp ..........................922
Fog............................................................................H3
Front Side Marker.................................................194
Headlamp/Sealed Beam .................................HP4666
Headlamp/Aero-Style ...........................................9004
License Plate ..........................................................168
Off-Road Lamp ........................................................H3
Park/Turn Signal..................................................2057
Tail/Stop/Turn Signal...........................................2057
INTERIOR LAMPS
DIMMER CONTROLLED LAMPS
Service procedures for most of the lamps in the instrument panel, Instrument cluster and switches are
located in Group 8E, Instrument Panel and Gauges.
Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after
the component is removed from the vehicle. Contact
local dealer for location of nearest ASC.
Ash Receiver...........................................................161
Cigar Lighter..........................................................161
INDICATOR LAMPS
Service procedures for most of the lamps in the instrument panel, instrument cluster and switches are
located in Group 8E, Instrument Panel and Gauges.
A/C Control...............................................................74
Airbag.................................................................PC194
Anti-lock Brake .................................................PC194
Brake Warning ..................................................PC194
Check Engine ....................................................PC194
EGR Reminder ..................................................PC194
Engine Oil Pressure .........................................PC194
Fasten Seat Belts .............................................PC194
Four Wheel Drive ..................................................161
Heater Control .......................................................158
High Beam.........................................................PC194
Illumination .......................................................PC194
Low Fuel ............................................................PC194
Low Washer Fluid.............................................PC194
Maintenance Required......................................PC194
Temperature Indicator......................................PC194
Turn Signal........................................................PC194
Upshift .................................................................PC74
NON-DIMMING LAMPS
Service procedures for most of the lamps in the following list can be found in Group 23, Body.
Dome ....................................................................211-2
Glove Compartment...............................................194
Overhead Console ...............................................212-2
Under Hood ............................................................105
RESTRAINT SYSTEMS
8M - 1
RESTRAINT SYSTEMS
CONTENTS
page
page
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 3
AIRBAG SYSTEM
WARNING: THIS SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM OR RELATED STEERING
WHEEL AND STEERING COLUMN COMPONENTS
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE. THEN
WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO
DISCHARGE BEFORE FURTHER SYSTEM SERVICE.
FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: THE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM
NITRATE.
THESE
MATERIALS
ARE
POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER OR HEAVY METALS MAY
PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE
OF MOISTURE) OR COMBUSTIBLE COMPOUNDS.
DO NOT ATTEMPT TO DISMANTLE THE MODULE
OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE OR BRING INTO CONTACT
WITH ELECTRICITY. DO NOT STORE AT TEMPERATURES EXCEEDING 200F.
WARNING: REPLACE AIRBAG SYSTEM COMPONENTS WITH PARTS SPECIFIED IN THE CHRYSLER
MOPAR PARTS CATALOG ONLY. SUBSTITUTE
PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR
OCCUPANT PROTECTION. THE FASTENERS,
SCREWS, AND BOLTS ORIGINALLY USED FOR THE
AIRBAG COMPONENTS HAVE SPECIAL COATINGS
AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED
WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT
FASTENERS PROVIDED IN THE SERVICE PACKAGE
OR SPECIFIED IN THE CHRYSLER MOPAR PARTS
CATALOG.
WARNING: WHEN A STEERING COLUMN HAS AN
AIRBAG MODULE ATTACHED, NEVER PLACE THE
COLUMN ON THE FLOOR OR OTHER SURFACE
WITH THE STEERING WHEEL OR AIRBAG MODULE
FACE DOWN.
GENERAL INFORMATION
The airbag system is a standard equipment safety
device on Dakota models. It is designed to protect the
driver from serious injury, caused by a frontal impact
of the vehicle. To inspect this system use Airbag System - Body Diagnostic Procedures manual. If the airbag module assembly is defective and non-deployed,
refer to Chrysler Corporation current return list for
proper handling procedures.
Following are general descriptions of the major
components in the Dakota airbag system. Refer to
Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
AIRBAG MODULE
The airbag module protective cover is the most visible part of the system. The module is mounted directly to the steering wheel. Under the airbag
module cover, the airbag cushion and its supporting
components are contained. The airbag module contains a housing to which the cushion and inflator are
attached and sealed. The airbag module is non-serviceable, and must be replaced if deployed or damaged in any way.
The inflator assembly is mounted to the back of the
module. The inflator seals the hole in the airbag
cushion so it can discharge the gas it produces directly into the cushion when supplied with the
8M - 2
RESTRAINT SYSTEMS
STORAGE
The airbag module must be stored in its original,
special container until used for service. Also, it must
be stored in a clean, dry environment; away from
sources of extreme heat, sparks, and high electrical
energy. Always place or store the module on a surface
with the trim cover facing up to minimize movement
in case of accidental deployment.
IMPACT SENSOR
The impact sensors provide verification of the direction and severity of the impact. Three impact sensors are used. One is called a safing sensor. It is
located inside the airbag control module (ACM),
which is mounted to a bracket under the instrument
panel above the heater and A/C housing. The other
two sensors are mounted on the radiator closure
panel on the left and right side of the vehicle.
The impact sensors are threshold sensitive
switches that complete an electrical circuit when an
impact provides a sufficient deceleration force to
close the switch. The sensors are calibrated for the
specific vehicle, and react to the severity and direction of the impact.
CLOCKSPRING
The clockspring is mounted on the steering column
behind the steering wheel. It is used to maintain a
continuous electrical circuit between the wiring harness and the drivers side airbag module. This assembly consists of a flat, ribbon-like electrically
conductive tape which winds and unwinds with the
steering wheel rotation.
DIAGNOSIS
A DRB scan tool is required for diagnosis of the airbag system. Refer to Airbag System - Body Diagnostic Procedures manual for more information.
RESTRAINT SYSTEMS
8M - 3
SERVICE PROCEDURES
AIRBAG SYSTEM SERVICE (DEPLOYED)
CLEANUP PROCEDURE
Begin cleanup by putting tape over the airbag exhaust vent (Fig. 2) so that no more powder will find
its way into the vehicle interior. Then remove the airbag and airbag module from the vehicle.
8M - 4
RESTRAINT SYSTEMS
LEFT SIDE
(1) Disconnect battery negative cable and isolate.
If airbag module is undeployed, wait 2 minutes for
system capacitor to discharge before further service.
(2) Remove battery holddown (Fig. 8) and move
battery rearward.
(3) Unplug connector from sensor.
(4) Remove 3 nuts holding left sensor to closure
panel support (Fig. 9) and remove sensor.
RESTRAINT SYSTEMS
8M - 5
RIGHT SIDE
(1) Disconnect battery negative cable and isolate.
If airbag module is undeployed, wait 2 minutes for
system capacitor to discharge before further service.
(2) Pull air cleaner inlet tube off radiator support.
(3) Unplug connector from right sensor.
(4) Remove 3 nuts holding right sensor to radiator
support (Fig. 9) and remove sensor.
If stud plate needs to be replaced, remove
push nut from stud and discard. Always use
new push nut (Fig. 9) when installing stud
plate.
(5) When installing, mount sensor (arrow pointed
forward) using 3 nuts provided with new sensor.
Torque nuts to 3 to 4 Nzm (24 - 36 in. lbs.).
(6) Connect sensor wiring lead from harness to
connector on body of sensor.
(7) Install air cleaner inlet tube to radiator support.
(8) Do not connect negative battery cable at this
time. See Airbag System Check for proper procedure.
8M - 6
RESTRAINT SYSTEMS
CLOCKSPRING REMOVE/INSTALL
(1) Place the front wheels in the straight-ahead position before starting the repair.
(2) Disconnect battery negative cable and isolate.
If airbag is undeployed, wait 2 minutes for system
capacitor to discharge before further service.
(3) Remove the airbag module. See Airbag Module
Remove/Install.
(4) Remove speed control switch and connector, if
equipped.
RESTRAINT SYSTEMS
(5) Remove the steering wheel with steering wheel
puller tool (C-3428B).
(6) Unplug wiring connectors from horn switches.
(7) Remove upper and lower steering column
shrouds to gain access to clockspring wiring (Fig. 13).
(8) Disconnect the 2-way connector between the
8M - 7
CLOCKSPRING CENTERING
If the rotating tape within the clockspring is not
positioned properly in relation to the steering wheel
and the front wheels, the clockspring may fail during
use. The clockspring MUST BE CENTERED, if it is
not known to be properly positioned, or if the front
wheels were moved from the straight-ahead position.
(1) Place front wheels in the straight-ahead position.
(2) Disconnect battery negative cable and isolate.
If airbag is undeployed, wait 2 minutes for system
capacitor to discharge before further service.
(3) Remove airbag module. Remove steering wheel
with steering wheel puller tool (C-3428B).
(4) Depress the two plastic auto-locking tabs (Fig.
14).
POWER LOCKS
8P - 1
POWER LOCKS
CONTENTS
page
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 2
GENERAL INFORMATION
Power door locks are optional equipment on Dakota
models. Both doors can be locked or unlocked electrically by operating the switch on either door panel.
The power door locks operate with battery power
supplied independent of the ignition switch.
Following are general descriptions of the major
components in the Dakota power door lock system.
Refer to Group 8W - Wiring Diagrams for complete
circuit descriptions and diagrams.
DIAGNOSIS
POWER LOCK SWITCH
(1) Check fuse 5 in fuseblock module. If OK, go to
next step. If not OK, replace fuse.
(2) Check for battery voltage at fuse 5. If OK, go to
next step. If not OK, repair circuit from power distribution center.
(3) Remove switch from trim panel. See Power
Lock Switch Remove/Install. Carefully separate multiple terminal block on wiring harness from switch
body.
(4) Check continuity between switch connector cavity for switch pin 2 and a good ground. Repeat check
between cavity for switch pin 4 and a good ground.
In each case, there should be continuity. If OK, go to
next step. If not OK, repair circuit to ground as required.
(5) Check for battery voltage at switch connector
cavity for switch pin 5. If OK, go to next step. If not
OK, repair circuit to fuse 5 in the fuseblock module.
(6) Test switch continuity. See Switch Continuity
chart (Fig. 1) to determine if continuity is correct in
the OFF, LOCK and UNLOCK switch positions. If
OK, go to Power Lock Motor diagnosis. If not OK, replace the switch.
8P - 2
POWER LOCKS
connector at the motor. Apply 12 volts across the motor terminals to check its operation in one direction.
Reverse the polarity to check the operation in the
other direction. If OK, repair wire harness from the
motor to the switch as required. If not OK, replace
the motor.
(3) If both motors are inoperative, the problem
may be caused by one shorted motor. Disconnecting a
shorted motor will allow the good motor to operate.
SERVICE PROCEDURES
POWER LOCK SWITCH REMOVE/INSTALL
(1) Remove power window/lock switches by inserting a standard blade screwdriver into notch on forward end of switch housing. Push screwdriver to
depress locking tab. Pull switch bezel out and forward to remove from door panel (Fig. 2).
POWER WINDOWS
8S - 1
POWER WINDOWS
CONTENTS
page
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 3
GENERAL INFORMATION
Power door windows are optional equipment on Dakota models. The power windows operate only with the
ignition switch in the ON position. This group covers diagnosis and service of the electrical components peculiar
to the power window system. For service of mechanical
components such as the regulator, lift plate or window
tracks refer to Group 23 - Body Components.
Following are general descriptions of the major
components in the Dakota power window system. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
CIRCUIT BREAKER
An automatic re-setting circuit breaker in the fuseblock module is used to protect the power window
system circuit. The circuit breaker can protect the
system from a short circuit, and can also protect the
system from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker can not be repaired. If faulty, it must be
replaced.
DIAGNOSIS
It is necessary that the window be free to slide up
and down for the power window system to function
properly. If the window is not free to move up and
down, the motor will overload and trip the circuit
breaker. To determine if the glass is free, disconnect
regulator plate from the glass and slide window up
and down by hand.
An alternate method is to shake the glass in the
door, with the glass positioned between the up and
down stop positions. Check that the glass can be
moved slightly from side to side, front to rear, and up
and down. Then check that window is not bound
tight in the tracks. If window is free, proceed with diagnosis that follows. If window is not free, refer to
Group 23 - Body Components for service procedures.
CIRCUIT BREAKER
Locate correct circuit breaker in fuseblock module.
Pull out slightly, but be sure that circuit breaker terminals still contact terminals in fuseblock module. Turn
ignition switch to ON position. Connect ground wire of
voltmeter to a good ground. With probe of voltmeter
positive lead, check both terminals of circuit breaker for
battery voltage. If only one terminal has battery voltage, circuit breaker is faulty and must be replaced. If
neither terminal has battery voltage, repair circuit from
ignition switch as required.
8S - 2
POWER WINDOWS
POWER WINDOWS
8S - 3
SERVICE PROCEDURES
POWER WINDOW SWITCH REMOVE/INSTALL
(1) Remove power window/lock switches by inserting a standard blade screwdriver into notch on forward end of switch housing. Push screwdriver to
depress locking tab. Pull switch bezel out and forward to remove from door panel (Fig. 3).
(7) Using a trim stick or other suitable widebladed flat tool, gently pry trim panel away from
door.
(8) Roll door watershield away from lower rear corner of door to reveal inside panel access opening.
(9) Raise window to full up position and keep it
there at all times while replacing motor. Place a
window block in door that will positively prevent window from dropping into door.
(10) Disconnect wiring connector for motor (Fig. 4).
(11) Remove 3 mounting screws that hold motor
POWER MIRRORS
8T - 1
POWER MIRRORS
CONTENTS
page
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 3
GENERAL INFORMATION
This group covers power outside mirrors and the
automatic day/night inside rear view mirror, which
are available options on Dakota models. Following
are general descriptions of the major components in
the Dakota power outside mirror and automatic day/
night inside rear view mirror systems. Refer to
Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
POWER MIRRORS
The power mirrors are connected to battery feed at
all times. Each mirror head contains two electric motors, two drive mechanisms and the mirror glass.
One motor and drive controls mirror up-and-down
movement, and the other controls right-and-left
movement.
The mirror glass is the only serviced replacement
part for the power mirror assembly. If any other component of the mirror unit is faulty or damaged, the
entire assembly must be replaced.
8T - 2
POWER MIRRORS
DIAGNOSIS
POWER MIRRORS
(1) Check fuse F1 in Power Distribution Center
(PDC). If OK, go to next step. If not OK, replace fuse.
(2) Check for battery voltage at fuse F1 in PDC. If
OK, go to next step. If not OK, repair circuit to fusible link cartridge fuse F in PDC.
(3) Remove power mirror switch from the instrument
panel. See Power Mirror Switch Remove/Install.
(4) Disconnect wiring harness connector from switch.
Check for battery voltage at pink wire. If OK, go to next
step. If not OK, repair circuit to fuse F1 in PDC.
(5) Check for continuity between black wire in
switch harness connector and a good ground. There
should be continuity. If OK, go to next step. If not
OK, repair circuit to ground.
(6) Check switch continuity as shown in the Mirror
Switch Continuity chart (Fig. 2). If OK, go to next
step. If not OK, replace switch.
POWER MIRRORS
pletely so that no light reaches the sensor. Use
only one finger pressed tightly against sensor,
or cover sensor completely with electrical tape.
(7) Shine a light into the rear facing sensor. The
mirror should darken. If OK, go to next step. If not
OK, replace mirror
8T - 3
(8) With the mirror darkened, place the transmission gear selector in Reverse. The mirror should return to its normal condition. If not OK, replace
mirror.
SERVICE PROCEDURES
POWER MIRROR SWITCH REMOVE/INSTALL
(1) Remove screws along bottom edge of knee
blocker (Fig. 4).
8T - 4
POWER MIRRORS
8U - 1
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
page
SERVICE PROCEDURES
................... 3
GENERAL INFORMATION
This group covers the buzzer warning system,
which is standard equipment on Dakota models. The
system provides an audible warning to the driver
when it monitors the following conditions:
key is in ignition switch with the drivers door open
head or park lamps are on with drivers door open
drivers seat belt is not buckled with ignition
switch in ON position.
Following are general descriptions of the major
components in the Dakota buzzer warning system.
Refer to Group 8W - Wiring Diagrams for complete
circuit descriptions and diagrams.
BUZZER MODULE
The buzzer module is located on the fuseblock module
(Fig. 1). It receives battery voltage at all times from
fuse 7 in the fuseblock module. It also receives a second
battery feed through fuse 16 that is switched on when
the ignition switch is in the ON or START position.
Other inputs to the module include the drivers
door jamb switch, the drivers seat belt switch, the ignition key-in switch, and the headlamp switch. The
only output of the module is a timed 4 to 8 second
feed to the seat belt reminder lamp in the instrument cluster. The timer function begins after the ignition switch is turned to the ON position.
The buzzer module can not be repaired. If faulty, it
must be replaced.
HEADLAMP SWITCH
The headlamp switch is located in the instrument
panel. It closes a path to ground when the park or
headlamps are on and the drivers door jamb switch
is closed (door open). The switch opens the ground
path when the park and headlamps are turned off.
The headlamp switch can not be repaired. If faulty, it
must be replaced. Refer to Group 8E - Instrument
Panel and Gauges for service procedures.
8U - 2
BUZZER MODULE
(1) Check fuse 7 and fuse 16 in the fuseblock module. If fuses are OK, go to next step. If not OK, replace fuses as required.
(2) Check for battery voltage at fuse 7 in fuseblock
module. If OK, go to next step. If not OK, repair feed
circuit from power distribution center as required.
(3) Turn ignition switch to ON position. Check for
battery voltage at fuse 16 in the fuseblock module. If
OK, go to next step. If not OK, repair feed from ignition switch as required.
(4) Turn ignition switch to OFF position. Replace
buzzer module with a known good unit and test operation.
If not OK, remove buzzer module and go to next step.
(5) Check for battery voltage at cavity for buzzer
terminal 7 in fuseblock module (Fig. 2). If OK, go to
next step. If not OK, repair circuit to fuse 7.
8U - 3
HEADLAMP SWITCH
(1) Remove headlamp switch from instrument
panel (refer to Group 8E - Instrument Panel and
Gauges for procedure). Unplug headlamp switch connector. Open drivers door. Check for continuity between connector cavity with black/light blue wire to a
good ground. There should be continuity until drivers door is closed. If OK, go to next step. If not OK,
repair circuit from headlamp switch to drivers door
jamb switch as required.
(2) Check for continuity between connector cavity
with light blue wire and cavity for terminal 6 of
buzzer module in fuseblock module. There should be
continuity. If OK, go to next step. If not OK, repair
circuit from headlamp switch to fuseblock module as
required.
(3) Check continuity between headlamp switch terminal for connector cavity with black/light blue wire
and terminal for cavity with light blue wire. There
should be no continuity with switch in off position,
and there should be continuity with switch in park
lamps or headlamps on position. If not OK, replace
headlamp switch.
SERVICE PROCEDURES
Service procedures for components of the buzzer system can be found in the appropriate group as follows:
drivers door jamb switch - refer to Group 8L - Lamps
ignition key-in switch - refer to Group 8D - Ignition Systems
WIRING DIAGRAMS
8W - 1
WIRING DIAGRAMS
CONTENTS
page
page
8W-44
8W-47
8W-49
8W-50
8W-51
8W-52
8W-53
8W-54
8W-60
8W-61
8W-62
8W-70
8W-80
8W-90
8W-95
tems or components between the models, an identifier is placed next to the component.
INTERIOR LIGHTING . . . . . . . . . .
AUDIO SYSTEM . . . . . . . . . . . . . .
OVERHEAD CONSOLE . . . . . . . . .
FRONT LIGHTING . . . . . . . . . . . . .
REAR LIGHTING . . . . . . . . . . . . . .
TURN SIGNALS . . . . . . . . . . . . . .
WIPERS . . . . . . . . . . . . . . . . . . . .
TRAILER TOW . . . . . . . . . . . . . . .
POWER WINDOWS . . . . . . . . . . .
POWER DOOR LOCKS . . . . . . . . .
POWER MIRRORS . . . . . . . . . . . .
SPLICE INFORMATION . . . . . . . .
CONNECTOR PIN OUTS . . . . . . .
CONNECTOR LOCATIONS . . . . . .
SPLICE LOCATIONS . . . . . . . . . . .
8W-44-1
8W-47-1
8W-49-1
8W-50-1
8W-51-1
8W-52-1
8W-53-1
8W-54-1
8W-60-1
8W-61-1
8W-62-1
8W-70-1
8W-80-1
8W-90-1
8W-95-1
SECTION IDENTIFICATION
Sections in Group 8W are organized by sub-systems. The sections contain circuit operation descriptions, helpful information, and system diagrams. The
intention is to organize information by system, consistently from year to year.
CONNECTOR LOCATIONS
Section 8W-90 contains Connector Location illustrations. The illustrations contain the connector
number and component identification. Connector Location charts in Section 8W-90 reference the illustration number for components and connectors.
Section 8W-80 shows each connector and the circuits involved with that connector. The connectors
are identified using the number on the Diagram
pages.
SPLICE LOCATIONS
Splice Location charts in Section 8W-70 show the
entire splice, and provide references to other sections
the splice serves.
Section 8W-95 contains illustrations that show the
general location of the splices in each harness. The
illustrations show the splice by number, and provide
a written location.
8W - 01 - 1
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7
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1
2
page
Take Outs . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Replacement . . . . . . . . . . . . . . . . . .
Terminal/Connector RepairMolex Connectors
Troubleshooting Tests . . . . . . . . . . . . . . . . . .
Troubleshooting Tools . . . . . . . . . . . . . . . . . .
Troubleshooting Wiring Problems . . . . . . . . .
Wire Code Identification . . . . . . . . . . . . . . . .
Wiring Repair . . . . . . . . . . . . . . . . . . . . . . . .
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2
8
6
4
4
5
1
6
KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND
BELTS.
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8W - 01 - 2
CIRCUIT IDENTIFICATION
All circuits in the diagrams use an alpha/numeric
code to identify the wire and its function (Fig. 3). To
identify which circuit code applies to a system, refer
to the Circuit Identification Code Chart. This chart
shows the main circuits only and does not show the
secondary codes that may apply to some models.
CONNECTORS
Connectors shown in the diagrams are identified
using the international standard arrows for male and
female terminals (Fig. 4). A connector identifier is
placed next to the arrows to indicate the connector
number (Fig. 4).
For viewing connector pin outs, with two terminals
or greater, refer to section 8W-80. This section identifies the connector by number and provides terminal
numbering, circuit identification, wire colors, and
functions.
All connectors are viewed from the terminal end
unless otherwise specified. To find the connector location in the vehicle refer to section 8W-90. This section uses the connector identification number from
the wiring diagrams to provide a figure number reference.
TAKE OUTS
The abbreviation T/O is used in the component location section to indicate a point in which the wiring
harness branches out to a component.
SYMBOLS
Various symbols are used throughout the Wiring
Diagrams. These symbols can be identified by referring to the symbol identification chart (Fig. 5).
8W - 01 - 3
8W - 01 - 4
(1) Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written diagnostic
procedure.
(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part from its protective
packing until it is time to install the part.
(5) Before removing the part from its package,
ground the package to a known good ground on the
vehicle.
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.
Jumper Wire - This is a test wire used to connect
two points of a circuit. It can be used to bypass an
open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND.
Voltmeter - Used to check for voltage on a circuit.
Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in todays vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-megohm or greater impedance.
Ohmmeter - Used to check the resistance between
two points of a circuit. Low or no resistance in a circuit means good continuity.
CAUTION: - Most of the electrical components used
in todays vehicle are Solid State. When checking
resistance in these circuits use a meter with a 10megohm or greater impedance. In addition, make
TROUBLESHOOTING TESTS
Before beginning any tests on a vehicles electrical
system, use the Wiring Diagrams and study the circuit. Also refer to the Troubleshooting Wiring Problems section in this section.
8W - 01 - 5
8W - 01 - 6
are listed and explained below. Always check for nonfactory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step, check for
proper operation of all items on the repaired circuit.
Refer to the wiring diagrams.
WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely
in place to prevent damage to the insulation.
(1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
TERMINAL/CONNECTOR REPAIRMOLEX
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert the terminal releasing special tool 6742
into the terminal end of the connector (Fig. 12).
8W - 01 - 7
CONNECTOR REPLACEMENT
(1)
(2)
from
(3)
(Fig.
Disconnect battery.
Disconnect the connector that is to be repaired
its mating half/component.
Remove connector locking wedge, if required
14).
8W - 01 - 8
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half.
(3) Remove connector locking wedge, if required
(Fig. 14).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Figs. 15 and 16).
(5) Cut the wire 6 inches from the back of the connector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assembly
that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and remove 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11 example 2).
(12) Twist the wires together (Fig. 11 example 3).
(13) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay attention to the current flow direction (Fig. 18).
8W - 10 - 1
FUSE BLOCK
GENERAL INFORMATION
This section covers the Fuse Block and all circuits
involved with it. For additional information on system operation, refer to the appropriate section of the
wiring diagrams.
DIAGRAM INDEX
Component
ABS Warning Lamp Relay
Buzzer . . . . . . . . . . . .
Circuit Breaker Cavity 2 .
Clutch Interlock Switch .
Fuse 1 . . . . . . . . . . . .
Fuse 3 . . . . . . . . . . . .
Fuse 4 . . . . . . . . . . . .
Fuse 5 . . . . . . . . . . . .
Fuse 6 . . . . . . . . . . . .
Fuse 7 . . . . . . . . . . . .
Fuse 8 . . . . . . . . . . . .
Fuse 9 . . . . . . . . . . . .
Fuse 10 . . . . . . . . . . .
Fuse 11 . . . . . . . . . . .
Fuse 12 . . . . . . . . . . .
Fuse 13 . . . . . . . . . . .
Fuse 14 . . . . . . . . . . .
Fuse 15 . . . . . . . . . . .
Fuse 16 . . . . . . . . . . .
Fuse 20 . . . . . . . . . . .
Fuse Block . . . . . . . . .
Hazard Flasher Relay . . .
Headlamp Switch . . . . .
Horn Relay . . . . . . . . .
Ignition Switch . . . . . . .
Time Delay Relay . . . . .
Turn Signal Flasher . . . .
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Page
. . . .2
. . . .2
. . . .4
. . . .3
. . . .4
. . . .4
. . . .4
. . . .6
. . . .6
. . . .6
. . . .5
. . . .3
. . . .3
. . . .3
. . . .3
. . . .5
. . . .3
. . . .3
. . . .3
. . . .6
. . . .2
. . . .2
. . . .5
. . . .2
. .3, 4
. . . .2
. . . .2
8W - 11 - 1
POWER DISTRIBUTION
GENERAL INFORMATION
This section covers the Power Distribution Center
(PDC) and all circuits involved with it. For additional
information on system operation, refer to the appropriate section of the wiring diagrams.
DIAGRAM INDEX
Component
Page
A/C Compressor Clutch Relay . . . . . . . . . . . . . . .8W-11-3, 5
ABS Power Relay . . . . . . . . . . . . . . . . . . . . . .8W-11-3, 8
ABS Warning Lamp Relay . . . . . . . . . . . . . . . . . . .8W-11-8
Automatic Shut Down Relay . . . . . . . . . . . . . . . .8W-11-3, 6
Buss Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-2
Clutch Pedal Position Switch . . . . . . . . . . . . . . . . .8W-11-4
Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-5
Engine Starter Relay . . . . . . . . . . . . . . . . . . . . .8W-11-3, 4
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . .8W-11-3, 7
Fuse Block Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9
Fuse Block Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9
Fuse Block Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9
Fuse Block Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . .8W-11-8
Fuse Block Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9
Fuse Block Fuse 14 . . . . . . . . . . . . . . . . . . .8W-11-5, 6, 7
Fuse Block Fuse 15 . . . . . . . . . . . . . . . . . . .8W-11-5, 6, 7
Fuse Block Fuse 16 . . . . . . . . . . . . . . . . . . .8W-11-5, 6, 7
Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-2, 8
Fuse F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-2, 9
Fuse A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-8
Fuse B . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-4, 5, 6, 7
Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-4, 5, 6, 7
Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9
Fuse F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9
Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-2
Ignition Switch . . . . . . . . . . . . . . . . . . .8W-11-4, 5, 6, 7, 9
Power Distribution Center . . . . . . . . . . . . . . . . . . .8W-11-2
Radiator Fan Control Relay . . . . . . . . . . . . . . . .8W-11-3, 5
8W - 15 - 1
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94 October 14, 1994
GROUND DISTRIBUTION
GENERAL INFORMATION
This section identifies the grounds, splices that
connect to those grounds, and the components that
connect those grounds. For additional information on
system operation, refer to the appropriate section of
the wiring diagrams. For an illustration of the physical location of each ground, refer to group 8W-90.
DIAGRAM INDEX
Component
G101 . . .
G102 . . .
G103 . . .
G104 . . .
G105 . . .
G106 . . .
G107 . . .
G108 . . .
G109 . . .
G110 . . .
G111 . . .
G201 . . .
G202 . . .
G203 . . .
G301 . . .
G302 . . .
G303 . . .
G304 . . .
S101 . . .
S113 . . .
S121 . . .
S129 . . .
S141 . . .
S142 . . .
S204 . . .
S306 . . .
S308 . . .
S310 . . .
S401 . . .
S403 . . .
S404 . . .
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Page
.8W-15-2
.8W-15-2
.8W-15-2
.8W-15-2
.8W-15-2
.8W-15-3
.8W-15-3
.8W-15-3
.8W-15-4
.8W-15-4
.8W-15-4
.8W-15-4
.8W-15-4
.8W-15-4
.8W-15-5
.8W-15-5
.8W-15-5
.8W-15-5
.8W-15-2
.8W-15-2
.8W-15-3
.8W-15-3
.8W-15-4
.8W-15-4
.8W-15-4
.8W-15-5
.8W-15-5
.8W-15-5
.8W-15-5
.8W-15-5
.8W-15-5
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
8W - 20 - 1
CHARGING SYSTEM
CHARGING SYSTEM
2.5L ENGINE
The charging system is an integral part of the battery and starting systems. Because all these systems
work in conjunction, diagnose and test them together.
Circuit A11 connects to the generator output terminal and splices to circuit A0. Circuit A0 connects to
the battery. A fusible link in circuit A11 between the
battery and the generator protects the charging system.
Circuit Z1 provides ground for the generator at terminal 4 of the generator connector. Circuit Z1 attaches to the top of the left side of the engine.
When the ignition switch is in either the START or
RUN positions it connects battery voltage from circuit A1 to the A21 circuit. Circuit A21 connects to the
generator field terminal (terminal 2). Circuit A1 originates in the Power Distribution Center (PDC) and is
connected to battery voltage. 40 amp fuse C in the
PDC protects the A1 circuit.
The Powertrain Control Module (PCM) has an internal voltage regulator that controls generator output. Circuit K20 connects to generator terminal 1
and PCM cavity 20. The PCM controls the generator
field on the K20 circuit.
When the engine operates and there is current in
the generator field, the generator produces a B+ voltage. The generator supplies B+ voltage to the battery
through the A11 and A0 circuits.
HELPFUL INFORMATION
Circuit A21 splices to supply battery voltage to the
coil side of the Automatic Shutdown (ASD) relay. If
battery voltage is not present on the A21 circuit at
the ASD relay, the PCM will not be able to energize
the relay. The ASD relay supplies battery voltage for
the fuel injectors, fuel pump module, ignition coil,
and the heated oxygen sensor.
Ground circuit Z1 also supplies ground for the A/C
compressor clutch.
DIAGRAM INDEX2.5L
Component
Battery . . . . . . . . . . . .
Fuse F1 . . . . . . . . . . . .
Fusible Link . . . . . . . . .
Generator . . . . . . . . . . .
Powertrain Control Module
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Page
.8W-20-2
.8W-20-2
.8W-20-2
.8W-20-2
.8W-20-2
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Page
.8W-20-3
.8W-20-3
.8W-20-3
.8W-20-3
.8W-20-3
.8W-20-3
DIAGRAM INDEX3.9L/5.2L
Component
Battery . . . . . . . . . . . .
Fuse F1 . . . . . . . . . . . .
Fusible Link . . . . . . . . .
Generator . . . . . . . . . . .
Power Distribution Center
Powertrain Control Module
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8W - 21 - 1
STARTING SYSTEM
INDEX
page
page
2.5L Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.9L and 5.2L Engines . . . . . . . . . . . . . . . . . . . . . . 1
Diagram Index2.5L . . . . . . . . . . . . . . . . . . . . . . . . 2
Diagram Index3.9L/2.5L . . . . . . . . . . . . . . . . . . . . 2
2.5L ENGINE
The Power Distribution Center (PDC) supplies battery voltage to the engine starter motor solenoid on
circuit T40 when the coil side of the engine starter
motor relay energizes.
Circuit A0 from the battery is double crimped at
the battery positive post. One branch of circuit A0
(battery positive cable) connects to the engine starter
motor. The other A0 branch supplies voltage to a bus
bar in the PDC. Fuse B (30 amp) connects to the bus
bar protects circuit C26. Circuit C26 splices to circuit
A0 which connects to the contact side of the engine
starter motor relay.
In the START position, the ignition switch connects
battery voltage from the PDC on circuit A1 with circuit A41. Circuit A41 feeds the coil side of the engine
starter motor relay. Circuit Z1 provides ground for
the coil side of the relay. The engine starter motor relay is located in the PDC.
Manual transmission equipped vehicles use a
clutch pedal position switch in circuit A41 between
the ignition switch and the engine starter motor relay. Before the relay will energize, the operator has
to depress the clutch pedal to close the clutch pedal
position switch.
When the engine starter motor relay energizes and
the contacts close, circuit T40 supplies battery voltage to the starter motor solenoid. Circuit A0 from the
battery supplies voltage to the engine starter motor
when the solenoid energizes.
HELPFUL INFORMATION
Circuit C26 splices to feed the contact sides of the
radiator fan relay and the A/C compressor clutch relay.
Fuse C, 40 amp, protects circuits A1 and A41.
Fuse C is located in the PDC.
Circuit Z1 also provides ground for the vehicle
speed sensor, A/C compressor clutch, 4x4 switch,
speed control, heated oxygen sensor, and PCM. The
engine will not start if the vehicle loses this
ground. The grounding point for the Z1 ground is
the left fender side shield.
AUTOMATIC TRANSMISSION
The Power Distribution Center (PDC) supplies battery voltage to the engine starter motor solenoid on
circuit T40 when the coil side of the engine starter
motor relay energizes.
Circuit A0 from the battery is double crimped at
the positive battery post. One branch of circuit A0
(battery positive cable) connects to the starter motor.
The other A0 branch supplies voltage to a bus bar in
the PDC. Fuse B (30 amp) connects to the bus bar
and protects circuit C26. Circuit C26 splices to circuit
A0 which connects to the contact side of the starter
motor relay.
The ignition switch supplies battery voltage to the
coil side of the engine starter motor relay on circuit
A41 when the key is moved to the START position
and the PARK/NEUTRAL switch is closed. Ground
for the coil side of the starter motor relay is supplied
by the case grounded PARK/NEUTRAL switch. Circuit T41 connects the coil side of the relay to the
PARK/NEUTRAL switch.
When the starter motor relay energizes and the
contacts close, circuit T40 supplies battery voltage to
the starter motor solenoid. Circuit A0 from the battery supplies voltage to the starter motor when the
solenoid energizes.
HELPFUL INFORMATION
The PARK/NEUTRAL switch closes when the
transmission is in either the PARK or NEUTRAL positions.
Circuit T41 splices to cavity 30 of the powertrain
control module (PCM). This input tells the PCM the
operator is starting the vehicle.
Circuit T41 is spliced to circuit Z1. Circuit Z1 provides ground for the vehicle speed sensor, A/C compressor clutch, 4x4 switch, vehicle speed control,
heated oxygen sensor, and PCM. The engine will
not start if the vehicle loses this ground. The
grounding point for the Z1 ground is the left fender
side shield.
8W - 21 - 2
MANUAL TRANSMISSION
The Power Distribution Center (PDC) supplies battery voltage to the engine starter motor solenoid on
circuit T40 when the coil side of the engine starter
motor relay energizes.
Circuit A0 from the battery is double crimped at
the positive battery post. One branch of circuit A0
(battery positive cable) connects to the starter motor.
The other A0 branch supplies voltage to a bus bar in
the PDC. Fuse B (30 amp) connects to the bus bar
and protects circuit C26. Circuit C26 splices to circuit
A0 which connects to the contact side of the starter
motor relay.
The ignition switch supplies battery voltage to the
coil side of the engine starter motor relay on circuit
A41 when the key is moved to the START position
and the operator depresses the clutch pedal. When
the operator depresses the clutch pedal, the clutch
pedal position switch closes. Ground for the coil side
of the engine starter motor relay is supplied on circuit T41. This circuit is spliced with circuit Z1. The
Z1 circuit terminates at the left fender side shield.
When the starter motor relay energizes, and the
contacts close, circuit T40 supplies battery voltage to
the starter motor solenoid. Circuit A0 from the battery supplies voltage to the starter motor when the
solenoid energizes.
HELPFUL INFORMATION
Circuit Z1 also provides ground for the vehicle
speed sensor, A/C compressor clutch, 4x4 switch, vehicle speed control, heated oxygen sensor, and PCM.
The engine will not start if the vehicle loses
this ground. The grounding point for the Z1 ground
is the left fender side shield.
DIAGRAM INDEX2.5L
Component
Battery . . . . . . . . . . . . . .
Clutch Pedal Position Switch
Fuse B . . . . . . . . . . . . . .
Fuse C . . . . . . . . . . . . . .
Engine Starter Motor . . . . .
Engine Starter Relay . . . . .
Ignition Switch . . . . . . . . .
Power Distribution Center . .
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Page
.8W-21-3
.8W-21-3
.8W-21-3
.8W-21-3
.8W-21-3
.8W-21-3
.8W-21-3
.8W-21-3
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Page
.8W-21-4, 5
. . .8W-21-4
. . .8W-21-5
. . .8W-21-4
. . .8W-21-4
. . .8W-21-5
. . .8W-21-4
. . .8W-21-4
.8W-21-4, 5
. . .8W-21-5
. . .8W-21-4
. . .8W-21-5
DIAGRAM INDEX3.9L/5.2L
Component
Battery . . . . . . . . . . . . . .
Clutch Pedal Position Switch
Fuse 3 . . . . . . . . . . . . . .
Fuse B . . . . . . . . . . . . . .
Fuse C . . . . . . . . . . . . . .
Fuse E . . . . . . . . . . . . . .
Engine Starter Motor . . . . .
Engine Starter Relay . . . . .
Ignition Switch . . . . . . . . .
Park/Neutral Position Switch
Power Distribution Center . .
Powertrain Control Module .
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8W-30 FUEL/IGNITION
8W - 30 - 1
FUEL/IGNITION
CONTENTS
page
page
FUEL/IGNITION2.5L ENGINE . . . . . . . . . . . . . . 7
GENERAL INFORMATION
FUEL/IGNITION2.5L ENGINE
INDEX
page
Automatic Shut Down (ASD) Relay .
Battery Feed . . . . . . . . . . . . . . . . . .
Data Link Connector . . . . . . . . . . . .
Diagram Index . . . . . . . . . . . . . . . .
Distributor Pick-Up . . . . . . . . . . . . .
EGR Solenoid . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor
EVAP/Purge Solenoid . . . . . . . . . . .
Fuel Injector . . . . . . . . . . . . . . . . . .
Fuel Pump Module . . . . . . . . . . . . .
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2
2
5
5
3
4
4
5
2
2
IGNITION SWITCH
When the ignition switch is in the RUN position, it
connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 50 amp fuse in cavity E of
the PDC protects the A2 and A22 circuits.
Circuit A22 connects to a bus bar in the fuse block.
The bus bar feeds circuits C1, F21, F20, and A20.
Circuits C1, F20, and A20 are protected by separate
fuses. A circuit breaker protects circuit F21.
Fuse 1, 30 amp, protects circuit C1. Circuit C1
feeds the blower motor switch.
The 30 amp circuit breaker in cavity 2 of the fuse
block protects circuit F21. The F21 circuit feeds the
power window switches.
Fuse 3, 15 amp, protects circuit F20. The F20 circuit is double crimped at the fuse. One branch of circuit F20 feeds just the Airbag Control Module (ACM).
The other branch feeds the overhead console, Powertrain Control Module (PCM), and the back-up lamp
switch.
Fuse 4, 5 amp, is only used on vehicles with ABS.
The fuse protects circuit A20. Circuit A20 provides an
page
Heated Oxygen Sensor . . . . . . . . .
Idle Air Control (IAC) Motor . . . . . .
Ignition Coil . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . .
Manifold Absolute Pressure Sensor
Power (Device) Ground . . . . . . . . .
Throttle Body Temperature Sensor
Throttle Position Sensor . . . . . . . .
Vehicle Speed Sensor . . . . . . . . . .
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3
3
2
1
4
5
4
4
3
8W - 30 - 2
BATTERY FEED
Circuit A14 from the Power Distribution Center
(PDC) supplies battery voltage to cavity 3 of the Powertrain Control Module (PCM). A 30 amp fuse in the
PDC, cavity D, protects circuit A14.
HELPFUL INFORMATION
Circuit A14 supplies power to the contact side of
the ASD relay.
FUEL INJECTOR
When the Powertrain Control Module (PCM)
grounds the Automatic Shut Down (ASD) relay, the
contacts close and connect circuits A14 and A142. A
30 amp fuse in cavity D of the PDC protects the A14
and A142 circuits.
Circuit A142 supplies battery voltage to the fuel injector. The PCM controls the ground path for the fuel
injector on circuit K11. Circuit K11 connects to cavity
16 of the PCM.
HELPFUL INFORMATION
Circuit A142 splices to supply voltage to the fuel
injector, distributor ignition coil, and heated oxygen
sensor. The A142 circuit also feeds circuit A141 which
in turn feeds circuit A61. Circuit A61 supplies voltage
to the fuel pump module.
For information regarding fuel injector operation,
refer to Group 14.
IGNITION COIL
When the Powertrain Control Module (PCM)
grounds the Automatic Shut Down (ASD) relay and
the contacts close, circuits A14 and A142 are connected. A 30 amp fuse, in cavity D of the PDC, protects the A14 and A142 circuits.
Circuit A142 supplies battery voltage to the distributor ignition coil. The PCM controls the ground path
for the ignition coil on circuit K19. Circuit K19 connects to cavity 19 of the PCM.
HELPFUL INFORMATION
Circuit A142 splices to supply voltage to the fuel
injector, distributor ignition coil, and heated oxygen
sensor. The A142 circuit also feeds circuit A141 which
feeds circuit A61. Circuit A61 supplies voltage to the
fuel pump module.
HELPFUL INFORMATION
Circuit G7 splices to the speedometer, combination
buzzer, and Daytime Running Lamps (DRL) module .
Circuit K7 splices to supply 8 volts to the pick-up
coil in the distributor.
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Distributor Pick-up coil
Throttle position sensor
Manifold absolute pressure sensor
8W - 30 - 3
HELPFUL INFORMATION
Circuit A142 splices to supply voltage to the fuel
injector, distributor ignition coil, and heated oxygen
sensor. The A142 circuit also feeds circuit A141 which
feeds circuit A61. Circuit A61 supplies voltage to the
fuel pump module.
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Distributor Pick-up coil
Throttle position sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Throttle body temperature sensor
Circuit Z12 also supplies ground for the data link
connector and the PCM. Circuit Z12 connects to cavities 11 and 12 of the PCM.
DISTRIBUTOR PICK-UP
The Powertrain Control Module (PCM) supplies 8
volts to the distributor pick-up coil on circuit K7. Circuit K7 connects to cavity 7 of the PCM.
The PCM receives the engine speed signal from the
distributor pick-up coil on circuit K24. Circuit K24
connects to cavity 24 of the PCM.
The PCM provides a ground for the distributor
pick-up coil (circuit K24) through circuit K4. Circuit
K4 connects to cavity 4 of the PCM connector.
HELPFUL INFORMATION
Circuit K7 splices to supply 8 volts to the vehicle
speed sensor.
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Distributor Pick-up coil
Throttle position sensor
Manifold absolute pressure sensor
8W - 30 - 4
HELPFUL INFORMATION
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Distributor Pick-up coil
Throttle position sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Throttle body temperature sensor
HELPFUL INFORMATION
Refer to Group 14 for throttle position sensor operation.
Circuit K6 splices to supply 5 volts to the manifold
absolute pressure sensor.
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Distributor Pick-up coil
Throttle position sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Throttle body temperature sensor
HELPFUL INFORMATION
Refer to Group 14 for MAP sensor operation.
Circuit K6 splices to supply 5 volts to the throttle
position sensor.
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Distributor Pick-up coil
Throttle position sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Throttle body temperature sensor
HELPFUL INFORMATION
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Distributor Pick-up coil
Throttle position sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Throttle body temperature sensor
EGR SOLENOID
The Powertrain Control Module (PCM) operates
the Exhaust Gas Recirculation (EGR) solenoid by
providing a ground path on circuit K35. Circuit K35
connects to PCM cavity 35. Circuit A21 supplies battery voltage to the EGR solenoid.
HELPFUL INFORMATION
In the RUN or START position, the ignition switch
connects circuit A1 from the fuse block and circuit
A21. Circuit A1 connects to battery voltage and is
protected by a 40 amp fuse in cavity C of the Power
Distribution Center (PDC).
Circuit A21 is double crimped at fuse 14 in fuse
block. This circuit splices to supply battery voltage to
EVAP/PURGE SOLENOID
The Powertrain Control Module (PCM) operates
the EVAP/purge solenoid by providing a ground path
on circuit K52. Circuit K52 connects to PCM cavity
52. Circuit A21 supplies battery voltage to the EVAP/
Purge solenoid.
HELPFUL INFORMATION
In the RUN or START position, the ignition switch
connects circuit A1 from the fuse block and circuit
A21. Circuit A1 connects to battery voltage and is
protected by a 40 amp fuse in cavity C of the Power
Distribution Center (PDC).
Circuit A21 is double crimped at fuse 14 in fuse
block. This circuit splices to supply battery voltage to
the EVAP purge solenoid, EGR solenoid, generator
field, data link connector and provides an input to
the PCM.
HELPFUL INFORMATION
The grounding point for circuit Z12 is the right
rear of the cylinder head.
Circuit Z12 also supplies a ground for the PCM
high current drivers and the heated oxygen sensor.
If the system loses ground for the ganged circuits
at the right rear of the cylinder head, the vehicle will
not operate. Check the connection at the gangedground circuit eyelet.
8W - 30 - 5
Internal to the PCM, the power (device) ground circuit connects to the PCM sensor return circuit (from
circuit K4).
HELPFUL INFORMATION
The grounding point for circuit Z12 is the right
rear of the cylinder head.
Circuit Z12 also supplies a ground for the PCM
high current drivers and the heated oxygen sensor.
If the system loses ground for the ganged circuits
at the right rear of the cylinder head, the vehicle will
not operate. Check the connection at the gangedground circuit eyelet.
DIAGRAM INDEX
Component
Page
Automatic Shut-Down Relay . . . . . . . . .8W-30-14, 15, 16, 17
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13
Data Link Connector . . . . . . . . . . . . . . . . . . . . . .8W-30-15
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-19
Distributor Ignition Coil . . . . . . . . . . . . . . . . . . . .8W-30-17
EGR Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-17
Engine Coolant Temperature Sensor . . . . . . . . . . . .8W-30-19
Engine Oil Pressure Sending Unit . . . . . . . . . . . . . .8W-30-17
EVAP/Purge Solenoid . . . . . . . . . . . . . . . . . . . . .8W-30-17
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-14
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12, 16, 17
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12, 16, 17
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12, 16, 17
Fuse C . . . . . . . . . . . . . . . . . . . . . . .8W-30-12, 15, 16, 17
Fuse D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-16
Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13
Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . .8W-30-15
Idle Air Control Motor . . . . . . . . . . . . . . . . . . . . .8W-30-18
Ignition Switch . . . . . . . . . . . . . . . . .8W-30-12, 13, 16, 17
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-19
Powertrain Control Module . . . .8W-30-14, 15, 16, 17, 18, 19
Throttle Body Temperature Sensor . . . . . . . . . . . . .8W-30-14
Throttle Position Sensor . . . . . . . . . . . . . . . . . . .8W-30-14
Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . .8W-30-18
8W - 30 - 6
page
IGNITION SWITCH
8W - 30 - 7
HELPFUL INFORMATION
Circuit A142 splices to supply voltage to the fuel
injectors, ignition coil, and heated oxygen sensor.
One of the splices in circuit A142 connects directly
to injectors 1, 3, 5, 7 and also connects to a splice
that feeds injectors 2, 4, 6, and 8. Refer to the diagrams.
For information about fuel injector operation, refer
to Group 14.
HELPFUL INFORMATION
Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay.
Circuit A21 splices to supply battery voltage to the
coil side of the ASD relay and fuel pump relay.
IGNITION COIL
BATTERY FEED
Circuit A14 from the Power Distribution Center
(PDC) supplies battery voltage to cavity 3 of the Powertrain Control Module (PCM). A 30 amp fuse in cavity D of the PDC protects circuit A14.
HELPFUL INFORMATION
Circuit A14 supplies power to the contact sides of
the Automatic Shut Down (ASD) relay and fuel pump
relay.
HELPFUL INFORMATION
Circuit A142 splices to supply voltage to the fuel
injectors, ignition coil, and heated oxygen sensor.
FUEL INJECTORS
When the Automatic Shut Down (ASD) relay contacts close, they connect circuits A14 and A142. Circuit A142 supplies voltage to the fuel injectors. Each
injector has a separate ground circuit controlled by
the Powertrain Control Module (PCM).
Circuit K11 provides ground for injector number
one. The K11 circuit connects to cavity 11 of the
PCM.
Circuit K12 provides ground for injector number
two. The K12 circuit connects to cavity 15 of the
PCM.
Circuit K13 provides ground for injector number
three. The K13 circuit connects to cavity 14 of the
PCM.
Circuit K14 provides ground for injector number
four. The K14 circuit connects to cavity 13 of the
PCM.
Circuit K15 provides ground for injector number
five. The K15 circuit connects to cavity 38 of the
PCM.
Circuit K16 provides ground for injector number
six. The K16 circuit connects to cavity 58 of the
PCM.
On the 5.2L engine, circuit K17 provides ground for
injector number seven. The K17 circuit connects to
cavity 17 of the PCM.
Also on the 5.2L engine, circuit K18 provides
ground for injector number eight. The K18 circuit
connects to cavity 18 of the PCM.
HELPFUL INFORMATION
Along with supplying voltage to the fuel pump relay contacts, circuit A14 splices to supply voltage to
the contact side of the ASD relay.
Circuit A21 splices to supply battery voltage to the
coil sides of the ASD relay and fuel pump relay.
8W - 30 - 8
HELPFUL INFORMATION
Circuit A14 splices to supply voltage to the contact
side of the Automatic Shut Down (ASD) relay. Circuit
A142 connects to circuit A14 when the ASD relay
contacts close.
HELPFUL INFORMATION
Circuit G7 splices to the speedometer, combination
buzzer, and Daytime Running Lamps (DRL) module.
Circuit K7 splices to supply 8 volts to the camshaft
position sensor and crankshaft position sensor.
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Camshaft position sensor
Crankshaft position sensor
Throttle position sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Intake air temperature sensor
HELPFUL INFORMATION
Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay.
Circuit A142 splices to supply voltage to the fuel
injectors, ignition coil, and heated oxygen sensor.
Circuit K4 splices to supply ground for the signals
from the following:
Camshaft position sensor
Crankshaft position sensor
Intake air temperature sensor
Throttle position sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Vehicle speed sensor
Circuit Z1 also supplies ground for the 4WD
switch, A/C compressor clutch, vehicle speed sensor,
speed control, starter relay (manual transmission),
and PCM.
HELPFUL INFORMATION
Circuit K7 splices to supply 8 volts to the crankshaft position sensor and the vehicle speed sensor.
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Crankshaft position sensor
Intake air temperature sensor
Throttle position sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Vehicle speed sensor
HELPFUL INFORMATION
Circuit K7 splices to supply 8 volts to the camshaft
position sensor and the vehicle speed sensor.
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Camshaft position sensor
Intake air temperature sensor
Throttle position sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Vehicle speed sensor
8W - 30 - 9
HELPFUL INFORMATION
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Camshaft position sensor
Crankshaft position sensor
Intake air temperature sensor
Throttle position sensor
Manifold absolute pressure sensor
Vehicle speed sensor
HELPFUL INFORMATION
Refer to Group 14 for throttle position sensor operation.
Circuit K6 splices to supply 5 volts to the manifold
absolute pressure sensor.
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Camshaft position sensor
Crankshaft position sensor
Intake air temperature sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Vehicle speed sensor
HELPFUL INFORMATION
Refer to Group 14 for MAP sensor operation.
Circuit K6 splices to supply 5 volts to the throttle
position sensor.
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Camshaft position sensor
Crankshaft position sensor
Intake air temperature sensor
8W - 30 - 10
HELPFUL INFORMATION
Circuit K4 splices to supply ground for the signals
from the following:
Heated oxygen sensor
Camshaft position sensor
Crankshaft position sensor
Throttle position sensor
Manifold absolute pressure sensor
Engine coolant temperature sensor
Vehicle speed sensor
HELPFUL INFORMATION
In the START position, the ignition switch connects
circuit A1 from the Power Distribution Center (PDC)
to circuit A41. A 40 amp fuse in cavity C of the PDC
protects circuits A1 and A41.
TCC SOLENOID
The TCC solenoid and overdrive solenoid are
molded together. They are only used on automatic
transmissions. The Powertrain Control Module
(PCM) operates the TCC solenoid by providing a
ground path on circuit K54. Circuit K54 connects to
PCM cavity 54. Circuit A21 supplies battery voltage
to the TCC solenoid.
HELPFUL INFORMATION
In the START or RUN position, the ignition switch
connects circuit A1 from the fuse block and circuit
UPSHIFT LAMP
On vehicles equipped with a manual transmission,
the Powertrain Control Module (PCM) provides a
ground path for the instrument cluster upshift lamp
on circuit K54. Circuit F14 provides battery voltage
to the lamp.
OVERDRIVE SOLENOID
The overdrive solenoid and TCC solenoid are
molded together. They are only used on automatic
transmissions. The Powertrain Control Module
(PCM) operates the overdrive solenoid by providing a
ground path on circuit T60. Circuit T60 connects to
PCM cavity 55. Circuit A21 supplies battery voltage
to the overdrive solenoid.
HELPFUL INFORMATION
In the START or RUN position, the ignition switch
connects circuit A1 from the fuse block and circuit
A21. Circuit A1 connects to battery voltage and is
protected by a 40 amp fuse in cavity C of the Power
Distribution Center (PDC).
Circuit A21 is double crimped at fuse 14 in fuse
block. The A21 branch from fuse 14 splices to supply
battery voltage to the EVAP/Purge solenoid, EGR solenoid, TCC solenoid, overdrive solenoid, data link
connector and provides an input to the PCM.
EGR SOLENOID
The Powertrain Control Module (PCM) operates
the Exhaust Gas Recirculation (EGR) solenoid by
providing a ground path on circuit K35. Circuit K35
connects to PCM cavity 35. Circuit A21 supplies battery voltage to the EGR solenoid.
HELPFUL INFORMATION
In the START or RUN position, the ignition switch
connects circuit A1 from the fuse block and circuit
A21. Circuit A1 connects to battery voltage and is
protected by a 40 amp fuse in cavity C of the Power
Distribution Center (PDC).
Circuit A21 is double crimped at fuse 14 in fuse
block. The A21 branch from fuse 14 splices to supply
battery voltage to the EVAP/Purge solenoid, EGR solenoid, TCC solenoid, overdrive solenoid, data link
connector and provides an input to the PCM.
EVAP/PURGE SOLENOID
The Powertrain Control Module (PCM) operates
the EVAP/Purge solenoid by providing a ground path
HELPFUL INFORMATION
In the START or RUN position, the ignition switch
connects circuit A1 from the fuse block and circuit
A21. Circuit A1 connects to battery voltage and is
protected by a 40 amp fuse in cavity C of the Power
Distribution Center (PDC).
Circuit A21 is double crimped at fuse 14 in fuse
block. The A21 branch from fuse 14 splices to supply
battery voltage to the EVAP/Purge solenoid, EGR solenoid, TCC solenoid, overdrive solenoid, data link
connector and provides an input to the PCM.
HELPFUL INFORMATION
The grounding point for circuit Z12 is the rear of
the right cylinder head.
Circuit Z12 also supplies a ground for the PCM
high current drivers.
If the system loses ground for the Z12 circuits at
the rear of the right cylinder head, the vehicle will
not operate. Check the connection at the gangedground circuit eyelet.
8W - 30 - 11
HELPFUL INFORMATION
The grounding point for circuit Z12 is the rear of
the right cylinder head.
Circuit Z12 also supplies a ground for the PCM
high current drivers and the heated oxygen sensor.
If the system loses ground for the Z12 circuits at
the right rear of the cylinder head, the vehicle will
not operate. Check the connection at the gangedground circuit eyelet.
DIAGRAM INDEX
Component
Page
Automatic Shut Down Relay . . . . . . . . . . . . . . . . .8W-30-22
Camshaft Position Sensor . . . . . . . . . . . . . . . . . .8W-30-25
Crankshaft Position Sensor . . . . . . . . . . . . . . . . .8W-30-24
Data Link Connector . . . . . . . . . . . . . . . . . . . . . .8W-30-23
Distributor Ignition Coil . . . . . . . . . . . . . . . . . . . .8W-30-21
Engine Coolant Temperature Sensor . . . . . . . . . . . .8W-30-25
EVAP/Purge Solenoid . . . . . . . . . . . . . . . . . . . . .8W-30-23
Exhaust Gas Recirculation Solenoid . . . . . . . . . . . .8W-30-23
Fuel Injector #1 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Fuel Injector #2 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21
Fuel Injector #3 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Fuel Injector #4 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21
Fuel Injector #5 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Fuel Injector #6 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21
Fuel Injector #7 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Fuel Injector #8 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27
Fuel Tank Gauge Level Sending Unit . . . . . . . . . . .8W-30-27
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 23, 27
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27
Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27
Fuse D . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27
Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . .8W-30-24
Idle Air Control Motor . . . . . . . . . . . . . . . . . . . . .8W-30-20
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27
Intake Air Temperature Sensor . . . . . . . . . . . . . . .8W-30-25
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-26
Powertrain Control Module . . . . . . . . . . . .8W-30-20, 21, 22,
23, 24, 25, 26, 27
Throttle Position Sensor . . . . . . . . . . . . . . . . . . .8W-30-24
Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . .8W-30-26
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
8W - 31 - 1
TRANSMISSION CONTROLS
OVERDRIVE SWITCH
UPSHIFT LAMP
TCC SOLENOID
The TCC solenoid and overdrive solenoid are
molded together. They are only used on automatic
transmissions. The Powertrain Control Module
(PCM) operates the TCC solenoid by providing a
ground path on circuit K54. Circuit K54 connects to
PCM cavity 54. Circuit A21 supplies battery voltage
to the TCC solenoid.
HELPFUL INFORMATION
In the START or RUN position, the ignition switch
connects circuit A1 from the Power Distribution Center (PDC) and circuit A21. Circuit A1 connects to battery voltage and is protected by a 40 amp fuse in
cavity C of the PDC.
Circuit A21 is double crimped at fuse 14 in fuse
block. The A21 branch from fuse 14 splices to supply
battery voltage to the EVAP/Purge solenoid, EGR solenoid, TCC solenoid, overdrive solenoid, data link
connector and provides an input to the PCM.
OVERDRIVE SOLENOID
The overdrive solenoid and TCC solenoid are molded
together. They are only used on automatic transmissions.
The Powertrain Control Module (PCM) operates the overdrive solenoid by providing a ground path on circuit T60.
Circuit T60 connects to PCM cavity 55. Circuit A21 supplies battery voltage to the overdrive solenoid.
HELPFUL INFORMATION
In the START or RUN position, the ignition switch
connects circuit A1 from the Power Distribution Center (PDC) and circuit A21. Circuit A1 connects to battery voltage and is protected by a 40 amp fuse in
cavity C of the PDC.
Circuit A21 is double crimped at fuse 14 in fuse
block. The A21 branch from fuse 14 splices to supply
battery voltage to the EVAP/Purge solenoid, EGR solenoid, TCC solenoid, overdrive solenoid, data link
connector and provides an input to the PCM.
DIAGRAM INDEX
Component
4WD Indicator Lamp . . . . . . . . . .
4WD Indicator Switch . . . . . . . . . .
Fuse 13 . . . . . . . . . . . . . . . . . . .
Fuse 16 . . . . . . . . . . . . . . . . . . .
Fuse C . . . . . . . . . . . . . . . . . . .
Headlamp Switch . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . .
Instrument Cluster . . . . . . . . . . . .
Overdrive Solenoid . . . . . . . . . . . .
Powertrain Control Module . . . . . .
TCC Solenoid . . . . . . . . . . . . . . .
Transmission Oil Temperature Lamp
Transmission Oil Temperature Sensor
Transmission Overdrive Switch . . . .
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Page
. . .8W-31-2
. . .8W-31-2
. . .8W-31-3
.8W-31-2, 3
.8W-31-2, 3
. . .8W-31-3
.8W-31-2, 3
. . .8W-31-3
. . .8W-31-3
. . .8W-31-3
. . .8W-31-3
. . .8W-31-2
. . .8W-31-2
. . .8W-31-3
8W - 32 - 1
ANTI-LOCK BRAKES
CONTENTS
page
page
GENERAL INFORMATION
(RWAL) system. When referring to the circuit descriptions or wiring diagrams, ensure that you use
the ones for the appropriate system.
... 3
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2
2
2
2
3
2
GENERAL INFORMATION
Four fuses supply power for the Anti-Lock Brake
System (ABS); fuses A, F and E in the Power Distribution Center (PDC) and fuse 4 in the fuse block.
Fuses A, F and E in the PDC are connected directly
to battery voltage and are HOT all times. Fuse 4 is
HOT when the ignition switch is the RUN position.
In the RUN position, the ignition switch connects
circuit A2 from a 20 amp fuse in cavity E of the PDC
with circuit A22. Circuit A22 connects to a bus bar in
the fuse block. The bus bar feeds circuit A20 through
fuse 4. Fuse 4 is a 5 amp fuse.
Circuit A20 is double crimped at the coil side of the
ABS warning lamp relay. The A20 circuit from the
ABS warning lamp relay splices to supply voltage to
pins 7 and 12 of the ABS control module and the coil
side of the ABS power relay.
Circuits Z7 and Z8 provide ground for the ABS control module. Both grounds terminate on the left
fender side shield. Circuit Z7 connects to cavity 20 of
the 37-way ABS control module connector. Circuit Z8
connects to cavity 1 of the two-way connector.
page
Front Anti-Lock Valve . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Anti-Lock Valve . . . . . . . . . . . . . . . . . . . . . . . .
Stop Lamp Switch Sense . . . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . . . .
2
1
2
2
1
8W - 32 - 2
rear anti-lock valve. The ABS control module activates the solenoids by providing separate ground
paths for each.
Circuit B254 connects to cavity 26 of the ABS control module and provides ground for the right rear
dump solenoid.
Circuit B252 connects to cavity 28 of the ABS control module and provides ground for the right rear
isolation solenoid.
The rear anti-lock valve has one reset switch that
provides an input to the ABS control module. Circuit
B19 from the reset switch connects to ABS control
module cavity 19.
8W - 32 - 3
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94 October 14, 1994
DIAGRAM INDEX
Component
Page
ABS Control Module . . . . . . . . . . . . . . . . .8W-32-5, 6, 7, 8
ABS Front Hydraulic Valve . . . . . . . . . . . . . . . . . . .8W-32-6
ABS Power Relay . . . . . . . . . . . . . . . . . . . . . . . .8W-32-5
ABS Rear Hydraulic Valve . . . . . . . . . . . . . . . . . . .8W-32-6
ABS Rear Wheel Sensor . . . . . . . . . . . . . . . . . . . .8W-32-7
ABS Warning Lamp Relay . . . . . . . . . . . . . . . . . . .8W-32-5
Brake Warning Lamp Switch . . . . . . . . . . . . . . . . .8W-32-7
Data Link Connector . . . . . . . . . . . . . . . . . . . . . .8W-32-8
Fuse A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-5
Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-5
Fuse F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-8
Fuse F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-8
4-WD Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-7
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-32-5, 7
Left Front Wheel Sensor . . . . . . . . . . . . . . . . . . . .8W-32-8
Right Front Wheel Sensor . . . . . . . . . . . . . . . . . . .8W-32-8
Stop Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-32-8
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4
4
4
4
3
GENERAL INFORMATION
Four fuses supply power for the Rear Wheel AntiLock (RWAL) Brake System. They are fuses C, and G
in the Power Distribution Center (PDC) and fuses 7
and 11 in the fuse block. Fuses C and G in the PDC
are connected directly to battery voltage and are
HOT all times. Fuse 11 in the fuse block is HOT
when the ignition switch is the RUN Position.
In the RUN position, the ignition switch connects
circuit A1 from a 40 amp fuse in cavity C of the PDC
with circuit A31. Circuit A31 connects to a bus bar in
the fuse block. The bus bar feeds circuit L5 through
fuse 11. Fuse 11 is a 20 amp fuse.
Circuit L5 is double crimped at fuse 11 and connects to cavity 3 of the RWAL control module. The L5
input tells the RWAL module when the vehicle is
running. The other wire connects to the turn signal
flasher.
Circuit F32 provides battery voltage to the RWAL
module at cavity 9. Circuit F32 is HOT at all times.
Fuse 7 in the fuse block protects circuit F32. Circuit
page
Park Brake Switch Input .
Rear Anti-Lock Valve . . . .
Rear Wheel Speed Sensor
Warning Lamp . . . . . . . .
...
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4
4
3
4
A3 from the PDC feeds the fuse block bus bar that
powers fuse 7 and circuit F32. Fuse G in the PDC
protects circuit A3.
Circuit Z2 provides ground for the RWAL control
module. The Z2 circle terminates at the instrument
panel left support. If the vehicle has intermittent
wipers, circuit Z2 also provides ground for the intermittent wiper module.
8W - 32 - 4
WARNING LAMP
The Rear Wheel Anti-Lock (RWAL) module provides ground for the instrument cluster Check AntiLock warning lamp on circuit B102. Circuit F14
provides voltage to the instrument cluster to feed the
warning lamp.
DIAGRAM INDEX
Component
Page
4WD Indicator Switdh . . . . . . . . . . . . . . . . . . . . .8W-32-11
Brake Warning Lamp Switch . . . . . . . . . . . . . . . . .8W-32-9
Data Link Connector (Service) . . . . . . . . . . . . . . . .8W-32-9
Dual Solenoid Hydraulic Valve . . . . . . . . . . . . . . .8W-32-10
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-9
Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-9
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-9
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . .8W-32-9
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-32-9
Rear Wheel Anti-Lock Control Module . . . . . .8W-32-9, 10, 11
Rear Wheel Hydraulic Valve . . . . . . . . . . . . . . . . . .8W-32-11
Rear Wheel Sensor . . . . . . . . . . . . . . . . . . . . . .8W-32-10
Rolls Test Connector (In-Plant Use Only) . . . . . . . .8W-32-10
Stop Lamp Switch . . . . . . . . . . . . . . . . . . . . . . .8W-32-10
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
8W - 33 - 1
In the CLOSED position, the stop lamp switch connects circuit V32 with circuit V30 to power the speed
control servo. Circuit Z1 provides ground for the
speed control servo.
Circuit V31 provides the SET/COAST signal to cavity 48 of the PCM. Circuit V33 sends the RESUME/
ACCEL signal to cavity 50 of the PCM.
Circuit V40 connects to cavity 29 of the PCM and
to ground through the stop lamp switch. The stop
lamp switch OPENS when the operator depresses the
brake pedal. The PCM disables speed control when
the stop lamp switch opens. From the stop lamp
switch, circuit Z1 provides ground for circuit V40.
HELPFUL INFORMATION
The grounding point for circuit Z1 (speed control
servo ground) is left fender side shield.
The grounding point for circuit Z1 from the stop
lamp switch is the instrument panel right lower reinforcement support.
Circuit V40 also connects to the ABS control module on vehicles with all wheel anti-lock brakes.
Circuit V40 also connects to the RWAL control
module on vehicles with rear wheel anti-lock brakes.
DIAGRAM INDEX
Component
ABS Control Module . . . . .
Fuse 15
Fuse C . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . .
Powertrain Control Module . .
RWAL Control Module . . . .
Stop Lamp Switch . . . . . . .
Vehicle Speed Control Servo
Vehicle Speed Control Switch
Page
. . . . . . . . . . . . . . . . .8W-33-3
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. . .8W-33-2
. . .8W-33-2
.8W-33-2, 3
. . .8W-33-3
. . .8W-33-3
. . .8W-33-2
. . .8W-33-2
8W - 40 - 1
INSTRUMENT CLUSTER
INDEX
page
Diagram Index
............................ 3
INSTRUMENT CLUSTER
The instrument cluster contains the gauges and
warning lamps. All gauges have magnetic movements.
When the ignition switch is in the START or RUN
position, circuit A21 feeds circuit F14 through a bus
bar in the fuse block and fuse 14. Circuit A1 from
fuse C in the Power Distribution Center (PDC) supplies voltage to circuit A21. Circuit A21 is HOT at all
times.
Circuit F14 connects to cavity D of the left cluster
connector. Circuit F14 provides battery voltage for
the warning lamps (except seat belt indicator lamp),
transmission up shift lamp, and all gauges.
Circuit E2 from fuse 13 in the fuse block feeds the
illumination lamps. Circuit E1 from the headlamp
switch powers fuse 13 when the parking lamps or
headlamp are ON.
Circuit Z1 provides ground for illumination and indicator lamps. The grounding point for circuit Z1 is
the instrument panel lower right reinforcement support.
page
Instrument Cluster
......................... 3
8W - 40 - 2
Circuit Z1 provides ground for the tachometer module. The grounding point for circuit Z1 is the instrument cluster lower right reinforcement support.
SPEEDOMETER
The speedometer and odometer receive a signal
from the vehicle speed sensor on circuit G7. Circuit
G7 connects to the Powertrain Control Module
(PCM).
ABS WARNING LAMP
ALL-WHEEL ANTI-LOCK BRAKES
The ABS module controls the ABS warning lamp
through the ABS warning lamp relay. When the ABS
module grounds the warning lamp relay on circuit
B47, the relay contacts close and complete the
ground path for the ABS warning lamp. Circuit B47
connects to pin 13 of the ABS module and the coil
side of the relay. Circuit A20 from fuse 4 in the fuse
block supplies power to the coil side of the relay.
Circuit G19 from the ABS warning lamp in the instrument cluster is double crimped at the contact
side of the ABS warning lamp relay. Power for the
bulb is supplied by circuit F14.
REAR WHEEL ANTI-LOCK (RWAL) BRAKES
The RWAL module provides ground for the instrument cluster Check Anti-Lock warning lamp on circuit B102. Circuit F14 provides voltage to the
instrument cluster to feed the warning lamp.
8W - 40 - 3
8W - 41 - 1
HORN/CIGAR LIGHTER
HORN
The horn system uses two switches and a horn relay. The horn switches are in the steering wheel
along with the speed control switches (if equipped).
Circuit A3 from fuse G in the Power Distribution
Center (PDC) feeds a fuse block bus bar that powers
circuit X1 through fuse 6. Circuit X1 is HOT at all
times and powers the coil and contact sides of the
horn relay.
When the horn switch is depressed, circuit X3 provides ground for the coil side of the relay and the
contacts close. When the contacts close, circuit X2
supplies voltage to the horn.
HELPFUL INFORMATION
The horn switch is grounded to the steering wheel.
Circuit X1 is double crimped at the horn relay. The
circuit connects to the instrument cluster and supplies power to the tachometer module (if equipped).
CIGAR LIGHTER
In the ACCESSORY or RUN position, the ignition
switch supplies voltage to fuse 9 in the fuse block on
circuit A31. Fuse 9 feeds circuit X22 which connects
to the cigar lighter. When the lighter is depressed,
the contacts inside of the lighter element close and
voltage flows to ground on circuit Z1.
HELPFUL INFORMATION
In the ACCESSORY or RUN position,the ignition
switch connects circuit A1 from Power Distribution
Center (PDC) with circuit A31. Circuit A1 is protected by fuse C.
Circuit Z1 terminates at the instrument panel
lower right reinforcement support.
DIAGRAM INDEX
Component
Cigar Lighter .
Fuse 6 . . . . .
Fuse 9
Fuse C . . . . .
Fuse G . . . . .
Horn . . . . . . .
Horn Relay . . .
Horn Switches
Ignition Switch
Page
. . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2
. . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2
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.8W-41-2
.8W-41-2
.8W-41-2
.8W-41-2
.8W-41-2
.8W-41-2
8W - 42 - 1
AIR CONDITIONING/HEATER
CONTENTS
page
page
GENERAL INFORMATION
Heater only applications use the same blower motor circuitry as the Air Conditioning/Heater systems.
Separate diagrams for the heater only system are
provided.
page
General Information . . . . . . . . . . . . . . . . . . . . . . . . 1
Radiator Fan Relay and Motor . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
powers fuse 1. Fuse 1 protects circuit C1 which supplies battery voltage to the blower motor.
The ground path for the blower motor is through
circuit H6 to the blower motor resistor block and
then through the fan switch in the A/C heater controls to circuit Z1. The blower motor resistor block
consists of four resistors connected in series. Ground
circuit Z1, which is the ground circuit, terminates at
the instrument panel lower right reinforcement.
Each resistor in the blower motor resistor block is
spliced to the fan switch on separate circuits; C4, C5,
C6, and C7. Depending on fan switch position, voltage passes through one or more resistors to ground.
Blower motor fan speed is controlled by the number
of resistors voltage passes through to ground.
When the fan switch is in the LOW position, circuit
C4 provides the ground path. In the M1 position, circuit C5 provides ground. In the M2 position, the
ground path is through circuit C6. Circuit C7 provides path for ground when the switch is in the
HIGH position.
BLOWER MOTOR
When the ignition switch is in the RUN position,
circuit A2 from fuse E in the Power Distribution Center (PDC) connects with circuit A22. Circuit A22 supplies voltage to a bus bar in the fuse block that
8W - 42 - 2
ertrain Control Module (PCM) receives an A/C request signal on circuit C20. Circuit C20 connects to
cavity 27 of the PCM.
After receiving the A/C request signal, the PCM
supplies ground for the radiator fan relay and the
A/C clutch relay. The coil side of the A/C clutch relay
is powered from contact side of the radiator fan relay.
The PCM supplies ground for the coil side of the
radiator fan relay on circuit C27. Circuit C27 connects to cavity 31 of the PCM. Circuit A21 from fuse
16 in the fuse block supplies battery voltage to the
coil side of the radiator fan relay. Circuit C26 from
fuse B in the Power Distribution Center (PDC) supplies voltage to the contact side of the relay.
When the PCM grounds the radiator fan relay, the
contacts close and connect circuits C26 and C25. Circuit C25 supplies power to the radiator fan motor
and the coil side of the A/C compressor clutch relay.
The PCM controls ground for the A/C clutch relay
on circuit C13. Circuit C13 connects to cavity 34 of
the PCM and splices to circuit C12. Circuit C12 connects to the coil side of the relay. Circuit C12 has an
in-line diode.
Circuit C26 provides voltage to the contact side of
the relay. When the relay contacts close, circuit C26
connects to circuit C3. Circuit C3 feeds the A/C compressor clutch. Ground for the compressor clutch is
provided on circuit Z1 which terminates on the engine at left rear of the cylinder head.
The A/C compressor clutch connector has a built-in
diode. The diode controls the induced voltage that results from the magnetic field collapsing when the
clutch disengages. The diode provides a current path
to protect other components and systems.
HELPFUL INFORMATION
Circuit C21 from the A/C heater control switch connects to the low pressure switch. Circuit C22 from
the low pressure switch connects to the high pressure
switch. Circuit C20 connects to the high pressure
switch and the PCM.
HELPFUL INFORMATION
Circuit C26 also powers the coil side of the A/C
compressor clutch relay.
DIAGRAM INDEX
Component
Page
A/C Compressor Clutch . . . . . . . . . . . . . . . . . . . . .8W-42-4
A/C Compressor Clutch Relay . . . . . . . . . . . . . . . .8W-42-4
A/C High Pressure Switch . . . . . . . . . . . . . . . . . . .8W-42-6
A/C Low Pressure Switch . . . . . . . . . . . . . . . . . . .8W-42-6
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4
Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . .8W-42-6
Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-5
Fuse B . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4, 5
Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-5
Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4
Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6
HVAC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4, 5
Powertrain Control Module . . . . . . . . . . . . . . .8W-42-4, 5, 6
Radiator Fan Control Relay . . . . . . . . . . . . . . . . . .8W-42-5
Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . . . .8W-42-5
8W - 42 - 3
BLOWER MOTOR
When the ignition switch is in the RUN position,
circuit A2 from fuse E in the Power Distribution Center (PDC) connects with circuit A22. Circuit A22 supplies voltage to a bus bar in the fuse block that
supplies powers fuse 1. Fuse 1 protects circuit C1
which supplies battery voltage to the blower motor.
The ground path for the blower motor is through
circuit H6 to the blower motor resistor block and
then through the fan switch in the A/C heater controls to circuit Z1. The blower motor resistor block
consists of four resistors connected in series. Ground
circuit Z1 terminates at the instrument panel lower
right reinforcement.
Each resistor in blower motor resistor block is
spliced to the fan switch on separate circuits; C4, C5,
C6, and C7. Depending on fan switch position, voltage passes through one or more resistors to ground.
Blower motor fan speed is controlled by the number
of resistors voltage passes through to ground.
When the fan switch is in the LOW position, circuit
C4 provides the ground path. In the M1 position, circuit C5 provides ground. In the M2 position, the
ground path is through circuit C6. Circuit C7 provides path for ground when the switch is in the
HIGH position.
HELPFUL INFORMATION
Circuit C21 from the A/C heater control switch
connects to the low pressure switch. Circuit C22 from
the low pressure switch connects to the high pressure
switch. Circuit C20 connects to the high pressure
switch and the PCM.
Circuit A21 splices to circuit A0 which connects to
contact side of the starter motor relay.
DIAGRAM INDEX
Component
Page
A/C Compressor Clutch . . . . . . . . . . . . . . . . . . . . .8W-42-7
A/C Compressor Clutch Relay . . . . . . . . . . . . . . . .8W-42-7
A/C High Pressure Switch . . . . . . . . . . . . . . . . . . .8W-42-8
A/C Low Pressure Switch . . . . . . . . . . . . . . . . . . .8W-42-8
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 10
Blower Motor Resistor . . . . . . . . . . . . . . . . . .8W-42-8, 10
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 10
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 9
Fuse B . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 9
Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 9
Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 10
Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10
HVAC Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10
Ignition Switch . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 9, 10
Powertrain Control Module . . . . . . . . . . . . . . .8W-42-7, 8, 9
Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . . . .8W-42-9
Radiator Fan Relay . . . . . . . . . . . . . . . . . . . . . . .8W-42-9
8W - 43 - 1
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94 October 14, 1994
AIRBAG SYSTEM
AIRBAG CONTROL MODULE (ACM)
HELPFUL INFORMATION
Circuit F14 is double crimped at fuse 14 in the fuse
block to feed the instrument cluster.
DIAGRAM INDEX
Two airbag impact sensors provide input to the Airbag Control Module (ACM). Each sensor has two circuits that connect to the ACM.
From the left impact sensor, Circuit R47 connects
to the ACM at cavity 6 of the 13-way connector. Circuit R49 connects to cavity 5 of the 13-way connector.
From the right impact sensor, Circuit R46 connects
to the ACM at cavity 13 of the 13-way connector. Circuit R48 connects to cavity 12 of the 13-way connector.
Component
Airbag Control Module
Clock Spring . . . . . .
Data Link Connector .
Fuse 3 . . . . . . . . . .
Fuse 14 . . . . . . . . . .
Fuse C . . . . . . . . . .
Fuse E . . . . . . . . . .
Ignition Switch . . . . .
Instrument Cluster . . .
Left Impact Sensor . .
Right Impact Sensor .
Squib . . . . . . . . . . .
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Page
.8W-43-2
.8W-43-2
.8W-43-2
.8W-43-2
.8W-43-3
.8W-43-2
.8W-43-2
.8W-43-2
.8W-43-2
.8W-43-2
.8W-43-2
.8W-43-2
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
8W - 44 - 1
INTERIOR LIGHTING
INDEX
page
Ash Receiver Lamp and Cigar Lamp . . .
Combination Buzzer . . . . . . . . . . . . . . . .
Courtesy Lamp and Ignition Switch Lamp
Day/Night Mirror . . . . . . . . . . . . . . . . . .
Diagram Index . . . . . . . . . . . . . . . . . . .
...
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...
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1
2
1
2
2
GENERAL INFORMATION
Circuit M1 supplies power to the underhood lamp,
glove box lamp, dome lamp, and the time delay relay.
Circuit M50 from the time delay relay powers the
courtesy lamp and ignition switch lamp. Circuit E2
supplies power to the ash receiver and cigar lighter
lamp.
Fuse 13 in the fuse block protects circuit E2. Circuit M1 is protected by the ignition off draw (IOD)
fuse (fuse F2) in the Power Distribution Center
(PDC).
page
Dome Lamp . . . . .
General Information
Glove Box Lamp . .
Time Delay Relay .
Underhood Lamp .
..
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..
..
..
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1
1
1
1
1
HELPFUL INFORMATION
Circuit M1 splices to supply voltage to the glove
box lamp, dome lamp, overhead console, ABS diagnostic connector, power mirror switch, and radio.
HELPFUL INFORMATION
Circuit E2 splices to supply voltage to illumination
lamps in the instrument cluster.
UNDERHOOD LAMP
Circuit M1 from the IOD fuse in the Power Distribution Center (PDC) supplies battery voltage for the
underhood lamp. A mercury switch, in series after
the lamp, connects the lamp to ground on circuit Z1.
When the hood is raised, mercury inside the switch
moves to a position where it connects circuit M1 to
ground circuit Z1, illuminating the lamp. Circuit Z1
terminates at the left fender side shield.
The underhood lamp is wired in parallel with other
components on circuit M1.
DOME LAMP
Circuit M1, from the IOD fuse (fuse F2) in the
Power Distribution Center (PDC), supplies power to
8W - 44 - 2
DAY/NIGHT MIRROR
The day/night mirror receives power from circuit
F20 when the ignition switch is in the RUN position.
Circuit Z1 provides ground for the day/night mirror.
The grounding point for circuit Z1 is the windshield
header.
When the back-up lamps switch closes, circuit L1
provides a signal to the day/night mirror. The day
night mirror turns OFF when the vehicle is in reverse.
COMBINATION BUZZER
The conbination buzzer module sounds an audible
warning tone. The tone sounds for seat belt warning
and when the ignition key is in the ignition switch
while the drivers door is open. The tone also sounds
when the ignition key is in the ON position while the
drivers side seat belt is not buckled. Refer to Group
8U for buzzer operation.
Fuses 7 and 16 in the fuse block protect the combination buzzer. Fuse 7 powers circuit F32 which
connects to the buzzer. Circuit A3 from fuse G in the
Power Distribution Center (PDC) supplies power to
the fuse block for fuse 7 and circuit F32.
Circuit G5 from fuse 16 also provides voltage to the
combination buzzer when the ignition switch is in
the START or RUN positions. The ignition switch
connects circuit A1 from fuse C in the PDC to circuit
A21. Circuit A21 connects to the fuse block.
When the parking lamps or headlamps are ON, the
headlamp switch connects circuit G16 from the drivers side door jamb switch to circuit G26. Circuit G26
HELPFUL INFORMATION
Circuit F32 also powers the stop lamp switch.
Circuit G5 is double crimped at the combination
buzzer. The G5 branch from the buzzer splices to
power the four-wheel drive lamp and the overdrive
lamp.
DIAGRAM INDEX
Component
Page
Ash Receiver Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
Cigar Lighter Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
Combination Buzzer . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3
Day/Night Mirror. . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3
Door Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
Fuse F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3, 4
Fuse F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3, 4
Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4, 5
Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
Headlamp Switch . . . . . . . . . . . . . . . . . . . . .8W-44-3, 4, 5
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5, 6
Ignition Switch Lamp . . . . . . . . . . . . . . . . . . . . . .8W-44-3
Overhead Console . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
Key-In Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3
Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
8W - 47 - 1
AUDIO SYSTEM
GENERAL INFORMATION
Two radio systems are available in this vehicle; the
radio with standard speaker system and a radio with
premium speaker system. The premium speaker system uses a power amplifier and radio choke relay not
used on the standard speaker system. When referencing the circuit descriptions or the diagrams, ensure that you use the correct ones.
RADIO OPERATION
In the ACCESSORY or RUN position, the ignition
switch connects circuit A1 from fuse C in the Power
Distribution Center (PDC) with circuit A31. Circuit
A31 powers a bus bar in the fuse block that feeds circuit X12 through fuse 12. Circuit X12 supplies battery voltage to the radio. The radio is case grounded.
RADIO MEMORY
Circuit M1 from the Ignition Off Draw (IOD) fuse
(fuse F2) in the Power Distribution Center (PDC)
supplies power for the radio memory. The IOD fuse is
removed during vehicle shipping to prevent excessive
battery draw.
Circuit A4 from fuse F in the PDC supplies voltage
to the IOD fuse. Circuit A4 is HOT at all times.
RADIO ILLUMINATION
When the parking lamps or headlamps are on, circuits E2 and L7 from the headlamp switch power the
radio illumination lamps. Fuse 13 in the fuse block powers circuit E2 which feeds the radio illumination lamp.
Circuit E1 from the headlamp switch supplies power to
fuse 13. Circuit L7 supplies voltage for the radio lamps.
The radio case ground completes the ground path for
the illumination and park lamp circuits.
HELPFUL INFORMATION
When the headlamp switch is in the park lamps or
headlamp ON position, it connects circuit F33 from
fuse 8 in the fuse block with circuits E1 and L7. Circuit E1 is powered by a variable resistor in the headlamp switch used to adjust illumination lamp
brightness.
Circuit A3 from fuse G in the PDC feeds the fuse
block bus bar that powers circuit F33 through fuse 8.
Circuits A3 and F33 are HOT at all times.
fuse G in the Power Distribution Center (PDC) connects to the fuse block bus bar that feeds circuit X1
through fuse 6. Circuits A3 and X1 are HOT at all
times.
When the radio supplies power for the relay, the
contact close and connect circuits X1 and X13. Circuit X13 supplies voltage to the amplifier circuits in
the speakers. Circuit X15 provides ground for the
amplifier circuit of the speakers.
SPEAKERSSTANDARD RADIO
Circuit X53 feeds the speaker in the left front door.
Circuit X55 is the return from the speaker to the radio.
Circuit X54 feeds the right front door speaker. Circuit X56 is the return from the speaker to the radio.
Circuit X51 feeds the speaker in the left rear of the
vehicle. Circuit X57 is the return from the speaker to
the radio.
Circuit X52 feeds the right rear speaker. Circuit
X58 is the return from the speaker to the radio.
SPEAKERSPREMIUM RADIO
When the radio choke relay energizes, circuit X13
supplies voltage to the amplifier circuits in each
speaker. Circuit X15 supplies ground for the amplifier
circuit. Circuit X15 grounds to the rear of the radio.
Circuit X53 feeds the speaker in the left front of
the vehicle. Circuit X55 is the return from the
speaker to the radio.
Circuit X54 feeds the right front door speaker. Circuit X56 is the return from the speaker to the radio.
Circuit X51 feeds the speaker in the left rear of the
vehicle. Circuit X57 is the return from the speaker to
the radio.
Circuit X52 feeds the right rear speaker. Circuit
X58 is the return from the speaker to the radio.
DIAGRAM INDEX
Component
Page
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-6
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 5
Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 5
Fuse F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 4
Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 4, 6
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 4
Ignition Off-Draw Fuse (Fuse F2) . . . . . . . . . . . . .8W-47-2, 4
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 5
Left Door Speaker . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 6
Left Rear Speaker . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 6
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 3, 4, 5
Radio Choke Relay . . . . . . . . . . . . . . . . . . . . . . .8W-47-6
Right Door Speaker . . . . . . . . . . . . . . . . . . . . .8W-47-3, 6
Right Rear Speaker . . . . . . . . . . . . . . . . . . . . .8W-47-3, 6
8W - 49 - 1
OVERHEAD CONSOLE
OVERHEAD CONSOLE
When the ignition switch is in the RUN position,
circuit F20 from fuse 3 in the fuse block supplies
power to the overhead console. If the vehicle is
equipped with Daytime Running Lamps (DRL), circuit F20 is double crimped at the overhead console
and connects to the DRL module.
When the headlamps or parking lamps are ON, circuits L7 and E2 provide voltage to the overhead console for illumination. Voltage on circuit L7 informs
the overhead console that the headlamps or parking
lamps are ON. Circuit E2 from fuse 13 in the fuse
block powers the illumination lamps in the overhead
console. Circuit E1 from the headlamp switch feeds
fuse 13 and circuit E2.
Circuit Z2 provides ground for the compass. The
grounding point for circuit Z2 is the windshield
header.
HELPFUL INFORMATION
If the vehicle has DRL, circuit Z1 also provides
ground for the DRL module.
Circuit M1 splices to supply voltage for the radio
memory, courtesy lamp, time delay relay, underhood
lamp, and glove box lamp.
Circuit E2 splices to provide voltage to the instrument cluster illumination lamps, the ash receiver
lamp, cigar lighter lamp and radio lamp.
Circuit A3 from fuse G in the PDC supplies power
to fuse 8 in the fuse block. Circuit F33 from fuse 8
supplies voltage to the headlamp switch for circuits
L7 and E1. Circuit E1 supplies power to circuit E2
through fuse 13.
In the RUN position, the ignition switch connects
circuit A2, from fuse E in the PDC, with circuit A2.
Circuit A2 powers circuit F20 through fuse 3 in the
fuse block.
DIAGRAM INDEX
Component
Ambient Temperature Sensor . . . . . . . . .
Automatic Day/Night Mirror . . . . . . . . . .
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . .
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . .
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . .
Fuse E . . . . . . . . . . . . . . . . . . . . . . .
Fuse F . . . . . . . . . . . . . . . . . . . . . . .
Fuse F2 . . . . . . . . . . . . . . . . . . . . . . .
Fuse G . . . . . . . . . . . . . . . . . . . . . . .
Headlamp Switch . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . .
Left Door Jamb Switch . . . . . . . . . . . . .
Overhead Console . . . . . . . . . . . . . . . .
Right Door Jamb Switch . . . . . . . . . . . .
Time Delay Relay . . . . . . . . . . . . . . . .
Transmission Range/Back-Up Lamp Switch
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Page
. . .8W-49-3
. . .8W-49-3
. . .8W-49-2
. . .8W-49-2
. . .8W-49-2
. . .8W-49-2
. . .8W-49-2
. . .8W-49-2
. . .8W-49-2
. . .8W-49-2
. . .8W-49-2
. . .8W-49-3
.8W-49-2, 3
. . .8W-49-3
. . .8W-49-2
. . .8W-49-3
8W - 50 - 1
FRONT LIGHTING
INDEX
page
page
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Off-Road Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Parking Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HEADLAMPS
PARKING LAMPS
Circuit A3 in the Power Distribution Center (PDC)
connects to a bus bar in the fuse block. One of the
four circuits powered by the bus bar is circuit F33.
Circuit F33 connects to the headlamp switch. Fuse G
in the PDC protects the A3 circuit. Fuse 8 in the fuse
block protects circuit F33.
The headlamp switch has three positions: ON,
PARK (parking lamps) and OFF, plus a dimmer
switch. When the headlamp switch is in the PARK or
ON position, the switch connects circuit F33 to circuit L7. From the headlamp switch, circuit L7
branches to power the front parking lamps and rear
tail lamps, side marker lamps, and rear license plate
lamps.
GROUND CIRCUIT
Circuit Z1 provides a ground for the parking lamps,
tail lamps, and rear license plate lamps. The grounding point for circuit Z1 is the dash panel, left of the
brake master cylinder.
HELPFUL INFORMATION
If the vehicle is equipped with factory installed fog
lamps, circuit L7 splices to feed the park lamp relay.
Check fuse G in PDC.
Check fuse 8 in the fuse block.
Circuit L7 also feeds the radio, if equipped.
When the headlamp switch is in the PARK or ON
position, the dimmer circuit, F33, also connects to
circuit E1. Circuit E1 feeds circuit E2, which powers
8W - 50 - 2
the ash receiver lamp, instrument cluster illumination lamps, under hood lamp, glove box lamp and radio lamp. Fuse 13 in the fuse block protects circuits
E1 and E2.
FOG LAMPS
The fog lamps are controlled by the fog lamp
switch, park lamp relay and high beam relay. The fog
lamps operate only when the headlamp switch is in
the ON position, and the operator has selected lowbeam operation. When the headlamps are in highbeam operation, the fog lamps will not operate.
Circuit A3 from fuse G in the Power Distribution
Center (PDC) supplies voltage to circuit F39 through
fuse 20 in the fuse block, Circuit F39 splices to supply power to the contact side of the park lamp relay.
Circuit L7 supplies power to the coil side of the
park lamp relay. Circuit L35 connects to the coil side
of the relay and to circuit Z1 through the fog lamp
switch. Ground for the coil side of the relay is provided on circuit Z1 through the fog lamp switch.
When the fog lamp switch closes, the park lamp relay contacts close connecting circuits F39 and L36.
Circuit L36 powers the contact side of the high beam
relay. When the headlamp high beams are off, the
high beam relay is not energized and voltage flows
through the normally closed contacts to circuit L39.
Circuit L39 supplies voltage to the fog lamps and
the illumination lamp in the fog lamp switch. Circuit
Z1 provides ground for the fog lamps.
If the high beam lamps are on, circuit L3 from the
headlamp switch energizes the high beam relay.
When the high beam relay energizes, the contacts
open and power is not supplied to the fog lamps. Circuit Z1 provides ground for the coil side of the high
beam relay.
The grounding point for circuit Z1 is the left fender
side shield.
HELPFUL INFORMATION
Circuit L3 powers the high beam circuit of the
headlamps.
OFF-ROAD LAMPS
Circuit A3 from fuse G in the Power Distribution
Center (PDC) supplies voltage to circuit F39 through
fuse 20 in the fuse block. Circuit F39 splices to supply power to the off-road lamp switch.
When the off road lamp switch closes, circuit F39
powers the illumination lamp in the switch and circuit L31. Circuit L31 feeds the off-road lamps. Circuit Z1 provides ground for the off-road lamps. The
grounding point for circuit Z1 is the left fender side
shield.
DIAGRAM INDEX
Component
Page
Daytime Running Lamps (DRL) Module . . . . . . . . . .8W-50-6
Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-3
Fog Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-50-7
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-8
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-6
Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-3, 6, 7
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-3
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-7
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-3
Headlamps2.5L . . . . . . . . . . . . . . . . . . . . . . . .8W-50-4
Headlamps3.9L/5.2L . . . . . . . . . . . . . . . . . . . . .8W-50-5
High Beam Relay . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-7
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-6
Off-Road Lamp Switch . . . . . . . . . . . . . . . . . . . . .8W-50-7
Off-Road Lamps . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-8
Park Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-7
Park/Turn Signal Lamps3.9L/5.2L . . . . . . . . . . . . .8W-50-5
Park/Turn Signal Lamps2.5L . . . . . . . . . . . . . . . .8W-50-4
Side Marker Lamps3.9L/5.2L . . . . . . . . . . . . . . .8W-50-5
Side Marker Lamps2.5L . . . . . . . . . . . . . . . . . . .8W-50-4
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
8W - 51 - 1
REAR LIGHTING
INDEX
page
page
Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Back-up Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GROUND CIRCUIT
Circuit Z1 provides a ground for the parking lamps,
tail lamps, and rear license plate lamps. The grounding point for circuit Z1 is the left inner fender panel.
There are two different license plate lamp systems;
a one lamp system or a two lamp system. If the vehicle is not equipped with a step bumper, it has the
one lamp system. Circuit H4 from the license plate
lamp connects to circuit Z1.
If the vehicle has a step bumper, it uses the two
lamp license plate lamp system. Circuit X2 from each
lamp connects to circuit Z1.
HELPFUL INFORMATION
If the vehicle is equipped with factory installed fog
lamps, circuit L7 splices to feed the park lamp relay.
If the vehicle is equipped with factory installed
trailer tow, circuit L7 splices to the trailer tow harness.
Check fuse G in PDC.
Check fuse 8 in the fuse block.
Circuit L7 also feeds the radio, if equipped.
When the headlamp switch is in the PARK or ON
position, the dimmer circuit, F33, also connects to
circuit E1. Circuit E1 feeds circuit E2, which powers
the ash receiver lamp, instrument cluster illumination lamps, under hood lamp, glove box lamp and radio lamp. Fuse 13 protects circuits E1 and E2.
GROUND CIRCUIT
Circuit Z1 provides a ground for the stop lamps,
back-up lamps and CHMSL lamps. The Z1 circuit
has more than one branch. Circuit Z1 also supplies
ground path for the tail lamps, parking lamps, side
marker lamps, rear license plate lamp, back-up
lamps, and turn signals. Both branches of circuit Z1
terminate at the dash panel, left of the brake master
cylinder.
HELPFUL INFORMATION
Check for blown fuse in circuit F32.
Check for continuity across the stop lamp switch
when it is closed.
If the vehicle is equipped with Rear Wheel AntiLock (RWAL) brakes, circuit F32 connects to the
RWAL module.
BACK-UP LAMPS
In the RUN position, the ignition switch connects
circuit A2 from fuse E in the Power Distribution Center (PDC) to circuit A22. Circuit A22 feeds a bus bar
in the fuse block that powers circuit F20 through
fuse 3.
Circuit F20 supplies power to the back-up lamp
switch. On automatic transmission equipped vehicles,
the back-up lamp switch is part of an assembly that
includes the PARK/NEUTRAL position switch.
8W - 51 - 2
When the operator puts the transmission in REVERSE, the back-up lamp switch connects circuit
F20 to circuit L1. Circuit L1 feeds the back-up lamps.
If the vehicle is equipped with trailer tow, a jumper
harness connects circuit B2 in line with circuit L1.
Circuit B2 splices to the trailer tow harness.
GROUND CIRCUIT
Circuit Z1 provides ground for the back-up lamps.
Circuit Z1 also supplies a ground path for the tail
lamps, parking lamps, CHMSL lamps, rear license
plate lamp, stop lamps, and turn signals. The
grounding point for circuit Z1 is the dash panel, left
of the brake master cylinder.
HELPFUL INFORMATION
Check for blown fuses in circuits A2 and F20.
Check for continuity across the back-up lamp
switch when it is closed.
Circuit F20 feeds the overhead console and airbag
control module.
Circuit L1 also connects to the day/night mirror.
DIAGRAM INDEX
Component
Back-Up Lamp Switch . . . . . . .
Back-Up Lamps . . . . . . . . . . . .
Center High Mounted Stop Lamps
Fuse G . . . . . . . . . . . . . . . . .
Fuse 7 . . . . . . . . . . . . . . . . .
Fuse 3 . . . . . . . . . . . . . . . . .
Fuse E . . . . . . . . . . . . . . . . .
Fuse 8 . . . . . . . . . . . . . . . . .
Headlamp Switch . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . .
License Plate Lamp . . . . . . . . .
Powertrain Control Module . . . .
RWAL Module . . . . . . . . . . . .
Stop Lamp Switch . . . . . . . . . .
Tail, Stop and Turn Signal Lamps
Turn Signal/Hazard Flasher Switch
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Page
. . .8W-51-3
. . .8W-51-4
. . .8W-51-5
.8W-51-3, 5
. . .8W-51-5
. . .8W-51-3
. . .8W-51-3
. . .8W-51-3
. . .8W-51-3
. . .8W-51-3
. . .8W-51-3
. . .8W-51-3
. . .8W-51-5
. . .8W-51-5
. . .8W-51-4
. . .8W-51-5
8W - 52 - 1
TURN SIGNALS
TURN SIGNALS
In the ACCESSORY or RUN position, the ignition
switch connects circuit A1 from fuse C in the Power
Distribution Center (PDC) to circuit A31. Circuit A31
feeds circuit L5 through fuse 11 in the fuse block.
Circuit L5 powers the turn signal flasher. Circuit
L6 from the flasher connects to the multi-function
switch to supply power to the turn signals. The
multi-function switch connects to the turn signal and
side marker lamps on circuits L60, L61, L62 and
L63.
HAZARD FLASHERS
Circuit A15 from the battery positive post supplies
power to the hazard flasher fuse (fuse F1) in the
Power Distribution Center (PDC). Circuit A15 has an
in-line fusible link.
GROUND CIRCUIT
Circuit Z1 provides a ground for the parking lamps,
turn/tail/stop lamps, and rear license plate lamps at
the left inner fender panel.
Circuit Z1 also provides a ground for the back-up
lamps and Center High Mounted Stop Lamp
(CHMSL) at the left inner fender panel.
Circuit Z1 also provide ground for the indicator
lamps, and side marker lamps at the left inner
fender panel.
HELPFUL INFORMATION
Check the fusible link in the A15 circuit.
DIAGRAM INDEX
Component
Fuse G . . . . . . . . . . . .
Fuse 7 . . . . . . . . . . . .
Fuse F2 (IOD Fuse) . . . .
Fuse C . . . . . . . . . . . .
Fusible Link . . . . . . . . .
Hazard Flasher . . . . . . .
Ignition Switch . . . . . . .
RWAL Module . . . . . . .
Stop Lamp Switch . . . . .
Turn Signal/Hazard Flasher
Turn Signal Flasher . . . .
. . . . .
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. . . . .
Switch
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Page
. . .8W-52-3
. . .8W-52-3
. . .8W-52-2
. . .8W-52-2
. . .8W-52-2
. . .8W-52-2
. . .8W-52-2
. . .8W-52-3
. . .8W-52-3
.8W-52-3, 4
. . .8W-52-2
8W-53 WIPERS
8W - 53 - 1
WIPERS
INDEX
page
page
Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Low Washer Fluid Warning Lamp . . . . . . . . . . . . . . 2
WipersIntermittent . . . . . . . . . . . . . . . . . . . . . . . . 1
WipersStandard . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WIPERSSTANDARD
control module. Circuit Z2 terminates at the instrument panel lower right reinforcement support.
When the operator moves the wiper switch to the
LOW speed position, the switch passes voltage to circuit V3. Circuit V3 feeds the wiper motor LOW speed
brushes. If the operator selects wiper HIGH speed
operation, the wiper switch passes current to circuit
V4. Circuit V4 feeds the wiper motor HIGH speed
brushes.
If the operator selects wiper DELAY operation, the
wiper switch provides an input to the intermittent
wiper control module on circuit V8. The DEALY portion of the wiper switch contains a variable resistor.
The variable resistor connects to the intermittent
wiper module on circuit V9. Voltage for the resistor is
supplied by circuit V6 through the wiper switch. The
amount of delay selected by the operator determines
the voltage drop through the resistor and the voltage
level received by the intermittent wiper module.
After the intermittent wiper control module determines the amount of delay selected, it cycles the wipers by periodically energizing circuit V17 which
connects to circuit V3 through the wiper switch. Circuit V3 powers the wiper motor LOW speed brushes.
As the windshield wiper motor turns, the park
switch, internal to the motor, moves from its
grounded position (down) to the powered RUN (up)
position. Circuit V7 provides an input to the intermittent wiper control module when the wiper switch
is in the OFF position. The intermittent wiper control module powers the park switch in the wiper motor on circuit V5.
The intermittent windshield wiper system is also
equipped with a pulse wipe feature. To activate this
feature, the operator presses the washer switch momentarily. When the washer switch closes, voltage
from circuit V6 passes through the switch to circuit
V10. Circuit V10 provides a signal to the intermittent wiper control module and supplies voltage for
the windshield washer pump. When the control module receives the signal on circuit V10, it cycles the
wipers on circuit V3 while the washer fluid pump operates.
The washer motor operates whenever the washer
switch closes and supplies voltage to the motor on
WIPERSINTERMITTENT
Fuse 10 in the fuse block powers the intermittent
wiper system. The intermittent wiper system operates at either DELAY, LOW or HIGH speeds.
In the ACCESSORY or RUN position, the ignition
switch connects circuit A1 from fuse C in the Power
Distribution Center (PDC) with circuit A31. Circuit
A31 supplies voltage to circuit V6 through fuse 10 in
the fuse block.
Circuit V6 splices to supply power to the wiper
switch circuitry in the multi-function switch, the intermittent wiper module and the park switch in the
wiper motor. The wiper motor is case grounded. Circuit Z2 provides ground for the intermittent wiper
8W - 53 - 2
circuit V10. Circuit Z1 provides ground for the pump
motor. Circuit Z1 terminates at the left fender side
shield.
HELPFUL INFORMATION
Circuit V3 is double crimped at the multi-function
switch to allow either the wiper switch or intermittent wiper control module to power the wiper motor
LOW speed brushes.
Ground circuit Z2 is double crimped at the intermittent wiper control module to provide ground for
the Rear Wheel Anti-Lock (RWAL) module.
8W-53 WIPERS
DIAGRAM INDEX
Component
Page
Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3, 4, 5
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3, 4, 5
Ignition Switch . . . . . . . . . . . . . . . . . . . . . .8W-53-3, 4, 5
Intermittent Wiper Switch . . . . . . . . . . . . . . . . . . .8W-53-4
Intermittent Wiper Motor . . . . . . . . . . . . . . . . . . . .8W-53-5
Intermittent Wiper Control Module . . . . . . . . . . . .8W-53-4, 5
Low Washer Fluid Sensor . . . . . . . . . . . . . . . . .8W-53-3, 5
Standard Wiper Motor . . . . . . . . . . . . . . . . . . . . .8W-53-3
Standard Wiper Switch . . . . . . . . . . . . . . . . . . . . .8W-53-3
Windshield Washer Pump Motor . . . . . . . . . . . . .8W-53-3, 5
8W - 54 - 1
TRAILER TOW
TRAILER TOW
The trailer tow jumper harness connects to the circuits for the stop lamps, turn signals, tail lamps and
back-up lamps. The harness wires are taped back
and sealed at the time of vehicle delivery.
Circuit D7 connects to circuit L62 which powers
the right turn signal/stop lamp. Circuit D8 connects
to circuit L63 which supplies power to left turn signal/stop lamp. Circuit B2 connects to circuit L1 for
the back-up lamps. The trailer tow harness also contains tail lamp circuit L7, and circuit X2. Circuit X2
is connected to ground circuit Z1.
DIAGRAM INDEX
Component
Page
Back-Up Lamps . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
Tail, Stop and Turn Signal Lamps . . . . . . . . . . . . . .8W-54-2
Trailer Tow Harness . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
8W - 60 - 1
POWER WINDOWS
POWER WINDOWS
In the RUN position, the ignition switch connects
circuit A2 from fuse E in the Power Distribution Center (PDC) to circuit A22. Circuit A22 powers circuit
F21 through the circuit breaker in cavity 2 of the
fuse block. Circuit F21 supplies battery voltage to the
left and right power window switches.
Circuit Z1 provides ground for the system through
the left power window switch. The grounding point
for circuit Z1 is the instrument panel lower right
panel reinforcement support.
The left power door switch contains two switches
for the left and right windows. The right power window switch on the passengers side of the vehicle only
operates the right window.
Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground
on circuit Z1.
When the drivers side switch is put in the UP position, the switch supplies voltage to circuit Q16. Circuit Q16 connects to the UP side of the passenger
side switch. Voltage passes through the passengers
side switch to the window motor on circuit Q12. The
ground path from the motor is on circuit Q22 back
through the passengers side switch to circuit Q26,
through the drivers side switch to ground on circuit
Z1.
PASSENGER SIDE SWITCH OPERATION
Circuit F21 splices to supply voltage to the right
window switch on the passenger side of the vehicle.
When the passenger side switch is put in the DOWN
position, the switch supplies voltage to the motor on
circuit Q22. The ground path from the motor is on
circuit Q12 back through the passenger side switch
to circuit Q16, through the drivers side switch to
ground on circuit Z1.
In the UP position, the passenger side switch supplies voltage to the window motor on circuit Q12. The
ground path from the motor is on circuit Q22 back
through the passenger side switch to circuit Q26,
through the drivers side switch to ground on circuit
Z1.
HELPFUL INFORMATION
Check fuse E in the PDC.
Check the circuit breaker in cavity 2 of the fuse
block.
DIAGRAM INDEX
Component
Circuit Breaker (Cavity 2 of Fuse Block)
Fuse E . . . . . . . . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . .
Left Window Lift Motor . . . . . . . . . .
Left Door Power Window Switch . . . .
Right Window Lift Motor . . . . . . . . .
Right Door Power Window Switch . . .
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Page
.8W-60-2, 3
.8W-60-2, 3
.8W-60-2, 3
. . .8W-60-2
. . .8W-60-2
. . .8W-60-3
. . .8W-60-3
8W - 61 - 1
DIAGRAM INDEX
Component
Fuse G . . . . . . . . . . .
Fuse 5 . . . . . . . . . . .
Left Door Motor . . . . .
Left Door Lock Switch .
Right Door Lock Switch
Right Door Motor . . . .
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Page
.8W-61-2, 3
.8W-61-2, 3
. . .8W-61-3
. . .8W-61-2
. . .8W-61-3
. . .8W-61-3
8W - 62 - 1
POWER MIRRORS
POWER MIRRORS
A single switch operates both the left and right
power mirrors. Each mirror has two motors; a LEFT/
RIGHT motor and a UP/DOWN motor. The motors
switch polarity to allow mirror adjustment.
Circuit A4 from fuse F in the Power Distribution
Center (PDC) supplies battery voltage to the Ignition
Off-Draw (IOD) fuse (fuse F2) in the PDC. The IOD
fuse powers the power mirror switch on circuit M1.
Circuit Z1 connects to the power mirror switch and
supplies ground for the power mirror system. The
grounding point for circuit Z1 is the instrument
panel lower right reinforcement support.
HELPFUL INFORMATION
Check fuse F in the PDC.
Check the IOD fuse (fuse F2) in the PDC.
Circuit M1 supplies voltage to the radio memory,
lamp, underhood lamp, time delay relay, dome lamp,
overhead console lamps and glove box lamp. Check
for proper operation of these items.
Move the switch to its various positions and listen
for the motors to click or try to move. Some movement or clicking indicates a poor connection or a mechanical problem with a mirror.
DIAGRAM INDEX
Component
Fuse F . . . . . . . . .
Fuse F2 (IOD Fuse) .
Left Mirror Motors . .
Power Mirror Switch
Right Mirror Motors .
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Page
.8W-62-2
.8W-62-2
.8W-62-2
.8W-62-2
.8W-62-2
8W - 70 - 1
SPLICE INFORMATION
GENERAL INFORMATION
This section identifies all splices shown in the diagrams. It also shows the splices in their entirety. All
circuits that are part of the splices are shown, and
SPLICE INDEX
Component
Page
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2
S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-3
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-3
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-3
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5
S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5
S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-6
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-6
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-6
S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-6
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7
S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8
S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8
S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8
S128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8
S129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-9
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-9
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-9
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-10
S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-10
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-10
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-11
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-11
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-11
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-11
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-11
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-12
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-12
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-12
Component
S143 . . . .
S144 . . . .
S145 . . . .
S201 . . . .
S202 . . . .
S203 . . . .
S204 . . . .
S205 . . . .
S206 . . . .
S207 . . . .
S208 . . . .
S209 . . . .
S210 . . . .
S211 . . . .
S212 . . . .
S213 . . . .
S214 . . . .
S215 . . . .
S216 . . . .
S301 . . . .
S302 . . . .
S303 . . . .
S304 . . . .
S305 . . . .
S306 . . . .
S307 . . . .
S308 . . . .
S309 . . . .
S310 . . . .
S311 . . . .
S312 . . . .
S313 . . . .
S314 . . . .
S315 . . . .
S316 . . . .
S317 . . . .
S318 . . . .
S401 . . . .
S402 . . . .
S403 . . . .
S404 . . . .
S405 . . . .
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Page
.8W-70-12
.8W-70-12
.8W-70-13
.8W-70-13
.8W-70-13
.8W-70-13
.8W-70-14
.8W-70-14
.8W-70-14
.8W-70-15
.8W-70-15
.8W-70-15
.8W-70-15
.8W-70-16
.8W-70-16
.8W-70-16
.8W-70-17
.8W-70-17
.8W-70-17
.8W-70-17
.8W-70-17
.8W-70-18
.8W-70-18
.8W-70-18
.8W-70-19
.8W-70-19
.8W-70-19
.8W-70-19
.8W-70-20
.8W-70-20
.8W-70-20
.8W-70-20
.8W-70-21
.8W-70-21
.8W-70-21
.8W-70-21
.8W-70-22
.8W-70-22
.8W-70-22
.8W-70-22
.8W-70-23
.8W-70-23
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
8W - 80 - 1
CONNECTOR LOCATIONS
Component
Page
C101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-3
C102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-3
C103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-3
C104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-3
C105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-3
C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-4
C107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-4
C108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-4
C109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-4
C110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-4
C111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5
C112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5
C113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5
C114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5
C115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5
C116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-6
C117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-7
C118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-7
C119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-7
C120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8
C121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8
C122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8
C123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8
C124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8
C125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8
C126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9
C127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9
C128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9
C129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9
C130 (2.5L) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-10
C130 (3.9L/5.2L) . . . . . . . . . . . . . . . . . . . . . . . .8W-80-11
C131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12
C132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12
C133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12
C134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12
C135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12
C136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12
C137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13
C138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13
C139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13
C140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13
C141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13
C142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13
C143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13
C144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-14
C145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-14
C146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-14
C147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-14
Component
C148 . . . .
C149 . . . .
C150 . . . .
C151 . . . .
C152 . . . .
C153 . . . .
C154 . . . .
C155 . . . .
C156 . . . .
C157 . . . .
C158 . . . .
C159 . . . .
C160 . . . .
C161 . . . .
C162 . . . .
C163 . . . .
C164 . . . .
C165 . . . .
C166 . . . .
C167 . . . .
C168 . . . .
C201 . . . .
C202 . . . .
C203 . . . .
C204 . . . .
C205 . . . .
C206 . . . .
C207 . . . .
C208 . . . .
C209 . . . .
C210 . . . .
C211 . . . .
C212 . . . .
C213 . . . .
C214 . . . .
C215 . . . .
C216 . . . .
C217 . . . .
C218 . . . .
C219 . . . .
C220 . . . .
C221 . . . .
C222 . . . .
C223 . . . .
C224 . . . .
C225 . . . .
C226 . . . .
C227 . . . .
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Page
.8W-80-14
.8W-80-14
.8W-80-15
.8W-80-15
.8W-80-15
.8W-80-15
.8W-80-15
.8W-80-15
.8W-80-16
.8W-80-16
.8W-80-16
.8W-80-16
.8W-80-16
.8W-80-16
.8W-80-17
.8W-80-17
.8W-80-17
.8W-80-17
.8W-80-18
.8W-80-18
.8W-80-18
.8W-80-19
.8W-80-19
.8W-80-19
.8W-80-19
.8W-80-20
.8W-80-20
.8W-80-20
.8W-80-20
.8W-80-21
.8W-80-21
.8W-80-21
.8W-80-21
.8W-80-21
.8W-80-22
.8W-80-22
.8W-80-22
.8W-80-22
.8W-80-22
.8W-80-23
.8W-80-23
.8W-80-23
.8W-80-23
.8W-80-24
.8W-80-24
.8W-80-24
.8W-80-24
.8W-80-24
8W - 80 - 2
Component
C228 . . . .
C229 . . . .
C230 . . . .
C231 . . . .
C232 . . . .
C233 . . . .
C234 . . . .
C235 . . . .
C236 . . . .
C301 . . . .
C302 . . . .
C303 . . . .
C304 . . . .
C305 . . . .
C306 . . . .
C307 . . . .
C308 . . . .
C309 . . . .
C310 . . . .
C311 . . . .
C312 . . . .
C313 . . . .
C314 . . . .
C315 . . . .
C316 . . . .
C317 . . . .
C318 . . . .
C319 . . . .
C320 . . . .
C321 . . . .
C322 . . . .
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Page
.8W-80-25
.8W-80-25
.8W-80-25
.8W-80-26
.8W-80-26
.8W-80-26
.8W-80-26
.8W-80-26
.8W-80-27
.8W-80-27
.8W-80-27
.8W-80-27
.8W-80-28
.8W-80-28
.8W-80-28
.8W-80-28
.8W-80-28
.8W-80-29
.8W-80-29
.8W-80-29
.8W-80-29
.8W-80-29
.8W-80-30
.8W-80-30
.8W-80-30
.8W-80-30
.8W-80-30
.8W-80-30
.8W-80-31
.8W-80-31
.8W-80-31
Component
C323 . . . .
C324 . . . .
C325 . . . .
C326 . . . .
C327 . . . .
C328 . . . .
C329 . . . .
C330 . . . .
C331 . . . .
C332 . . . .
C333 . . . .
C334 . . . .
C335 . . . .
C336 . . . .
C337 . . . .
C338 . . . .
C339 . . . .
C340 . . . .
C401 . . . .
C402 . . . .
C403 . . . .
C404 . . . .
C405 . . . .
C406 . . . .
C407 . . . .
C408 . . . .
C409 . . . .
C410 . . . .
C411 . . . .
C412 . . . .
C413 . . . .
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Page
.8W-80-31
.8W-80-31
.8W-80-31
.8W-80-32
.8W-80-32
.8W-80-32
.8W-80-32
.8W-80-32
.8W-80-33
.8W-80-33
.8W-80-33
.8W-80-33
.8W-80-34
.8W-80-34
.8W-80-34
.8W-80-34
.8W-80-35
.8W-80-35
.8W-80-36
.8W-80-36
.8W-80-36
.8W-80-36
.8W-80-37
.8W-80-37
.8W-80-37
.8W-80-37
.8W-80-38
.8W-80-38
.8W-80-38
.8W-80-38
.8W-80-38
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
1995 AN Dakota
Publication No. 81-370-5110
TSB 08-55-94
October 14, 1994
8W - 90 - 1
CONNECTOR LOCATIONS
GENERAL INFORMATION
This section provides illustrations identifying component and connector locations in the vehicle. A con-
CONNECTOR LOCATIONS
Connector #
C101 . . . . .
C102 . . . . .
C103 . . . . .
C104 . . . . .
C105 . . . . .
C106 . . . . .
C107 . . . . .
C108 . . . . .
C109 . . . . .
C110 . . . . .
C111 . . . . .
C112 . . . . .
C113 . . . . .
C114 . . . . .
C115 . . . . .
C116 . . . . .
C117 . . . . .
C118 . . . . .
C119 . . . . .
C120 . . . . .
C121 . . . . .
C122 . . . . .
C123 . . . . .
C124 . . . . .
C125 . . . . .
C126 . . . . .
C127 . . . . .
C128 . . . . .
C129 . . . . .
C130 . . . . .
C131 . . . . .
C132 . . . . .
C133 . . . . .
C133 . . . . .
C133 . . . . .
C134 . . . . .
C134 . . . . .
C134 . . . . .
C135 . . . . .
C135 . . . . .
C135 . . . . .
C136 . . . . .
C137 . . . . .
C138 . . . . .
C139 . . . . .
C140 . . . . .
C140 . . . . .
C141 . . . . .
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Color
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
GY .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
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Location
Fig.
Rear of Right Headlamp . . . . . . . . . 2
Right Side Marker Lamp . . . . . . . .2
Right Front Turn Signal Lamp . . .. . .2
Airbag Right Impact Sensor . . . . . .1
Right Fender Side Shield3.9L, 5.2L .1
Right Fender Side Shield3.9L, 5.2L .1
Right Fender Side Shield . . . . . . . .1
Right Fender Side Shield
Right Fender Side Shield . . . . . . . .1
Windshield Wiper Motor . . . . . . . . .2
Left Side of Dash Panel . . . . . . . .21
Near Bulkhead Connector
Washer Fluid Reservoir . . . . . . . . .2
Washer Fluid Reservoir . . . . . . . . .2
Below Master Cylinder . . . . . . . . . .2
Left of Vacuum Brake Booster . .2, 10
ABS Hydraulic Unit . . . . . . . . . . . .2
ABS Hydraulic Unit . . . . . . . . . . . .2
ABS Hydraulic Unit . . . . . . . . . . . .2
Near Battery . . . . . . . . . . . . . . . .2
Near Battery, Below PDC
Below ABS Hydraulic Unit . . . . . . . .2
Below Battery Tray . . . . . . . . . . . .3
Rear of Left Headlamp . . . . . . . . . .2
Air Bag Left Impact Sensor . . . . . . .1
Left Front Turn Signal Lamp . . . . . .2
Left Front Side Marker Lamp . . . . . .2
Right Fender Side Shield2.5L . . . .1
Right Fender Side Shield3.9L, 5.2L .1
At PCM, Right Fender Side Shield . .1
Near Blower Motor Resistor Block . .1
On Receiver/Drier . . . . . . . . . . . . .1
Right Side of Dash Panel2.5L . . . .1
Rear of Fuel Rail3.9L . . . . . . . . .6
Rear of Fuel Rail5.2L . . . . . . . . .7
Right Side of Dash Panel2.5L . . . .1
Right of Distributor3.9L . . . . . . .6
Right of Distributor5.2L . . . . . . .7
Right Side of Dash Panel2.5L . . . .1
On Throttle Body3.9L . . . . . . . . .6
On Throttle Body5.2L . . . . . . . . .7
Below Windshield Wiper Motor . . . .5
Below Windshield Wiper Motor
Radiator Fan Motor . . . . . . . . . . . .3
Speed Control Servo . . . . . . . . . . .1
No. 2 Injector3.9L . . . . . . . . . . .6
No. 2 Injector5.2L . . . . . . . . . . .7
No. 4 Injector3.9L . . . . . . . . . . .6
Connector #
C141 . . . . .
C142 . . . . .
C142 . . . . .
C143 . . . . .
C144 . . . . .
C144 . . . . .
C145 . . . . .
C145 . . . . .
C146 . . . . .
C146 . . . . .
C147 . . . . .
C148 . . . . .
C148 . . . . .
C148 . . . . .
C149 . . . . .
C149 . . . . .
C150 . . . . .
C150 . . . . .
C150 . . . . .
C151 . . . . .
C151 . . . . .
C151 . . . . .
C152 . . . . .
C153 . . . . .
C153 . . . . .
C153 . . . . .
C154 . . . . .
C154 . . . . .
C154 . . . . .
C155 . . . . .
C156 . . . . .
C156 . . . . .
C156 . . . . .
C157 . . . . .
C157 . . . . .
C158 . . . . .
C159 . . . . .
C160 . . . . .
C161 . . . . .
C162 . . . . .
C163 . . . . .
C164 . . . . .
C164 . . . . .
C164 . . . . .
C165 . . . . .
C166 . . . . .
C167 . . . . .
C168 . . . . .
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Color
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
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Location
No. 4 Injector5.2L . . . . . . . .
No. 6 Injector3.9L . . . . . . . .
No. 6 Injector5.2L . . . . . . . .
No. 8 Injector5.2L . . . . . . . .
No. 1 Injector3.9L . . . . . . . .
No. 1 Injector5.2L . . . . . . . .
No. 3 Injector3.9L . . . . . . . .
No. 3 Injector5.2L . . . . . . . .
No. 5 Injector3.9L . . . . . . . .
No. 5 Injector5.2L . . . . . . . .
No. 7 Injector5.2L . . . . . . . .
Rear of Generator2.5L . . . . .
Rear of Generator3.9L . . . . .
Rear of Generator5.2L . . . . .
Near No.2 Injector3.9L . . . . .
Near No.2 Injector5.2L . . . . .
On Thermostat Housing2.5L . .
Next to Generator3.9L . . . . . .
Next to Generator5.2L . . . . . .
Side of A/C Compressor2.5L .
Side of A/C Compressor3.9L .
Side of A/C Compressor5.2L .
On A/C Line at Compressor
Side of Throttle Body2.5L . . .
Rear of Throttle Body3.9L . . .
Rear of Throttle Body5.2L . . .
On Throttle Body2.5L . . . . . .
On Throttle Body3.9L . . . . . .
On Throttle Body5.2L . . . . . .
Rear of Engine . . . . . . . . . . . .
Rear Left of Engine Block2.5L
Near Distributor3.9L . . . . . . .
Near Distributor5.2L . . . . . . .
Distributor3.9L . . . . . . . . . .
Distributor5.2L . . . . . . . . . .
Left Side of Transmission . . . . .
Left Side of Transmission . . . . .
Back-up Lamp Switch . . . . . . .
Top Front of Engine . . . . . . . .
Top of Transmission . . . . . . . .
On Transfer Case . . . . . . . . . .
Ignition Coil2.5L . . . . . . . . .
Ignition Coil3.9L . . . . . . . . .
Ignition Coil5.2L . . . . . . . . .
Starter Motor . . . . . . . . . . . . .
On Throttle Body2.5L . . . . . .
On Throttle Body2.5L . . . . . .
Distributor2.5L . . . . . . . . . .
Fig.
. . .7
. . .6
. . .7
. . .7
. . .6
. . .7
. . .6
. . .7
. . .6
. . .7
. . .7
. . .5
. . .6
. . .7
. . .6
. . .7
. . .5
. . .6
. . .7
. . .5
. . .6
. . .7
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.5
.6
.7
.5
.6
.7
.8
.5
.6
.7
.6
.7
.8
.8
.8
.8
.8
.8
.5
.6
.7
.4
.5
.5
.5
8W - 90 - 2
Connector #
C201 . . . . .
C202 . . . . .
C203 . . . . .
C204 . . . . .
C205 . . . . .
C206 . . . . .
C207 . . . . .
C208 . . . . .
C209 . . . . .
C210 . . . . .
C211 . . . . .
C212 . . . . .
C213 . . . . .
C214 . . . . .
C215 . . . . .
C216 . . . . .
C217 . . . . .
C218 . . . . .
C219 . . . . .
C220 . . . . .
C221 . . . . .
C222 . . . . .
C223 . . . . .
C224 . . . . .
C225 . . . . .
C226 . . . . .
C227 . . . . .
C228 . . . . .
C229 . . . . .
C230 . . . . .
C231 . . . . .
C232 . . . . .
C233 . . . . .
C234 . . . . .
C235 . . . . .
C236 . . . . .
C301 . . . . .
C302 . . . . .
C303 . . . . .
C304 . . . . .
C305 . . . . .
C306 . . . . .
C307 . . . . .
C308 . . . . .
C309 . . . . .
C310 . . . . .
C311 . . . . .
C312 . . . . .
C313 . . . . .
C314 . . . . .
C315 . . . . .
C316 . . . . .
C317 . . . . .
C318 . . . . .
C319 . . . . .
C320 . . . . .
C321 . . . . .
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Location
Fig.
Bottom Right Side of I.P. . . . . . . .10
Behind Right Kick Panel . . . . .10, 11
Right Middle of I.P. . . . . . . . . . . .10
Right End of I.P. . . . . . . . . . . . . .12
Lower Right of I.P . . . . . . . . .10, 15
Overhead Console
Left of Steering Column . . . . .10, 11
Right Side of Dash Panel . . . . . . . .1
Rear of Airbag Control Module . . . .11
Behind Top of Glove Box . . . . . . .11
Rear of Radio . . . . . . . . . . . . . . .9
Rear of Radio . . . . . . . . . . . . . . .9
Ash Receiver
Rear of Airbag Control Module . . . .11
Rear of Cigar Lighter . . . . . . . . . . .9
Rear of A/C Heater Controls . . . . . .9
Behind Bottom Center of I.P. . . . . . .9
Stop Lamp Switch . . . . . . . . . . . .11
Right of Steering Column . . . . . . .10
Rear of Cluster . . . . . . . . . . . . . . .9
Rear of Cluster . . . . . . . . . . . . . . .9
Behind Headlamp Switch . . . . . . . .9
Above Headlamp Switch . . . . . .9, 10
Behind Knee Bolster . . . . . . . . . . .9
Bottom Edge of Knee Bolster
Rear of Headlamp Switch . . . . . . . .9
Lower Left of I.P . . . . . . . . . . . .10
Center Left of I.P. . . . . . . . . .10, 15
Near Steering Column Support . . . .13
Front Left of Steering Column . . . .13
Ignition Switch . . . . . . . . . . . . . .13
Ignition Switch . . . . . . . . . . . . . .13
Steering Column . . . . . . . . . . . . .13
Lower Left of I.P. . . . . . . . . . . . . .9
Top of Clutch Pedal
Behind Left Kick Panel . . . .9, 16, 17
Behind Left Door Panel . . . . . . . .15
Behind Left Door Panel . . . . . . . .15
Behind Left Door Panel . . . . . . . .15
Behind Left Door Panel . . . . . . . .15
Behind Left Door Panel . . . . . . . .15
Behind Left Door Panel . . . . . . . .15
Behind Left Door Panel . . . . . . . .15
Behind Right Door Panel . . . . . . .15
Behind Right Door Panel . . . . . . .15
Behind Right Door Panel . . . . . . .15
Behind Right Door Panel . . . . . . .15
Behind Right Door Panel . . . . . . .15
Behind Right Door Panel . . . . . . .15
Behind Right Door Panel . . . . . . .15
Right Rear Speaker . . . . . . . .16, 17
Right Rear Speaker . . . . . . . .16, 17
Center Rear of Headliner . . . . .16, 17
Left Rear Speaker . . . . . . . . .16, 17
Left Rear Speaker . . . . . . . . .16, 17
Floor Console . . . . . . . . . . . .16, 17
Below Drivers Seat . . . . . . . . .16, 17
Connector #
C322 . . . . .
C323 . . . . .
C324 . . . . .
C325 . . . . .
C326 . . . . .
C327 . . . . .
C328 . . . . .
C329 . . . . .
C330 . . . . .
C331 . . . . .
C332 . . . . .
C333 . . . . .
C334 . . . . .
C335 . . . . .
C336 . . . . .
C337 . . . . .
C338 . . . . .
C339 . . . . .
C340 . . . . .
C401 . . . . .
C402 . . . . .
C403 . . . . .
C404 . . . . .
C405 . . . . .
C406 . . . . .
C407 . . . . .
C408 . . . . .
C409 . . . . .
C410 . . . . .
C411 . . . . .
C412 . . . . .
C413 . . . . .
C414 . . . . .
C415 . . . . .
C416 . . . . .
D101 . . . . .
D102. . . . . .
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Color
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
GY .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
BK .
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D102. . . . . . . . . . . . .
D102 . . . . . . . . . . . .
D201
G101
G102
G103
G104
G105
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G106
G107
G107
G108
G108
G109
G109
G110
G111
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Location
Fig.
Rear of Bed . . . . . . . . . . . . .14, 19
Right Rear of Frame . . . . . . . .14, 19
Left End of Bed . . . . . . . . . . . . .19
Rear of Bed . . . . . . . . . . . . .14, 19
Frame Near Left Rear Wheel . . . . .19
Top of Fuel Tank . . . . . . . . . . . . .19
Frame Near Left Rear Wheel . . . . .19
Tailgate, Behind CHMSL . . . . . . . .20
Vehicle Speed Sensor . . . . . . . . . .8
Rear of Left Fog Lamp . . . . . . . . .18
Above Overhead Console . . . . . . . .12
Rear of Rear View Mirror . . . . . . .12
Rear of Knee Bolster . . . . . . . . . .18
Rear of Knee Bolster . . . . . . . . . .18
Rear of Knee Bolster . . . . . . . . . .18
Right of Steering Column . . . . . . .18
Right of Steering Column . . . . . . .18
Right of Washer Fluid Reservoir . . .18
Rear of Right Fog Lamp . . . . . . . .18
Right Rear Turn Signal Lamp . . . . .14
Left Rear Turn Signal Lamp . . . . . .14
Right Back-Up Lamp . . . . . . . . . .14
Left Back-Up Lamp . . . . . . . . . . .14
Tailgate, Behind CHMSL . . . . . . . .20
Tailgate, Behind CHMSL . . . . . . . .20
Rear of Left Headlamp . . . . . . . . . .2
Rear of Right Headlamp . . . . . . . . .2
Rear of Left Headlamp . . . . . . . . . .2
Rear of Right Headlamp . . . . . . . . .2
Top of Rear Axle . . . . . . . . . . . . .19
Radiator Center Support . . . . . . . . .1
Left Side of Dash Panel . . . . . . . .21
Behind Step Bumper . . . . . . . . . .14
Behind Step Bumper . . . . . . . . . .14
Rear of Frame
Between PCM and A/C Clutch Relay
A/C Compressor Clutch
Connector2.5L . . . . . . . . . . . .5
A/C Compressor Clutch
Connector3.9L . . . . . . . . . . . .6
A/C Compressor Clutch
Connector5.2L . . . . . . . . . . . .7
Near T/O for Park Brake Switch . . . .
Dash Panel, Near Resistor Block . . .2
Bracket on Brake Master Cylinder . . .2
Left Fender Side Shield . . . . . . . . . .
Above ABS Hydraulic Unit . . . . . . .2
Radiator Top Support, Above
Headlamp . . . . . . . . . . . . . . . . .2
Rear of Cylinder Head2.5L . . . . . .5
Below A/C Compressor3.9L . . . . .6
Below A/C Compressor5.2L . . . . .7
Rear of Engine2.5L Engine . . . . .5
Right Side of Engine3.9L/5.2L
Below A/C Compressor3.9L . . . . .6
Below A/C Compressor5.2L . . . . .7
Battery Negative Post
Rear of Cylinder Head2.5L Engine .5
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Color
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Location
Fig.
Battery Negative Post3.9L/5.2L
Right Side of Dash Panel . . . . . . . .1
Left of Radio . . . . . . . . . . . . . . . .9
Left of Radio . . . . . . . . . . . . . . . .9
Dash Panel, Left of Master Cylinder .2
Connector #
G302 . . . . .
G303 . . . . .
G304 . . . . .
8W - 90 - 3
Color
Location
Fig.
. . . . . . . Center of Windshield Header . . . . .12
. . . . . . . Near PDC . . . . . . . . . . . . . . . . .18
. . . . . . . Dash Panel, Left of Master
Cylinder . . . . . . . . . . . . . . . . . .2
8W - 90 - 4
8W-90 CONNECTOR LOCATIONS
8W - 90 - 6
8W - 90 - 7
8W - 90 - 8
8W - 90 - 9
8W - 90 - 10
8W - 90 - 12
8W-90 CONNECTOR LOCATIONS
8W - 90 - 14
8W - 90 - 15
8W - 90 - 16
8W - 90 - 18
8W - 90 - 19
8W - 90 - 20
8W - 95 - 1
SPLICE LOCATIONS
GENERAL INFORMATION
The illustrations referenced in this section show
the general location of each splice. Individual splice
SPLICE LOCATIONS
Splice
Number
S101. . .
S102 . .
S103 . .
S104 . .
S105 . .
S106 . .
S107 . .
S108 . .
S109 . .
S110 . .
S111 . .
S112 . .
S113 . .
S114 . .
S115 . .
S116 . .
S117 . .
S118 . .
S119 . .
S120 . .
S121 . .
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S122 . . . . . .
S123 . . . . . .
S124 . . . . . .
S125 . . . . . .
S126
S127
S128
S129
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S130
S131
S132
S133
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S134
S135
S135
S136
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S137
S138
S139
S140
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Locations
Fig.
Below Coolant Reservoir . . . . . . . . . . . . .1, 2
After Coolant Reservoir . . . . . . . . . . . . . . .1
After Coolant Reservoir . . . . . . . . . . . . .1, 2
Before T/O for Right Headlamp Ground . . . . .1
After Wiper Motor T/O . . . . . . . . . . . . . .1, 2
Before Bulkhead Connector . . . . . . . . . . .1, 2
Near Washer Fluid Reservoir . . . . . . . . . .1, 2
Below Washer Fluid Reservoir . . . . . . . . .1, 2
Below Washer Fluid Reservoir . . . . . . . . .1, 2
Below Washer Fluid Reservoir . . . . . . . . .1, 2
Below Washer Fluid Reservoir . . . . . . . . .1, 2
Between Washer Fluid Reservoir and PDC .1, 2
Before T/O for Left Headlamp Ground . . . .1, 2
Before T/O for Left Headlamp Ground . . . .1, 2
After T/O for Left Headlamp Ground . . . . . . .1
Below PDC . . . . . . . . . . . . . . . . . . . . .1, 2
Below PDC . . . . . . . . . . . . . . . . . . . . . . .1
Near PDC Connector . . . . . . . . . . . . . . .1, 2
Before Wiper Motor T/O . . . . . . . . . . . . . . .2
Near Blower Motor Resistor Block . . . . . . . .2
Between PCM and Blower Motor Resistor
Block . . . . . . . . . . . . . . . . . . . . . . . .2, 3
After PCM . . . . . . . . . . . . . . . . . . . . . . . .2
After T/O for Injector No. 1 . . . . . . . . . . .2, 3
Between Blower Motor Resistor and Wiper
Motor . . . . . . . . . . . . . . . . . . . . . . . . .2
Between Data Link Connector T/O and
Speed Control Servo T/O . . . . . . . . . . . . .3
Before T/O for Low Washer Fluid Level Sensor .2
Below PDC . . . . . . . . . . . . . . . . . . . . . . .2
Near PCM Connector . . . . . . . . . . . . . . . . .3
Between PCM and Blower Motor Resistor
Block . . . . . . . . . . . . . . . . . . . . . . . . .3
Near Blower Motor Resistor Block . . . . . . . .3
Near Blower Motor Resistor Block . . . . . . . .3
After T/O for Injector No. 6 . . . . . . . . . . . .3
Between Take Outs for Injector No. 4
and No. 6 . . . . . . . . . . . . . . . . . . . . . .3
Before T/O For IAC Motor . . . . . . . . . . . . . .3
Near T/O for Injector No. 7, 3.9L/5.2L . . . . . .3
After T/O for Temperature Sensor, 2.5L . . . . .4
Between T/O for Injector No. 7 and T/O
for Oil Pressure Sending Unit . . . . . . . . . .3
Above Bulkhead Connector . . . . . . . . . . . . .2
Between PCM and A/C Compressor Clutch Relay
Between PCM and A/C Compressor Clutch Relay
After Battery Positive Post . . . . . . . . . . . . .4
Splice
Number
S141 . . . . .
S142 . . . . .
S143 . . . . .
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S144 . . . . . .
S145 . . . . . .
S201 . . . . . .
S202
S203
S204
S205
S206
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S207 . . . . . .
S208
S209
S210
S211
S212
S213
S214
S215
S216
S301
S302
S303
S304
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S305 . . . . . .
S306 . . . . . .
S307
S308
S309
S310
S311
S312
S313
S314
S315
S316
S317
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Locations
Fig.
Before T/O for Temperature Sending Unit . . . .4
Before T/O for Oil Pressure Sending Unit . . . .4
Before Oil Pressure Sending Unit T/O and
Engine Ground T/O . . . . . . . . . . . . . . . .4
Before T/O for IAC Motor . . . . . . . . . . . . . .4
Before T/O for Ignition Coil . . . . . . . . . . . . .4
Between Radio Take Outs and Stop Lamp
Switch Take Out . . . . . . . . . . . . . . . . . .5
Before T/O for Stop Lamp Switch . . . . . . . .5
Before T/O for A/C-Heater Controls . . . . . . . .5
In A/C-Heater Controls T/O . . . . . . . . . . . . .5
After A/C-Heater Controls T/O . . . . . . . . . . .5
Between A/C-Heater Controls T/O and
IP Cluster T/Os . . . . . . . . . . . . . . . . . . .5
Between A/C-Heater Controls T/O and
IP Cluster T/Os . . . . . . . . . . . . . . . . . . .5
Before IP Cluster Take Outs . . . . . . . . . . . .5
In T/O for Overdrive Switch . . . . . . . . . . . .5
Near Overdrive Switch T/O . . . . . . . . . . . . .5
After Overdrive Switch T/O . . . . . . . . . . . . .5
Near Fuse Block . . . . . . . . . . . . . . . . . . . .5
Near Fuse Block . . . . . . . . . . . . . . . . . . . .5
Diode Before Bulkhead Connector . . . . . . . . .5
Diode Before Bulkhead Connector . . . . . . . . .5
Before Park Brake Switch T/O . . . . . . . . . . .5
Near T/O for Left Door Speaker . . . . . . . . . .6
Before T/O for Right Door Speaker . . . . . . . .6
After T/O for Right Door Speaker . . . . . . . . .6
Between CHMSL T/O and Fuel Pump
Module T/O . . . . . . . . . . . . . . . . . . . . .7
Between CHMSL T/O and Fuel Pump
Module T/O . . . . . . . . . . . . . . . . . . . . .7
Between CHMSL T/O and Fuel Pump
Module T/O . . . . . . . . . . . . . . . . . . . . .7
Before T/O for Stop Lamp Switch . . . . . . . .7
Before Overhead Console and T/O for Ground .9
Before Take Outs for Fog Lamps . . . . . . . . .8
After T/O for Fog Lamp Ground . . . . . . . . . .8
After Fog Lamp Switch T/O . . . . . . . . . . . . .8
Before Park Lamp Relay and High Beam Relay .8
In Fog Lamp Switch T/O . . . . . . . . . . . . . .8
In Trailer Tow Harness . . . . . . . . . . . . . . . .7
In Trailer Tow Harness . . . . . . . . . . . . . . . .7
In Trailer Tow Harness . . . . . . . . . . . . . . . .7
In Trailer Tow Harness . . . . . . . . . . . . . . . .7
8W - 95 - 2
Splice
Number
S318 . . . . .
S401 . . . . .
S402 . . . . .
Locations
Fig.
. In Trailer Tow Harness . . . . . . . . . . . . . . . .7
. Before T/O for Right Back-Up Lamp . . . . . .11
. In CHMSL Harness, Before Lamps . . . . . . .10
Splice
Number
S403 . . . . .
S404 . . . . .
S405 . . . . .
Locations
Fig.
. In CHMSL Harness, Before Lamps . . . . . . .10
. Before T/O for Left Back-Up Lamp . . . . . . .11
. Between License Plate Lamps . . . . . . . . . .11
8W - 95 - 4
8W-95 SPLICE LOCATIONS
8W - 95 - 6
8W-95 SPLICE LOCATIONS
8W - 95 - 7
8W - 95 - 8
8W - 95 - 9
8W - 95 - 10
8W - 95 - 11
ENGINE
9 - 1
ENGINE
CONTENTS
page
page
ENGINE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 5
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 67
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 99
2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
page
Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . 2
Form-In-Place Gaskets . . . . . . . . . . . . . . . . . . . . . . 1
Honing Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Measuring with Plastigage . . . . . . . . . . . . . . . . . . . . 3
Repair Damaged or Worn Threads . . . . . . . . . . . . . 4
FORM-IN-PLACE GASKETS
SURFACE PREPARATION
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some instances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
Scrape or wire brush all gasket surfaces to remove
all loose material. Inspect stamped parts to ensure
gasket rails are flat. Flatten rails with a hammer on
a flat plate, if required. Gasket surfaces must be free
of oil and dirt. Make sure the old gasket material is
removed from blind attaching holes.
There are several places where form-in-place gaskets are used on the engine. DO NOT use form-inplace gasket material unless specified. Care
must be taken when applying form-in-place gaskets.
Bead size, continuity and location are of great importance. Too thin a bead can result in leakage while too
much can result in spill-over. A continuous bead of
the proper width is essential to obtain a leak-free
joint.
Two types of form-in-place gasket materials are
used in the engine area (Mopar Silicone Rubber Adhesive Sealant and Mopar Gasket Maker). Each have
different properties and cannot be used interchangeably.
GASKET APPLICATION
Assembling parts using a form-in-place gasket requires care.
Mopar Silicone Rubber Adhesive Sealant should be
applied in a continuous bead approximately 3 mm
(0.12 inch) in diameter. All mounting holes must be
circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
inch) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a
shop towel. Components should be torqued in place
while the sealant is still wet to the touch (within 10
minutes). The use of a locating dowel is recommended during assembly to prevent smearing the
material off location.
Mopar Gasket Maker should be applied sparingly
to one gasket surface. The sealant diameter should
be 1.00 mm (0.04 inch) or less. Be certain the material surrounds each mounting hole. Excess material
9 - 2
ENGINE
To provide best vehicle performance and lowest vehicle emissions, it is most important that the tune-up
be done accurately. Use the specifications listed on
the Vehicle Emission Control Information label found
on the engine compartment hood.
(1) Test cranking amperage draw (refer to Group
8B, Battery/Starter/Generator Service for the proper
procedures).
(2) Tighten the intake manifold bolts (refer to
Group 11, Exhaust System and Intake Manifold for
the proper specifications).
(3) Perform cylinder compression test:
(a) Check engine oil level and add oil, if necessary.
(b) Drive the vehicle until engine reaches normal
operating temperature.
(c) Select a route free from traffic and other
forms of congestion, observe all traffic laws and
briskly accelerate through the gears several times.
The higher engine speed may help clean out valve
seat deposits which can prevent accurate compression readings.
ENGINE PERFORMANCE
Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone
equipped with 220 grit stones, is the best tool for this
job. In addition to deglazing, it will reduce taper and
out-of-round as well as removing light scuffing, scoring or scratches. Usually a few strokes will clean up
a bore and maintain the required limits.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylinder surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). 20-60 strokes, depending on the bore condition, will be sufficient to
provide a satisfactory surface. Using honing oil
C-3501-3880 or a light honing oil available from major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
ENGINE
The hone marks should INTERSECT at 50 to 60
for proper seating of rings (Fig. 1).
(4) A controlled hone motor speed between 200 and
9 - 3
9 - 4
ENGINE
CAUTION: Be sure that the tapped holes maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCK
ENGINE
9 - 5
ENGINE DIAGNOSIS
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine tune-ups.
These malfunctions may be classified as either performance (e.g., engine idles rough and stalls) or mechanical (e.g., a strange noise).
Refer to the Service DiagnosisPerformance chart
and the Service DiagnosisMechanical chart for possible causes and corrections of malfunctions. Refer to
Group 14, Fuel System for the fuel system diagnosis.
GENERAL INFORMATION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine tune-ups.
These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g.,
engine idles rough and stalls).
Refer to the Service DiagnosisMechanical Chart
and the Service DiagnosisPerformance Chart for
possible causes and corrections of malfunctions. Refer
to Group 14, Fuel System for the fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can
not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis
is provided within the following diagnosis:
Cylinder Compression Pressure Test.
Cylinder Combustion Pressure Leakage Test.
Engine Cylinder Head Gasket Failure Diagnosis.
Intake Manifold Leakage Diagnosis.
9 - 6
ENGINE
If bubbles are not visible, install a radiator pressure tester and pressurize the coolant system.
If a cylinder is leaking combustion pressure into
the water jacket, the tester pointer will pulsate with
every combustion stroke of the cylinder.
ENGINE
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces. See Group 9, Engines for
proper repair procedures of these items.
(4) If no leaks are detected, pressurized the crankcase as outlined in the, Inspection (Engine oil Leaks
in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly
turning the crankshaft, it is possible the crankshaft
seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be
polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
9 - 7
9 - 8
ENGINE
SERVICE DIAGNOSISPERFORMANCE
ENGINE
SERVICE DIAGNOSISMECHANICAL
9 - 9
9 - 10
ENGINE
SERVICE DIAGNOSISLUBRICATION
2.5L ENGINE
9 - 11
2.5L ENGINE
INDEX
page
Camshaft, Crankshaft and Intermediate Shafts
Timing Procedure . . . . . . . . . . . . . . . . . . . . .
Checking Engine Oil Pressure . . . . . . . . . . . . .
Crankshaft and Intermediate Shaft . . . . . . . . . .
Crankshaft Oil Seals Service . . . . . . . . . . . . . .
Crankshaft Service . . . . . . . . . . . . . . . . . . . . .
Cylinder Block, Piston and Connecting Rod
Assembly Service . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Valve Assembly Service . . .
Cylinder Head ComponentsIn-Vehicle Service
Engine Assembly . . . . . . . . . . . . . . . . . . . . . .
Engine Core Plugs . . . . . . . . . . . . . . . . . . . . .
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18
44
28
29
30
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34
24
19
21
14
38
page
Engine Front Mounts . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication System . . . . . . . . . . . . . . . . . .
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Support . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate Shaft Service . . . . . . . . . . . . . . . . . .
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . .
Solid Mount Compressor Bracket Service . . . . . . .
Timing System and Seals Service . . . . . . . . . . . . .
Valve ServiceCylinder Head Removed . . . . . . . .
13
39
13
13
11
32
45
42
42
15
16
25
GENERAL INFORMATION
SPECIFICATION
9 - 12
2.5L ENGINE
2.5L ENGINE
9 - 13
ENGINE MOUNTS
9 - 14
2.5L ENGINE
(16) Disconnect the starter motor wires.
(17) Remove upper transmission housing bolts.
(18) Lower the vehicle.
(19) Support transmission with a transmission stand.
(20) Install an engine lifting fixture. Attach a
chain hoist to fixture eyebolt.
(21) Loosen engine mount through bolts.
(22) Remove engine to transmission struts and
bolts.
(23) Raise engine until front mount insulators clear
the crossmember retaining brackets. Move engine forward until drive pinion shaft clears the clutch disc.
(24) Remove engine from engine compartment and
install on engine repair stand.
(25) Remove the engine lifting fixture.
ENGINE ASSEMBLY
REMOVAL
(1) Scribe the hood hinge outlines on the hood. Remove the hood.
(2) Drain cooling system (refer to Group 7, Cooling
System for the proper procedure).
(3) Remove the battery.
(4) Remove the air cleaner.
(5) Disconnect the radiator and heater hoses. Remove electric cooling fan and radiator (refer to Group
7, Cooling System).
(6) Remove air conditioning compressor mounting
bolts and set compressor aside (if equipped).
(7) Remove the vacuum lines.
(8) Disconnect the accelerator linkage and speed
control (if equipped).
(9) Perform the Fuel System Pressure Release procedure (refer to Group 14, Fuel System).
(10) Disconnect the fuel lines and brackets.
(11) If equipped, remove the power steering hoses
and cap ends of open hoses.
(12) Disconnect the body wiring harness.
(13) Raise the vehicle on a hoist.
(14) Disconnect exhaust pipe at manifold.
(15) Remove starter motor.
INSTALLATION
(1) Attach an engine lifting fixture to the engine.
Attach a chain hoist to fixture eyebolt.
(2) Remove engine from repair stand and position
in engine compartment.
(3) Move engine rearward until drive pinion shaft
engages the clutch disc or torque converter.
(4) Install engine to transmission struts and bolts.
(5) Loose install engine mount through bolts and
nuts.
(6) lower engine mount into mount brackets. Tighten
the thru-bolt nuts to 68 Nzm (50 ft. lbs.) torque.
(7) Remove transmission stand from the transmission.
(8) Raise the vehicle on a hoist.
(9) Install transmission to clutch housing bolts.
Tighten the bolts to 41 Nzm (30 ft. lbs.) torque.
(10) Connect the starter motor wires.
(11) Install starter motor.
(12) Install exhaust pipe to manifold. Tighten the
bolts to 27 Nzm (20 ft. lbs.).
(13) Lower the vehicle.
(14) Install vacuum lines.
(15) Connect the fuel lines and brackets.
(16) Connect the accelerator linkage and speed
control (if equipped).
(17) Position and install the radiator. Install the
fan shroud (refer to Group 7, Cooling System). Connect the radiator and heater hoses.
(18) Connect body wiring harness.
(19) Connect power steering hoses, if so equipped.
(20) If equipped, install the air conditioning compressor to bracket. If system was opened, evacuate
and charge the air conditioning system (refer to
Group 24, Heater and Air Conditioning).
(21) Fill the cooling system (refer to Group 7, Cooling System for the proper procedure).
(22) Install battery.
(23) Install the air cleaner.
(24) Start the engine and warm to operating temperature. Adjust the engine, if necessary.
2.5L ENGINE
9 - 15
ACCESSORIES REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove (and install/adjust) belts, Refer to Accessory Drive Belts in Cooling System, Group 7.
(3) Remove air conditioning compressor (in vehicle
with lines and set aside) (Fig. 4).
(4) Remove generator pivot bolt and remove generator (in vehicle: turn wiring side up and disconnect).
(5) Remove air conditioner compressor belt idler.
SOLID MOUNT BRACKETREMOVAL
(1) Remove five side mounting bolts #1, #4 , #5, #6,
and #7 (Fig. 4).
(2) Remove front mounting nut, #2, and remove (or
loosen) front bolt #3*.
*In vehicle: fully loosen bolt and remove with assembly.
9 - 16
2.5L ENGINE
2.5L ENGINE
(6) Loosen timing belt tensioner screw (Fig. 4) and
remove timing belt.
9 - 17
9 - 18
2.5L ENGINE
(3) Install timing belt.
2.5L ENGINE
(10) Position both halves of timing belt cover together (Fig. 4).
(11) Install fasteners holding cover to cylinder
head and block. Tighten fasteners to 4 Nzm (40 in.
lbs.) torque.
(12) Valve Timing Check; (timing belt cover installed). With number one cylinder at TDC, small
hole in sprocket must be centered in timing belt
cover hole (Fig. 10). If hole is not aligned correctly
perform procedure again.
(13) Install spark plugs.
9 - 19
CLEANING
Before installation, clean cylinder head and cover
mating surfaces.
CURTAIN INSTALLATION
Install curtain manifold side first with cutouts over
cam towers and contacting cylinder head floor, then
press opposite distributor side into position below cylinder head rail. Curtain is retained in position with
rubber bumpers (Fig. 1).
COVER INSTALLATION
Before installation, clean cylinder head and cover
mating surfaces. Make certain rails are flat.
(1) Install a new gasket on valve cover.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(2) Install curtain, cover and gasket assembly to
head and tighten to 12 Nzm (105 in.lbs.).
(3) Install timing belt cover (refer to Timing Belt
Service in this section).
(4) Connect the negative cable from the battery.
9 - 20
2.5L ENGINE
2.5L ENGINE
9 - 21
CAMSHAFT SERVICE
Refer to TIMING SYSTEM AND SEALS for camshaft timing belt and sprocket removal and installation, and CYLINDER HEAD In Vehicle Service.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove timing belt cover (refer to Timing Belt
Service in this section).
9 - 22
2.5L ENGINE
Fig. 7 Camshaft
CAMSHAFT END PLAY
(1) Oil camshaft journals and install camshaft
without cam followers. Tighten screws to specified
torque.
(2) Using a suitable tool, move camshaft as far
rearward as it will go.
(3) Zero dial indicator (Fig. 8).
(4) Move camshaft as far forward as it will go.
(5) End play travel: 0.13 - 0.33 mm (0.005 - 0.013
in.)
(6) Remove bearing caps and camshaft.
INSPECTION
Check bearing cap and oil feed holes for blockage.
Inspect bearing cap and cylinder head journals for
wear and/or oversize, Refer to CYLINDER HEAD,
Inspect and Specifications.
INSTALLATION
(1) Install cam followers in correct order as removed.
(2) Apply Mopar Gasket Maker to No.1 and No.5
bearing cap (Fig. 9).
(3) Align camshaft bearing caps in proper sequence
with Cap No. 1 at timing belt end and Cap No. 5 at
transmission end. Arrows on Caps No. 1, 2, 3, 4
must point toward timing belt to prevent cap breakage (Fig. 10).
(4) Caps must be installed before camshaft seals
are installed.
2.5L ENGINE
9 - 23
(2) Rotate cam until base circle is in contact position with rocker arm. Depress valve spring with Special Tool C-4682 (Fig. 11) and slide rocker arm in
place. Keep rockers in order. It is possible for the
valve spring retainer locks to become dislocated when
depressing the valve spring. Check and make sure
the locks are in their proper location.
(3) Install valve cover as previously outlined in
this section.
REMOVAL
(1) Remove rocker arms as previously outlined in
this section.
(2) Rotate crankshaft until piston is at TDC on
compression.
(3) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure.
(4) Using Special Tool C-4682 (Fig. 11) compress
valve springs and remove valve locks.
(5) Remove valve spring.
(6) Remove valve stem seal by gently prying sideto-side with a screwdriver blade. Once dislodged from
guide post, seal may be easily removed.
INSTALLATION
(1) Install valve seals (Fig. 12) as outlined in step
(2) of Valve Gear Reassembly - After Valve Service in this section.
(2) Using Special Tool C-4682 compress valve
springs only enough to install locks. Correct alignment of tool is necessary to avoid nicking valve stems
(air pressure required), piston at TDC.
(3) Install rocker arms as previously outlined in
this section.
9 - 24
2.5L ENGINE
CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. Refer to Fuel System Group 14.
(2) Disconnect negative battery cable. Drain cooling system. Refer to Cooling System, Group 7.
(3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle
body.
(4) Remove throttle linkage.
(5) Loosen power steering pump and remove belt.
(6) Remove power brake vacuum hose from intake
manifold.
(7) Remove water hoses from water crossover.
(8) Raise vehicle and remove exhaust pipe from
manifold.
(9) Remove power steering pump assembly and set
aside.
(10) Disconnect coil wiring connector and coil wire
from coil.
(11) Disconnect dipstick tube from thermostat
housing and ROTATE bracket from stud.DO NOT
bend the bracket.
(12) Refer to Solid Mount Compressor Bracket removal in, this Group.
(13) Remove cylinder head cover and curtain from
head.
(14) Remove cylinder head bolts.
INSPECT HEAD AND CAMSHAFT BEARING
JOURNALS
(1) Cylinder head must be flat within 0.1 mm (.004
in.)(Fig. 13).
(2) Inspect camshaft journals for scoring and journal caps for oversize markings. When servicing cylinder head or camshaft, it is necessary to be certain
that oversized camshafts are used only in oversized
heads. Identify oversize components follows:
CLEANING
Remove all gasket material from cylinder head and
block. Be careful not gouge or scratch aluminum
head sealing surface.
INSTALLATION
CAUTION: Head bolt diameter is 11 mm. These
bolts are identified with 11 on the head of the bolt.
10 mm bolts will thread into the 11 mm hole but will
strip the cylinder block bolt hole.
Since the Cylinder head bolts are torqued using a new procedure they should be examined
BEFORE reuse. If the threads are necked down
the bolts should be replaced. (Fig. 14).
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
2.5L ENGINE
(2) Tighten the cylinder head bolts in the sequence
shown in (Fig. 15). Using the 4 step torque turn
method, tighten according to the following values:
First All to 61 Nzm (45 ft. lbs.)
Second All to 88 Nzm (65 ft. lbs.)
Third All (again) to 88 Nzm (65 ft. lbs.)
Fourth + 1/4 Turn Do use a not torque wrench
for this step.
Bolt torque after 1/4 turn should be over 90 ft.
lbs. If not, replace the bolt.
(3) Rotate dipstick tube on bracket.
(4) Tighten bracket retaining nut to 23 Nzm (200
in. lbs.)
(5) Install cylinder head cover and curtain. Refer
to cover sealing of this group for procedure.
9 - 25
9 - 26
2.5L ENGINE
(5) Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this,
coat valve seat LIGHTLY with Prussian blue then
set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve
face, contact is satisfactory. If the blue is transferred
to top edge of the valve face, lower valve seat with a
15 degrees stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone.
Intake valve seat diameter 40.45 mm (1.593 in.)
Exhaust valve seat diameter 34.84 mm (1.371 in.)
2.5L ENGINE
Valve seats which are worn or burned can be reworked, provided that correct angle and seat width
are maintained. Otherwise cylinder head must be replaced.
(6) When seat is properly positioned the width of
intake seats should be 1.75 to 2.25 mm (0.69 to .088
in.) The width of the exhaust seats should be 1.50 to
2.00 mm (0.059 to 0.078 in.) (Fig. 22 Dimension 1).
(7) Check valve tip to valve spring seat dimensions
after grinding to seats or faces. Grind valve tip to
give 49.76 to 51.04 mm (1.960 to 2.009 in.) over valve
spring seat when installed in the head (Fig. 23). The
valve tip diameter should be no less than 7.0 mm
(0.275 in.), if necessary, the tip chamfer should be reground to prevent seal damage when the valve is installed.
(8) Check the valve spring installed height after
refacing the valve and seat (Fig. 24).
CAUTION: If more than 0.5 mm (0.020 in.) must be
ground from the valve tip, check the clearance between the rocker arm and the valve spring retainer.
If the clearance is below 1.25 mm (0.050 in.), grind
the rocker arm ears until proper clearance is obtained.
9 - 27
CLEANING
Clean all valve guides, valves and valve spring assemblies thoroughly suitable cleaning solution before
reassembling.
VALVE GEAR REASSEMBLY AFTER VALVE
SERVICE
(1) Coat valve stems with lubrication oil and insert
in cylinder head.
(2) Install new valve stem seals on all valves. The
valve stem seals should be pushed firmly and
squarely over valve guide. The lower edge of the seal
should be resting on the valve guide boss.
CAUTION: When oversize valves are used, the corresponding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
(3) Install valve spring seats and springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction
of compression. Nicked valve stems may result from
misalignment of the valve spring compressor.
CAUTION: When depressing the valve spring retainers with Special Tool C-3422-B the locks can become dislocated. Check to make sure both locks
are in their correct location after removing tool.
9 - 28
2.5L ENGINE
in.). To completely collapse adjuster for dry lash measurement, pry off retainer cap, disassemble, drain
the adjuster of oil, reassemble, and install. After performing dry lash check, refill adjuster with oil (do not
reuse retainer cap/s) and allow 10 minutes for adjuster/s to bleed down before rotating cam.
2.5L ENGINE
9 - 29
9 - 30
2.5L ENGINE
CRANKSHAFT SERVICE
CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to insure correct assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 2, 4 and 5 are
interchangeable. Upper main bearing halves of 1, 2,
4 and 5 are interchangeable.
CRANKSHAFT MAIN JOURNALS
The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be
held to 0.025 mm (.001 in.). Journal grinding should
not exceed 0.305 mm (0.012 in.) under the standard
journal diameter. Do NOT grind thrust faces of Number 3 main bearing. Do NOT nick crank pin or bearing fillets. After grinding, remove rough edges from
crankshaft oil holes and clean out all passages.
2.5L ENGINE
9 - 31
9 - 32
2.5L ENGINE
INTERMEDIATE SHAFT SERVICE
REMOVAL
CAUTION: The oil pump and distributor must be removed before attempting to remove intermediate
shaft.
2.5L ENGINE
INSTALLATION
(1) Lubricate distributor drive gear when installing.
(2) Apply Mopar Gasket Maker as shown in (Fig.
18) and install intermediate shaft retainer.
(3) Install retaining screws and torque to 12 Nzm
(105 in. lbs.).
9 - 33
9 - 34
2.5L ENGINE
2.5L ENGINE
9 - 35
9 - 36
2.5L ENGINE
PISTON RINGREMOVAL
(1) ID mark on face of upper and intermediate piston rings must point toward piston crown.
(2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 8).
FITTING RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 in.) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 9).
2.5L ENGINE
9 - 37
CONNECTING RODS
(1) Follow procedure specified in the Standard Service Procedures Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance
(Fig. 16). Refer to specifications (Fig. 19).
CAUTION: Do not rotate crankshaft or the Plastigage may be smeared.
The rod bearing bolts should be examined before reuse. If the threads are necked down the
bolts should be replaced. (Fig. 17)
9 - 38
2.5L ENGINE
INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder
block or head. Be sure to remove old sealer. Lightly
coat inside of cup plug hole with sealer. Make certain
the new plug is cleaned of all oil or grease. Using
proper drive plug, drive plug into hole so that the
sharp edge of the plug is at least 0.5 mm (0.020 in.)
inside the lead-in chamfer (Fig. 20).
It is in not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately.
2.5L ENGINE
9 - 39
MAIN/ROD BEARINGS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to crankpin
journals (Fig. 2).
ACCESSORY SHAFT
Two separate holes supply oil to the accessory
shaft.
CAMSHAFT/HYDRAULIC LIFTERS
A vertical hole at the number five bulkhead routes
(through a restrictor) pressurized oil up past a cylinder head bolt to an oil gallery running the length of
the cylinder head. Hydraulic adjusters are supplied
directly from this gallery while diagonal holes supply
oil to the camshaft journals. The camshaft journals
are partially slotted to allow a predetermined
amount of pressurized oil to pass into the bearing
cap cavities with small holes directed to spray lubricate the camshaft lobes.
SPLASH LUBRICATION
Oil returning to the pan from pressurized components supplies lubrication to the valve stems. Cylinder bores and wrist pins are splash lubricated from
directed holes in the connecting rods.
2.5L ENGINE
9 - 41
9 - 42
2.5L ENGINE
OIL PAN
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect air pump relief valve rubber hose.
(3) Raise vehicle and drain engine oil.
(4) Remove clutch housing to block strut and housing lower cover (Fig. 3).
2.5L ENGINE
9 - 43
(2) Limits:
0.03 mm (0.001 in.) min
0.09 mm (0.0035 in.) max.
(3) Thickness: 23.96 mm (0.9435 in.) min. Outer
Diameter: 62.7 mm (2.469 in.) min (Fig. 9).
(4) Install with large chamfered edge in pump
body (Fig. 9).
9 - 44
2.5L ENGINE
INSTALLATION
(1) Apply Mopar Gasket Maker to pump body-toblock interface (machined surface).
(2) Lubricate oil pump rotor & shaft and drive
gear.
(3) Turn crankshaft and intermediate shaft until
markings on sprockets are in line (arrows Fig. 16).
(4) Slot in oil pump shaft must be parallel to center line of crankshaft when intermediate shaft and
crankshaft are properly timed (Fig. 17).
(5) Install pump full depth and rotate back and
forth slightly to ensure proper positioning and alignment through full surface contact of pump and block
machined interface surfaces (Fig. 7).
CAUTION: Pump must be held in fully seated position (described above) while installing screws.
2.5L ENGINE
9 - 45
OIL FILTER
ANTI-DRAIN BACK VALVE
Installation: Apply liquid (Teflon Type) sealant to
valve-to-block threads (Fig. 19). Tighten assembly to
55 Nzm (40 ft. lbs.).
FILTER
CAUTION: When servicing the oil filter (Fig. 19)
avoid deforming the filter can by installing the remove/install tool band strap against the can-to-base
lock seam. The lock-seam joining the can to the
base is reinforced by the base plate.
(1) Using Tool C-4065, turn filter counter-clockwise
to remove from base. Properly discard filter.
(2) Wipe base clean, then inspect gasket contact
surface.
(3) Lubricate gasket of new filter with clean engine
oil.
(4) Install new filter until gasket contacts base.
Tighten filter 1 turn or 20 Nzm (15 ft. lbs.). Use filter
wrench if necessary.
(5) Start engine and check for leaks.
9 - 46
2.5L ENGINE
ENGINE SPECIFICATIONS
2.5L ENGINE
ENGINE SPECIFICATIONSCONT.
9 - 47
9 - 48
2.5L ENGINE
TORQUE SPECIFICATIONS
3.9L ENGINE
9 - 49
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page
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arms and Push Rods . . . . . . . . . . . . .
Timing Chain Cover . . . . . . . . . . . . . . . . . . . .
Valve Components ReplaceClyinder Head Not
Removed . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Seal and Spring Replacement . . . .
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Valve Springs . . . . . . . . . . . . . . . .
Vibration Damper . . . . . . . . . . . . . . . . . . . . . .
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54
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60
56
60
GENERAL INFORMATION
The 3.9 Liter (238 CID) six-cylinder engine is a VType, lightweight, single cam, overhead valve engine
with hydraulic roller tappets (Fig. 1).
9 - 50
3.9L ENGINE
3.9L ENGINE
9 - 51
REMOVAL2WD
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Support the transmission with a jack.
(4) TRANSMISSION
AUTOMATIC
Remove engine support bracket/insulator thru-bolt
(Fig. 9).
Raise the transmission and engine slightly.
Remove stud nuts attaching insulator to crossmember (Fig. 9). Remove insulator.
MANUAL
Remove the stud nuts attaching the insulator to
the transmission extension (Fig. 10).
Raise the transmission and engine slightly.
Remove stud nuts attaching insulator to crossmember (Fig. 10). Remove insulator.
INSTALLATION2WD
(1) If the engine support bracket (Automatic Transmissions) was removed, position the bracket to the
9 - 52
3.9L ENGINE
MANUAL
Install the insulator onto crossmember. Tighten
the stud nuts to 41 Nzm (30 ft. lbs) torque.
Lower the transmission and engine while aligning
the insulator studs into the transmission extension.
Install the stud nuts. Tighten the stud nuts to 41
Nzm (30 ft. lbs) torque.
(3) Remove transmission jack.
(4) Lower the vehicle.
(5) Connect the negative cable to the battery.
REMOVAL4WD
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Support the transmission with a transmission
jack.
(4) TRANSMISSION
AUTOMATIC
Remove stud nuts holding the insulator to the
crossmember (Fig. 11).
Raise rear of transmission SLIGHTLY.
Remove bolts holding the insulator to the insulator
bracket (Fig. 11). Remove the insulator.
3.9L ENGINE
Remove bolts holding the insulator to the transmission (Fig. 12). Remove the insulator.
9 - 53
ENGINE ASSEMBLY
REMOVAL
(1) Scribe hood hinge outlines on hood. Remove the
hood.
(2) Remove the battery.
(3) Drain cooling system (refer to Group 7, Cooling
System for the proper procedure).
(4) Remove the air cleaner.
(5) Disconnect the radiator and heater hoses. Remove radiator (refer to Group 7, Cooling System).
(6) Set fan shroud aside.
(7) Remove the vacuum lines.
(8) Remove the distributor cap and wiring.
(9) Disconnect the accelerator linkage.
(10) Remove throttle body.
(11) Disconnect the fuel line.
(12) Disconnect the starter wires.
(13) Disconnect the oil pressure wire.
(14) Discharge the air conditioning system, if
equipped (refer to Group 24, Heating and Air Conditioning for service procedures).
(15) Disconnect the air conditioning hoses.
(16) Disconnect the power steering hoses, if
equipped.
(17) Remove starter motor (refer to Group 8B, Battery/Starter/Generator Service).
(18) Remove the generator (refer to Group 8B, Battery/Starter/Generator Service).
(19) Raise and support the vehicle on a hoist.
(20) Disconnect exhaust pipe at manifold.
(21) Refer to Group 21, Transmissions for transmission removal.
CAUTION: DO NOT lift the engine by the intake
manifold.
(22) Install an engine lifting fixture.
(23) 2WD VEHICLESRemove engine front
mount bolts.
(24) 4WD VEHICLESThe engine and front driving axle (engine/axle/transmission) are connected
through insulators and support brackets. Separate
the engine as follows:
LEFT SIDERemove 2 bolts attaching (engine/
pinion nose/transmission) bracket to transmission
bell housing. Remove 2 bracket to pinion nose adaptor bolts. Separate engine from insulator by removing
upper nut washer assembly and bolt from engine
support bracket.
RIGHT SIDERemove 2 bracket to axle (disconnect housing) bolts and 1 bracket to bell housing bolt.
Separate engine from insulator by removing upper
nut washer assembly and bolt from engine support
bracket.
(25) Lower the vehicle.
(26) On automatic transmission vehicles, disconnect the engine from the torque converter drive plate.
9 - 54
3.9L ENGINE
On manual transmission vehicles, move engine forward until drive pinion shaft clears the clutch disc.
Remove engine from engine compartment.
(27) Install engine assembly on engine repair
stand.
INSTALLATION
(1) Remove engine from the repair stand and position in the engine compartment.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Refer to Group 21, Transmissions for transmission installation.
(5) Install the front engine mounts.
(6) Lower the vehicle.
(7) Remove engine lifting fixture.
(8) Install the generator (refer to Group 8B, Battery/Starter/Generator Service).
(9) Install starter motor (refer to Group 8B, Battery/Starter/Generator Service).
(10) Connect power steering hoses, if equipped.
(11) Connect air conditioning hoses.
(12) Evacuate and charge the air conditioning system, if equipped (refer to Group 24, Heater and Air
Conditioning for service procedures).
(13) Using a new gasket, install throttle body.
Tighten the throttle body bolts to 23 Nzm (200 in.
lbs.) torque.
(14) Connect the accelerator linkage.
(15) Connect the starter wires.
(16) Connect the oil pressure wire.
(17) Install the distributor cap and wiring.
(18) Connect the vacuum lines.
(19) Connect the fuel line.
(20) Install the radiator (refer to Group 7, Cooling
System). Connect the radiator hoses and heater
hoses.
(21) Install fan shroud in position.
(22) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure).
(23) Install the air cleaner.
(24) Install the battery.
(25) Warm engine and adjust.
(26) Install hood and line up with the scribe
marks.
(27) Road test vehicle.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect closed ventilation system and evaporation control system from cylinder head cover.
(3) Remove cylinder head cover and gasket. The
gasket may be used again.
3.9L ENGINE
9 - 55
CYLINDER HEADS
The alloy cast iron cylinder heads (Fig. 3) are held
in place by 8 bolts. The spark plugs are located in
the peak of the wedge between the valves.
9 - 56
3.9L ENGINE
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness exceeds 0.00075 mm/mm (0.00075 inch/inch) times the
span length in any direction, either replace head or
lightly machine the head surface.
FOR EXAMPLE:A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable outof-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is acceptable.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Position the new cylinder head gaskets onto the
cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(3) Starting at top center, tighten all cylinder head
bolts, in sequence, to 68 Nzm (50 ft. lbs.) torque (Fig.
4). Repeat procedure, tighten all cylinder head bolts
to 143 Nzm (105 ft. lbs.) torque. Repeat procedure to
confirm that all bolts are at 143 Nzm (105 ft. lbs.)
torque.
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(4) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 Nzm
(21 ft. lbs.) torque.
3.9L ENGINE
9 - 57
REMOVAL
(1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring
Compressor Tool MD-998772-A
(3) Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped
and cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE INSPECTION
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
VALVE GUIDES
Measure valve stem guide clearance as follows:
(a) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 5). The special
sleeve places the valve at the correct height for
checking with a dial indicator.
VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 9). Valves with less than 1.190 mm
(0.047 inch) margin should be discarded.
VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 10).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading.
9 - 58
3.9L ENGINE
3.9L ENGINE
(2) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(3) Install new seals on all valve guides. Install
valve springs and valve retainers.
(4) Compress valve springs with Valve Spring
Compressor Tool MD-998772-A, install locks and release tool. If valves and/or seats are ground, measure
the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If
spacers are installed, measure from the top of spacer.
If height is greater than 42.86 mm (1-11/16 inches),
install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
HYDRAULIC TAPPETS
Before disassembling any part of the engine to correct tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending unit. The pressure should be
between 207-552 kPa (30-80 psi) at 3,000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick.
The oil level in the pan should never be above the
FULL mark or below the ADD OIL mark on dipstick.
Either of these 2 conditions could be responsible for
noisy tappets.
OIL LEVEL
HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose
length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length which
allows valves to seat noisily. Any leaks on intake side
of oil pump through which air can be drawn will create the same tappet action. Check the lubrication
system from the intake strainer to the pump cover,
including the relief valve retainer cap. When tappet
noise is due to aeration, it may be intermittent or
constant, and usually more than 1 tappet will be
noisy. When oil level and leaks have been corrected,
operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets
to be bled out.
9 - 59
9 - 60
3.9L ENGINE
DISASSEMBLE
(1) Pry out plunger retainer spring clip (Fig. 12).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
retainer and plunger spring (Fig. 12). Check valve
could be flat or ball.
ASSEMBLE
(1) Clean all tappet parts in a solvent that will remove all varnish and carbon.
(2) Replace tappets that are unfit for further service with new assemblies.
(3) If plunger shows signs of scoring or wear, install a new tappet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seating, install a new tappet assembly.
(4) Assemble tappets (Fig. 12).
VIBRATION DAMPER
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine.
(3) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley.
(6) Remove vibration damper bolt and washer from
end of crankshaft.
(7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 1).
VALVE TIMING
(1) Turn crankshaft until the No.6 exhaust valve is
closing and No.6 intake valve is opening.
INSTALLATION
(1) Position the vibration damper onto the crankshaft.
3.9L ENGINE
9 - 61
(2) Place a torque wrench and socket over camshaft sprocket attaching bolt. Apply torque in the direction of crankshaft rotation to take up slack; 41
Nzm (30 ft. lbs.) torque with cylinder head installed
or 20 Nzm (15 ft. lbs.) torque with cylinder head removed. With a torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads installed, apply 14 Nzm (30 ft. lbs.) torque in the reverse direction. With the cylinder heads removed,
apply 20 Nzm (15 ft. lbs.) torque in the reverse direction. Note the amount of chain movement (Fig. 4).
9 - 62
3.9L ENGINE
(10) Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment
of timing marks (Fig. 5).
CLEANING
Be sure mating surfaces of chain case cover and
cylinder block are clean and free from burrs.
The water pump mounting surface must be
cleaned.
INSTALLATION
(1) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone Rubber Adhesive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
CAUTION: If chain cover is replaced for any reason,
make sure the oil hole (passenger side of cover) is
plugged.
(2) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
the oil seal in the groove of the tool.
(3) Position the seal and tool onto the crankshaft
(Fig. 7).
(4) Tighten the 4 lower chain case cover bolts to
13Nzm (10 ft.lbs.) to prevent the cover from tipping
during seal installation.
(5) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 8).
(6) Loosen the 4 bolts tightened in step 4 to allow
realignment of front cover assembly.
(7) Tighten the 4 lower chain case cover bolts to
13Nzm (10 ft.lbs.) to prevent the cover from tipping
during seal installation.
3.9L ENGINE
9 - 63
CAMSHAFT
This procedure requires that the engine is removed
from the vehicle.
The camshaft has an integral oil pump and distributor drive gear (Fig. 9).
REMOVAL
(1) Remove intake manifold.
(2) Remove cylinder head covers.
(3) Remove timing case cover and timing chain.
(4) Remove rocker arms.
(5) Remove push rods and tappets. Identify each
part so it can be installed in the original location.
(6) Remove distributor and lift out the oil pump
and distributor drive shaft.
(7) Remove camshaft thrust plate; note location of
oil tab (Fig. 10).
REMOVALBEARING
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
9 - 64
3.9L ENGINE
(3) Hold tool in position with a distributor lockplate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block. Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in
thrust plate. Tighten bolts to 24 Nzm (210 in. lbs.)
torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.
(5) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(6) Place timing chain around both sprockets.
(7) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in camshaft sprocket.
(8) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(9) Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment
of timing marks (Fig. 13).
DISTRIBUTOR BUSHING
DISTRIBUTER REMOVAL
Refer to Group 8D, Ignition Systems for the proper
procedure.
3.9L ENGINE
(2) Hold puller screw and tighten puller nut until
bushing is removed.
9 - 65
DISTRIBUTOR INSTALLATION
Refer to the Component Removal/Installation section of Group 8D, Ignition Systems for the proper
procedure. See Distributor. After the distributor has
been installed, its rotational position must be set using the SET SYNC mode of the DRB scan tool. Refer
to Checking Distributor Position following the Distributor Installation section in Group 8D, Ignition
system. Do not attempt to adjust ignition timing
by rotating the distributor. It has no effect on
ignition timing. Adjusting distributor position
will effect fuel synchronization only.
Before installing the distributor, the oil pump drive
shaft must be aligned to number one cylinder.
(1) Rotate crankshaft until No.1 cylinder is at top
dead center on the firing stroke.
(2) When in this position, the timing mark on vibration damper should be under 0 on the timing indicator.
(3) Install the shaft so that after the gear spirals
into place, it will index with the oil pump shaft. The
slot on top of oil pump shaft should be aligned towards left front intake manifold attaching bolt hole
(Fig. 17).
OIL PAN
REMOVAL2WD
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Disconnect distributor cap and position away
from cowl.
(4) Raise vehicle.
(5) Drain engine oil.
(6) Remove exhaust pipe.
(7) Loosen side engine mount bolts.
(8) Raise engine by way of oil pan using a block of
wood between the jack and oil pan.
(9) When engine is high enough, place bolts (similar in size to the engine mount bolts) in the engine
mount attaching points on the frame brackets.
9 - 66
3.9L ENGINE
REMOVAL4WD
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove front driving axle (refer to Group 3,
Drive Axles and Group 2, Front Suspension for the
proper procedures).
(6) Remove exhaust pipe.
(7) Remove transmission lower (dust) cover.
(8) Remove oil pan and one-piece gasket.
CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the engine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean solvent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distortion. Straighten flange, if necessary.
INSTALLATION2WD
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 1).
INSTALLATION4WD
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 1).
(2) Install the dowels in the cylinder block (Fig. 2).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
3.9L ENGINE
(6) Install the oil pan bolts. Tighten the bolts to 24
Nzm (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 Nzm (215 in. lbs.)
torque.
(8) Install the drain plug. Tighten drain plug to 34
Nzm (25 ft. lbs.) torque.
(9) Install front driving axle (refer to Group 3,
Drive Axles and Group 2, Front Suspension for the
proper procedures).
(10)
(11)
(12)
(13)
(14)
(15)
9 - 67
LUBRICATION SYSTEM
A geartype positive displacement pump is
mounted at the underside of the rear main bearing
cap. The pump draws oil through the screen and inlet tube from the sump at the rear of the oil pan. The
oil is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery which extends the entire length on the right side of the block.
The oil then goes down to the No. 1 main bearing,
back up to the left side of the block and into the oil
gallery on the left side of the engine.
Galleries extend downward from the main oil gallery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod rotates. This oil throwoff lubricates the camshaft lobes,
distributor drive gear, cylinder walls, and piston
pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. The camshaft bearings receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the camshaft sprocket to the timing chain. Oil drains back to
the oil pan under the number one main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
tappets which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.
The oil then passes down through the push rod guide
holes, and the oil drain back passages in the cylinder
head past the valve tappet area, and returns to the
oil pan.
9 - 68
3.9L ENGINE
3.9L ENGINE
9 - 69
OIL PUMP
OIL PUMP PRESSURE
The MINIMUM oil pump pressure is 41.4 kPa (6
psi) at curb idle. The MAXIMUM oil pump pressure
is 207-552 kPa (30-80 psi) at 3,000 RPM or more.
CAUTION: If oil pressure is ZERO at curb idle, DO
NOT run engine at 3,000 RPM.
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing
cap.
DISASSEMBLE
(1) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and insert a self-threading sheet metal screw into cap.
(b) Clamp screw into a vise and while supporting
oil pump, remove cap by tapping pump body using
a soft hammer. Discard retainer cap and remove
spring and relief valve (Fig. 3).
INSPECTION
Mating surface of the oil pump cover should be
smooth. Replace pump assembly if cover is scratched
or grooved.
Lay a straightedge across the pump cover surface
(Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can
be inserted between cover and straightedge, pump
assembly should be replaced.
9 - 70
3.9L ENGINE
ASSEMBLE
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 Nzm (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling rotor cavity with engine oil.
INSTALLATION
(1) Install oil pump. During installation slowly rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
3.9L ENGINE
9 - 71
REMOVAL
(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.
(4) Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered
during this operation.
(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and
connecting rod assemblies, rotate crankshaft to center the connecting rod in the cylinder bore and at
BDC. Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mating rod.
INSPECTION
All measurements are at 21C (70
33F).
Check the crankshaft connecting rod journal for excessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore (Fig. 1).
FITTING PISTONS
Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylinder wall is 0.013-0.038 mm (0.0005-0.0015 inch) at
21C (70F).
Piston diameter should be measured at the top of
skirt, 90 to piston pin axis. Cylinder bores should be
FITTING RINGS
(1) Measurement of end gaps:
(a) Measure piston ring gap 2 inches from bottom of cylinder bore. An inverted piston can be
used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measuring.
(b) Insert feeler gauge in the gap. The top compression ring gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
ring gap should be between 0.508-0.762 mm (0.0200.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be filed
to the correct dimension. Rings with excess gaps
should not be used.
(2) Install rings and confirm ring side clearance:
(a) Install oil rings being careful not to nick or
scratch the piston.
(b) Install the compression rings using Installation Tool C-4184. The top compression may be installed with either side up. The second compression
ring must be installed with the identification mark
face up (toward top of piston) and the chamfer
should face down. An identification mark on the
ring is a drill point, a stamped letter O, an oval
depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 2). Clearance should be 0.038-
9 - 72
3.9L ENGINE
INSTALLATION
(1) Be sure that compression ring gaps are staggered so that neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 3).
(3) Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, connecting rod cap and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 Nzm (45 ft. lbs.) torque.
(9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine into the vehicle.
CRANKSHAFT
A crankshaft which has undersize journals will be
stamped with 1/4 inch letters near the notch of the
No.6 crankshaft counterweight (Fig. 4).
FOR EXAMPLE: R2 stamped on the No.6 crankshaft counterweight indicates that the No.2 rod journal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in)
undersize. R3 M2 indicates that the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 in)
undersize.
3.9L ENGINE
9 - 73
CLEANING
Clean Loctite 515 residue and sealant from the cylinder block and rear cap mating surface. Do this before applying the Loctite drop and the installation of
rear cap.
INSTALLATION
(1) Lightly oil the new upper seal lips with engine
oil.
(2) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine
oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(6) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap
(Fig. 5). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant application.
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bearing cap.
(3) Remove the vibration damper.
(4) Remove the timing chain cover.
(5) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(6) Lift the crankshaft out of the block.
(7) Remove and discard the crankshaft rear oil
seals.
(8) Remove and discard the front crankshaft oil
seal.
INSPECTION OF JOURNALS
The crankshaft connecting rod and main journals
should be checked for excessive wear, taper and scoring. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch).
Journal grinding should not exceed 0.305 mm
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.2 main bearing. DO
NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and
clean out all oil passages.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction as the engine rotates.
9 - 74
3.9L ENGINE
3.9L ENGINE
(3) Lightly oil the new upper seal lips with engine
oil.
(4) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(5) Position the crankshaft into the cylinder block.
(6) Lightly oil the new lower seal lips with engine
oil.
(7) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(8) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap
(Fig. 5). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant application.
(9) To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(10) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 Nzm (85 ft. lbs.) torque.
(11) Install oil pump.
(12) Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 6). Apply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(13) Install new front crankshaft oil seal.
(14) Immediately install the oil pan.
9 - 75
9 - 76
3.9L ENGINE
CYLINDER BLOCK
Remove the engine assembly from the vehicle.
DISASSEMBLE
(1) Remove the cylinder head.
(2) Remove the oil pan.
(3) Remove the piston/connecting rod assemblies.
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-ofround and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coordinated with the fitting of pistons and rings so
specified clearances may be maintained.
Refer to Standard Service Procedures in the beginning of this Group for the proper honing of cylinder
bores.
OIL LINE PLUG
The oil line plug is located in the vertical passage
at the rear of the block between the Oil-To-Filter and
Oil-From-Filter passages (Fig. 9). Improper installation or plug missing could cause erratic, low or no oil
pressure.
The oil plug must come out the bottom. Use flat
dowel, down the oil pressure sending unit hole from
the top, to remove oil plug.
(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 inch) finish wire or
equivalent into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to
7-11/16 inches) from machined surface of block (Fig.
9). If plug is too high, use a suitable flat dowel to position properly.
(4) If plug is to low, remove oil pan and rear main
bearing cap. Use suitable flat dowel to position properly. Coat outside diameter of new plug with Mopar
(Stud and Bearing Mount Adhesive), or equivalent.
Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16
inches) from bottom of the block.
(5) Assemble engine and check oil pressure.
3.9L ENGINE
9 - 77
INSTALLATION
(1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
CAUTION: DO NOT drive cup plug into the casting
as restricted coolant flow can result and cause serious engine problems.
(2) Using proper plug driver, drive cup plug into
hole. The sharp edge of the plug should be at least
0.50 mm (0.020 inch) inside the lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be filled and the vehicle
placed in service immediately.
ASSEMBLE
(1) Install the
(2) Install the
(3) Install the
(4) Install the
9 - 78
3.9L ENGINE
ENGINE SPECIFICATIONS
3.9L ENGINE
ENGINE SPECIFICATIONSCONT.
9 - 79
9 - 80
3.9L ENGINE
ENGINE SPECIFICATIONSCONT.
3.9L ENGINE
TORQUE SPECIFICATIONS
9 - 81
9 - 82
5.2L ENGINE
5.2L ENGINE SERVICE PROCEDURES
INDEX
page
Camshaft . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover . . . . . . . . . . . . . .
Cylinder Heads . . . . . . . . . . . . . . . . . .
Distributor . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . .
Engine Front Mounts . . . . . . . . . . . . . .
Engine Rear Support . . . . . . . . . . . . . .
Front Crankshaft Oil Seal Replacement
General Information . . . . . . . . . . . . . .
Hydraulic Tappets . . . . . . . . . . . . . . . .
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95
86
87
97
85
82
84
95
82
91
page
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arms and Push Rods . . . . . . . . . . . . .
Timing Chain Cover . . . . . . . . . . . . . . . . . . . .
Valve Components ReplaceClyinder Head Not
Removed . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Seal and Spring Replacement . . . .
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Valve Springs . . . . . . . . . . . . . . . .
Vibration Damper . . . . . . . . . . . . . . . . . . . . . .
. . . 97
. . . 87
. . . 93
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87
89
87
92
89
92
GENERAL INFORMATION
The 5.2 Liter (318 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve engine with hydraulic roller tappets (Fig. 1).
5.2L ENGINE
9 - 83
9 - 84
5.2L ENGINE
REMOVAL2WD
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Support the transmission with a jack.
(4) Remove engine support bracket/insulator thrubolt (Fig. 9).
(5) Raise the transmission and engine slightly.
(6) Remove stud nuts attaching insulator to crossmember (Fig. 9). Remove insulator.
INSTALLATION2WD
(1) If the engine support bracket was removed, position the bracket to the transmission extension (Fig.
9). Tighten the bolts to 68 Nzm (50 ft. lbs.) torque.
(2) Install the insulator onto crossmember. Tighten
the stud nuts to 41 Nzm (30 ft. lbs) torque.
(3) Lower the transmission and engine while aligning the engine support bracket to the insulator.
(4) Install thru-bolt in bracket and insulator.
Tighten thru-bolt nut to 68 Nzm (50 ft. lbs.) torque.
(5) Remove transmission jack.
(6) Lower the vehicle.
5.2L ENGINE
9 - 85
REMOVAL4WD
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle on a hoist.
(3) Support the transmission with a transmission
jack.
(4) Remove stud nuts holding the insulator to the
crossmember (Fig. 10).
(5) Raise rear of transmission SLIGHTLY.
(6) Remove bolts holding the insulator to the insulator bracket (Fig. 10). Remove the insulator.
INSTALLATION4WD
(1) If the insulator bracket was removed, install
the bracket to the transmission (Fig. 10). Tighten the
bolts to 28 Nzm (250 in. lbs.) torque.
(2) Install the bolts holding insulator to insulator
bracket. Tighten the bolts to 28 Nzm (250 in. lbs.)
torque.
(3) Lower rear of transmission while aligning the
insulator studs into the mounting support bracket.
Install stud nuts and tighten to 28 Nzm (250 in. lbs.)
torque.
(5) Remove the transmission jack.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
ENGINE ASSEMBLY
REMOVAL
(1) Scribe hood hinge outlines on hood. Remove the
hood.
(2) Remove the battery.
(3) Drain cooling system (refer to Group 7, Cooling
9 - 86
5.2L ENGINE
INSTALLATION
(1) Remove engine from the repair stand and position in the engine compartment.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(5) Install the engine front mounts.
Refer to Group, 21 Transmissions for transmission
installation
(8) Install the inspection plate.
(9) Remove transmission support.
(10) Install exhaust pipe to manifold.
(11) Lower the vehicle.
(12) Remove engine lifting fixture.
(13) Install the generator (refer to Group 8B, Battery/Starter/Generator Service).
(14) Install starter motor (refer to Group 8B, Battery/Starter/Generator Service).
(15) Connect power steering hoses, if equipped.
(16) Connect air conditioning hoses.
(17) Evacuate and charge the air conditioning system, if equipped (refer to Group 24, Heater and Air
Conditioning for service procedures).
(18) Using a new gasket, install throttle body.
Tighten the throttle body bolts to 23 Nzm (200 in.
lbs.) torque.
(19) Connect the accelerator linkage.
(20) Connect the starter wires.
(21) Connect the oil pressure wire.
(22) Install the distributor cap and wiring.
(23) Connect the vacuum lines.
(24) Connect the fuel lines.
5.2L ENGINE
VALVE COMPONENTS REPLACECLYINDER HEAD
NOT REMOVED
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Disconnect spark plug wires by pulling on the
boot straight out in line with plug.
(2) Remove cylinder head cover and gasket.
(3) Remove the rocker arm bolts and pivots (Fig.
2). Place them on a bench in the same order as removed.
(4) Remove the push rods and place them on a
bench in the same order as removed.
9 - 87
CYLINDER HEADS
The alloy cast iron cylinder heads (Fig. 3) are held
in place by 10 bolts. The spark plugs are located in
the peak of the wedge between the valves.
The 5.2L cylinder head is identified by the foundry
mark NH.
CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(2) Install the push rods in the same order as removed.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 Nzm (21 ft. lbs.) torque.
(4) Install cylinder head cover.
(5) Connect spark plug wires.
9 - 88
5.2L ENGINE
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness exceeds 0.00075 mm/mm (0.00075 inch/inch) times the
span length in inches in any direction, either replace
head or lightly machine the head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable outof-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is acceptable.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Apply Perfect Sealant No.5, or equivalent, to
both sides of the gasket (Fig. 4).
(2) Position the new cylinder head gaskets onto the
cylinder block.
(3) Position the cylinder heads onto head gaskets
and cylinder block.
(4) Starting at top center, tighten all cylinder head
bolts, in sequence, to 68 Nzm (50 ft. lbs.) torque (Fig.
5). Repeat procedure, tighten all cylinder head bolts
to 143 Nzm (105 ft. lbs.) torque. Repeat procedure to
confirm that all bolts are at 143 Nzm (105 ft. lbs.)
torque.
5.2L ENGINE
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kickdown cables.
(15) Install the fuel lines.
(16) Install the generator and drive belt. Tighten
generator mounting bolt to 41 Nzm (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 Nzm
(200 in. lbs.) torque. Refer to Group 7, Cooling System for adjusting the belt tension.
(17) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) Place the cylinder head cover gaskets in position and install cylinder head covers. Tighten the
bolts to 11 Nzm (95 in. lbs.) torque.
(19) Install closed crankcase ventilation system.
(20) Connect the evaporation control system.
(21) Install the air cleaner.
(22) Install the heat shields. Tighten the bolts to
41 Nzm (30 ft. lbs.) torque.
(23) Fill cooling system (refer to Group 7, Cooling
System for proper procedure).
(24) Connect the negative cable to the battery.
9 - 89
REMOVAL
(1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring
Compressor Tool MD-998772-A.
(3) Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped
and cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE INSPECTION
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
VALVE GUIDES
Measure valve stem guide clearance as follows:
(a) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 6). The special
sleeve places the valve at the correct height for
checking with a dial indicator.
9 - 90
5.2L ENGINE
VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 11).
5.2L ENGINE
fer to specifications to obtain specified height and allowable tensions. Discard the springs that do not
meet specifications.
HYDRAULIC TAPPETS
Before disassembling any part of the engine to correct tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending unit. The pressure should be
between 207-552 kPa (30-80 psi) at 3,000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick.
The oil level in the pan should never be above the
FULL mark or below the ADD OIL mark on dipstick.
Either of these 2 conditions could be responsible for
noisy tappets.
9 - 91
OIL LEVEL
HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running this condition could create foam in
the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose
length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length which
allows valves to seat noisily. Any leaks on intake side
of oil pump through which air can be drawn will create the same tappet action. Check the lubrication
system from the intake strainer to the pump cover,
including the relief valve retainer cap. When tappet
noise is due to aeration, it may be intermittent or
constant, and usually more than 1 tappet will be
noisy. When oil level and leaks have been corrected,
operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets
to be bled out.
9 - 92
5.2L ENGINE
REMOVAL
(1) Remove the air cleaner.
(2) Remove cylinder head cover.
(3) Remove rocker assembly and push rods. Identify push rods to ensure installation in original location.
(4) Remove intake manifold.
(5) Remove yoke retainer and aligning yokes.
(6) Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening in cylinder head and seat
tool firmly in the head of tappet.
(7) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location.
(8) If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet.
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to
work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. DO NOT disassemble a tappet on a dirty work bench.
DISASSEMBLE
(1) Pry out plunger retainer spring clip (Fig. 13).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
retainer and plunger spring (Fig. 13). Check valve
could be flat or ball.
ASSEMBLE
(1) Clean all tappet parts in a solvent that will remove all varnish and carbon.
(2) Replace tappets that are unfit for further service with new assemblies.
(3) If plunger shows signs of scoring or wear, install a new tappet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seating, install a new tappet assembly.
(4) Assemble tappets (Fig. 13).
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and push rods in their original
positions. Ensure that the oil feed hole in the side of
the tappet body faces up (away from the crankshaft).
(3) Install aligning yokes with ARROW toward
camshaft.
(4) Install yoke retainer. Tighten the bolts to 23
Nzm (200 in. lbs.) torque. Install intake manifold.
(5) Install push rods in original positions.
(6) Install rocker arm.
(7) Install cylinder head cover.
(8) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become
quiet.
VALVE TIMING
(1) Turn crankshaft until the No.6 exhaust valve is
closing and No.6 intake valve is opening.
(2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.1 intake valve. Allow spring load to bleed tappet down giving in effect
a solid tappet.
(3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as possible. Zero the indicator.
(4) Rotate the crankshaft clockwise (normal running direction) until the valve has lifted 0.254 mm
(0.010 inch). The timing of the crankshaft should
now read from 10 before top dead center to 2 after
top dead center. Remove spacer.
CAUTION: DO NOT turn crankshaft any further
clockwise as valve spring might bottom and result
in serious damage.
(5) If reading is not within specified limits:
(a) Check sprocket index marks.
(b) Inspect timing chain for wear.
(c) Check accuracy of DC mark on timing indicator.
VIBRATION DAMPER
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine.
(3) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley.
5.2L ENGINE
(6) Remove vibration damper bolt and washer from
end of crankshaft.
(7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 1).
9 - 93
INSTALLATION
(1) Position the vibration damper onto the crankshaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 2).
9 - 94
5.2L ENGINE
sive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
(2) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
the oil seal in the groove of the tool.
CLEANING
Be sure mating surfaces of chain case cover and
cylinder block are clean and free from burrs.
The water pump mounting surface must be
cleaned.
INSTALLATION
(1) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone Rubber Adhe-
5.2L ENGINE
9 - 95
CAMSHAFT
9 - 96
5.2L ENGINE
Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1
pint of Mopar Crankcase Conditioner, or equivalent. The oil mixture should be left in engine
for a minimum of 805 km (500 miles). Drain at
the next normal oil change.
(2) Install Camshaft Gear Installer Tool C-3509
with tongue back of distributor drive gear (Fig. 12).
5.2L ENGINE
9 - 97
DISTRIBUTOR
REMOVAL
Refer to Group 8D, Ignition Systems for the proper
procedure.
REMOVALDRIVE SHAFT BUSHING
(1) Remove the intake manifold (refer to Group 11,
Exhaust System and Intake Manifold).
(2) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a
tight fit is obtained (Fig. 14).
(3) Hold puller screw and tighten puller nut until
bushing is removed.
OIL PAN
REMOVAL2WD
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Disconnect distributor cap and position away
from cowl.
9 - 98
5.2L ENGINE
INSTALLATION2WD
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 1).
REMOVAL4WD
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove front driving axle (refer to Group 3,
Drive Axles and Group 2, Front Suspension for the
proper procedures).
(6) Remove exhaust pipe.
(7) Remove transmission lower (dust) cover.
(8) Remove oil pan and one-piece gasket.
CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the engine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean solvent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distortion. Straighten flange, if necessary.
5.2L ENGINE
(9) Raise engine by way of oil pan with a wood
block placed between jack and oil pan.
(10) Remove temporary bolts from frame brackets
and lower engine. Tighten side engine mount bolts to
specifications.
(11) Install exhaust pipe.
(12) Lower vehicle.
(13) Connect the distributor cap.
(14) Install dipstick.
(15) Connect the negative cable to the battery.
(16) Fill crankcase with oil to proper level.
INSTALLATION4WD
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 1).
(2) Install the dowels in the cylinder block (Fig. 2).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
9 - 99
LUBRICATION SYSTEM
A geartype positive displacement pump is
mounted at the underside of the rear main bearing
cap. The pump draws oil through the screen and inlet tube from the sump at the rear of the oil pan. The
oil is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery which extends the entire length on the right side of the block.
The oil then goes down to the No. 1 main bearing,
back up to the left side of the block and into the oil
gallery on the left side of the engine.
Galleries extend downward from the main oil gallery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod rotates. This oil throwoff lubricates the camshaft lobes,
distributor drive gear, cylinder walls, and piston
pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. The camshaft bearings receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the camshaft sprocket to the timing chain. Oil drains back to
the oil pan under the number one main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
tappets which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.
The oil then passes down through the push rod guide
holes, and the oil drain back passages in the cylinder
head past the valve tappet area, and returns to the
oil pan.
9 - 100
5.2L ENGINE
5.2L ENGINE
9 - 101
OIL PUMP
OIL PUMP PRESSURE
The MINIMUM oil pump pressure is 41.4 kPa (6
psi) at curb idle. The MAXIMUM oil pump pressure
is 207-552 kPa (30-80 psi) at 3,000 RPM or more.
CAUTION: If oil pressure is ZERO at curb idle, DO
NOT run engine at 3,000 RPM.
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing
cap.
DISASSEMBLE
(1) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and insert a self-threading sheet metal screw into cap.
(b) Clamp screw into a vise and while supporting
oil pump, remove cap by tapping pump body using
a soft hammer. Discard retainer cap and remove
spring and relief valve (Fig. 3).
INSPECTION
Mating surface of the oil pump cover should be
smooth. Replace pump assembly if cover is scratched
or grooved.
Lay a straightedge across the pump cover surface
(Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can
be inserted between cover and straightedge, pump
assembly should be replaced.
9 - 102
5.2L ENGINE
ASSEMBLE
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 Nzm (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling rotor cavity with engine oil.
INSTALLATION
(1) Install oil pump. During installation slowly rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
5.2L ENGINE
9 - 103
REMOVAL
(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.
(4) Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered
during this operation.
(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and
connecting rod assemblies, rotate crankshaft to center the connecting rod in the cylinder bore and at
BDC. Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mating rod.
INSPECTION
Check the crankshaft connecting rod journal for excessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore (Fig. 1).
Pistons and cylinder bores should be measured at
normal room temperature, 21C (70F).
FITTING PISTONS
Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylinder wall is 0.013-0.038 mm (0.0005-0.0015 inch) at
21C (70F).
Piston diameter should be measured at the top of
skirt, 90 to piston pin axis. Cylinder bores should be
FITTING RINGS
(1) Measurement of end gaps:
(a) Measure piston ring gap 2 inches from bottom of cylinder bore. An inverted piston can be
used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measuring.
(b) Insert feeler gauge in the gap. The top compression ring gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
ring gap should be between 0.508-0.762 mm (0.0200.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be properly filed to the correct dimension. Rings with excess gaps should not be used.
(2) Install rings and confirm ring side clearance:
(a) Install oil rings being careful not to nick or
scratch the piston.
(b) Install the compression rings using Installation Tool C-4184. The top compression may be installed with either side up. The second compression
ring must be installed with the identification mark
face up (toward top of piston) and the chamfer
should face down. An identification mark on the
ring is a drill point, a stamped letter O, an oval
depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 2). Clearance should be 0.038-
9 - 104
5.2L ENGINE
INSTALLATION
(1) Be sure that compression ring gaps are staggered so that neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 3).
(3) Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385). Be sure position of rings
does not change during this operation.
(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, connecting rod cap and cylinder bore number are the
same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 Nzm (45 ft. lbs.) torque.
(9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine into the vehicle.
CRANKSHAFT
A crankshaft which has undersize journals will be
stamped with 1/4 inch letters on the milled flat on
the No.8 crankshaft counterweight (Fig. 4).
FOR EXAMPLE: R2 stamped on the No.8 crankshaft counterweight indicates that the No.2 rod journal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in)
undersize. R3 M2 indicates that the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 in)
undersize.
5.2L ENGINE
REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bearing cap.
(3) Remove the vibration damper.
(4) Remove the timing chain cover.
(5) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(6) Lift the crankshaft out of the block.
(7) Remove and discard the crankshaft rear oil
seals.
(8) Remove and discard the front crankshaft oil seal.
INSPECTION OF JOURNALS
The crankshaft connecting rod and main journals
should be checked for excessive wear, taper and scoring. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch).
Journal grinding should not exceed 0.305 mm
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and
clean out all oil passages.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction as the engine rotates.
CLEANING
Clean Loctite 515 residue and sealant from the cylinder block and rear cap mating surface. Do this before applying the Loctite drop and the installation of
rear cap.
9 - 105
INSTALLATION
(1) Lightly oil the new upper seal lips with engine
oil.
(2) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine
oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(6) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap
(Fig. 5). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant application.
9 - 106
5.2L ENGINE
5.2L ENGINE
(4) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(5) Position the crankshaft into the cylinder block.
(6) Lightly oil the new lower seal lips with engine
oil.
(7) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(8) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap
(Fig. 5). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant application.
(9) To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
(10) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 Nzm (85 ft. lbs.) torque.
(11) Install oil pump.
(12) Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 6). Apply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(13) Install new front crankshaft oil seal.
(14) Immediately install the oil pan.
9 - 107
9 - 108
5.2L ENGINE
CYLINDER BLOCK
Remove the engine assembly from the vehicle.
DISASSEMBLE
(1) Remove the cylinder head.
(2) Remove the oil pan.
(3) Remove the piston/connecting rod assembly.
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-ofround and taper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coordinated with the fitting of pistons and rings so
specified clearances may be maintained.
Refer to Standard Service Procedures in the beginning of this Group for the proper honing of cylinder
bores.
OIL LINE PLUG
The oil line plug is located in the vertical passage
at the rear of the block between the Oil-To-Filter and
Oil-From-Filter passages (Fig. 9). Improper installation or plug missing could cause erratic, low or no oil
pressure.
The oil plug must come out the bottom. Use flat
dowel, down the oil pressure sending unit hole from
the top, to remove oil plug.
(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 inch) finish wire or
equivalent into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to
7-11/16 inches) from machined surface of block (Fig.
9). If plug is too high, use a suitable flat dowel to position properly.
(4) If plug is too low, remove oil pan and rear main
bearing cap. Use suitable flat dowel to position properly. Coat outside diameter of new plug with Mopar
(Stud and Bearing Mount Adhesive), or equivalent.
Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16
inches) from bottom of the block.
(5) Assemble engine and check oil pressure.
5.2L ENGINE
9 - 109
INSTALLATION
(1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
CAUTION: DO NOT drive cup plug into the casting
as restricted coolant flow can result and cause serious engine problems.
(2) Using proper plug drive, drive cup plug into
hole. The sharp edge of the plug should be at least
0.50 mm (0.020 inch) inside the lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be filled and the vehicle
placed in service immediately.
ASSEMBLE
(1) Install the
(2) Install the
(3) Install the
(4) Install the
9 - 110
5.2L ENGINE
ENGINE SPECIFICATIONS
5.2L ENGINE
ENGINE SPECIFICATIONSCONT.
9 - 111
9 - 112
5.2L ENGINE
ENGINE SPECIFICATIONSCONT.
5.2L ENGINE
TORQUE SPECIFICATIONS
9 - 113
11 - 1
page
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 12
GENERAL INFORMATION
EXHAUST SYSTEM
The basic exhaust system consists of exhaust manifold(s), exhaust pipe, catalytic converter, heat
shield(s), muffler and tailpipe (Fig. 1).
The exhaust system uses a single muffler with a
single monolithic-type catalytic converter.
The exhaust manifolds are equipped with ball
flange outlets to assure a tight seal and strain free
connections.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the system contacts any body panel, it may amplify objectionable noises originating from the engine or body.
When inspecting an exhaust system, critically inspect for cracked or loose joints, stripped screw or
bolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to repair.
When replacement is required, use original equipment parts (or their equivalent). This will assure
proper alignment and provide acceptable exhaust
noise levels.
CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields. Light overspray near the
edges is permitted. Application of coating will result
in excessive floor pan temperatures and objectionable fumes.
CATALYTIC CONVERTER
The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may
occur. If a converter is heat-damaged, correct the
cause of the damage at the same time the converter
11 - 2
HEAT SHIELDS
11 - 3
SERVICE PROCEDURES
INDEX
page
Catalytic Converter . . . . . . . . . . . . . .
Exhaust Manifold3.9L / 5.2L Engines
Exhaust Pipe . . . . . . . . . . . . . . . . . .
Extension Pipe . . . . . . . . . . . . . . . . .
Heat Shield2.5L Engines . . . . . . . .
........... 4
. . . . . . . . . 11
........... 3
........... 4
........... 6
page
Heat Shield3.9L / 5.2L Engines . . . . .
Intake / Exhaust Manifolds2.5L Engine
Intake Manifold3.9L / 5.2L Engines . . .
Muffler . . . . . . . . . . . . . . . . . . . . . . . . .
Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . .
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EXHAUST PIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
(3) Remove the exhaust manifold-to-exhaust pipe
nuts (Fig. 1).
(4) On manual transmission vehicles, remove the
INSTALLATION
(1) Align and connect the exhaust pipe to the catalytic converter flange (Fig. 3).
(2) Connect the exhaust pipe to the exhaust manifold. Tighten the nuts to 27 Nzm (20 ft. lbs.) torque.
(3) On manual transmission vehicles, position the
spacer and clamp bolt onto the support bracket. Install the clamp bolt nuts and tighten to 47 Nzm (35
ft. lbs.) torque.
(4) Lower the vehicle.
6
6
9
4
5
11 - 4
CATALYTIC CONVERTER
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
(3) Remove the clamp nuts holding the catalytic
converter flange to the exhaust pipe (Fig. 3).
(4) Remove the clamp nuts holding the catalytic
converter flange to the extension pipe (Fig. 4) or muffler (Fig. 5 or 6).
(5) Remove the catalytic converter. You may have
to loosen up other sections of the exhaust system.
INSTALLATION
(1) Align and connect the catalytic converter flange
to the exhaust pipe (Fig. 3).
(2) Install the catalytic converter flange into the
extension pipe (Fig. 4) or muffler (Fig. 5 or 6).
(3) If other sections of the exhaust system where
loosened in removal, refer to that section for the
tightening procedures.
(4) At the catalytic converter flange connections,
install the clamp and nuts. Tighten the clamp nuts to
47 Nzm (35 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration.
(3) Remove the muffler clamp nuts from the front
(Fig. 5 or 6) and rear hanger (Fig. 7 or 8).
(4) Disconnect the muffler from the tailpipe. The
EXTENSION PIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration.
(3) Remove the front (Fig. 4) and rear clamp nuts
(Fig. 5 or 6).
(4) It may be necessary to loosen other sections of
the exhaust system to remove the extension pipe.
INSTALLATION
(1) Position the extension pipe in the muffler (Fig.
5 or 6) and the catalytic converter flange (Fig. 4).
(2) If other sections of the exhaust system where
loosened in removal, refer to the section for tightening procedures.
(3) Install the clamps and nuts. Tighten the nuts
to 47 Nzm (35 ft. lbs.) torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
INSTALLATION
(1) If the 2.5L engine front muffler support assembly (Fig. 5) was removed, install the bolts into the
frame. Tighten the bolts to 23 Nzm (200 in. lbs.)
torque.
(2) If the 3.9L or 5.2L engine upper front muffler
hanger (Fig. 6) was removed, install the bolts into
11 - 5
TAILPIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration.
(3) Loosen the nuts on the muffler rear hanger
clamp. (Fig. 7 or 8).
(4) Remove the tailpipe hanger clamp bolt. (Fig. 9).
(5) Remove the tailpipe.
11 - 6
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (refer to Group 7,
Cooling System for the proper procedure).
(3) Remove the air cleaner and disconnect all vacuum lines, electrical wiring and fuel lines from the
throttle body.
(4) Remove throttle linkage.
(5) Remove the throttle body mounting bolts and
lift the throttle body and gasket from the intake
manifold (Fig. 14). Discard the gasket.
(6) Remove power steering and air pump support
bracket.
(7) Remove power brake vacuum hose from intake
manifold.
(8) Remove diverter valve assembly and disconnect
air injection tube assembly from the exhaust manifold.
(9) Remove water hoses from water crossover.
(10) Raise vehicle and remove exhaust pipe from
the exhaust manifold.
(11) Remove the EGR tube (Fig. 15).
11 - 7
11 - 8
INSTALLATION
(1) Install a new intake and exhaust manifold gasket coated lightly on the manifold side with Mopar
Gasket Sealer, or equivalent.
(2) Set the exhaust manifold in place. Tighten the
retaining nuts, starting at center and progressing
outward in both directions, to 23 Nzm (200 in. lbs.)
torque. Repeat this procedure until all nuts are at
the specified torque.
(3) Set the intake manifold in place.
(4) Raise vehicle and torque retaining bolts, starting at the center and progressing outward in both directions, to 23 Nzm (200 in. lbs.) torque. Repeat this
procedure until all bolts are at the specified torque.
(5) Install the intake manifold strut. Tighten the
bolt to 95 Nzm (70 ft. lbs.) torque. Tighten the nut to
54 Nzm (40 ft. lbs.) torque.
(6) Install the EGR tube with a new gasket.
Tighten the attaching bolts to 23 Nzm (200 in. lbs.)
torque.
(7) Install exhaust pipe to the exhaust manifold.
Tighten the nuts to 27 Nzm (20 ft. lbs.) torque.
(8) Lower the vehicle.
(9) Connect the water hoses to the water crossover.
(10) Install diverter valve assembly and connect
air injection tube assembly to the exhaust manifold.
(11) Install power brake vacuum hose to the intake
manifold.
(12) Install power steering and air pump support
bracket.
(13) Install throttle linkage.
(14) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 20 Nzm
(175 in. lbs.) torque.
(15) Install the air cleaner and connect all vacuum
lines, electrical wiring and fuel lines to the throttle
body.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (refer to Group 7,
Cooling System for the proper procedures).
(3) Remove the generator (refer to Group 8B Battery/Starting/Charging Systems).
(4) Remove the air cleaner.
(5) Remove the fuel lines and fuel rail (refer to
Group 14, Fuel System).
(6) Disconnect the accelerator linkage and, if so
equipped, the speed control and transmission kickdown cables.
(7) Remove the return spring.
(8) Remove the distributor cap and wires.
(9) Disconnect the coil wires.
(10) Disconnect the heat indicator sending unit
wire.
(11) Disconnect the heater hoses and bypass hose.
(12) Remove the closed crankcase ventilation and
evaporation control systems.
(13) Remove intake manifold bolts.
(14) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(15) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(16) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 17). Discard the throttle body gasket.
11 - 9
(a) Turn the intake manifold upside down. Support the manifold.
(b) Remove the bolts and lift the pan off the
manifold. Discard the gasket.
CLEANING
Clean manifold in solvent and blow dry with compressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) Install the plenum pan, if removed, as follows:
(a) Turn the intake manifold upside down. Support the manifold.
(b) Place a new plenum pan gasket onto the seal
rail of the intake manifold. Position the pan over
the gasket. Align all the gasket and pan holes with
the intake manifold.
(c) Hand start all bolts.
(d) Tighten the bolts, in sequence (Fig. 18), as
follows:
11 - 10
11 - 11
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise the vehicle.
(3) Remove the bolts and nuts attaching the exhaust pipe to the exhaust manifold.
(4) Lower the vehicle.
(5) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(6) Remove manifold from the cylinder head.
CLEANING
Clean mating surfaces on cylinder head and manifold, wash with solvent and blow dry with compressed air. Inspect manifold for cracks.
INSPECTION
Inspect mating surfaces of manifold for flatness
with a straight edge. Seal surfaces must be flat
within 0.1 mm (0.004 inch) overall.
INSTALLATION
CAUTION: If the studs came out with the nuts
when removing the exhaust manifold, install new
studs.
(1) Position the exhaust manifolds on the two
studs located on the cylinder head. Install conical
washers and nuts on these studs (Figs. 23 and 24).
(2) Install new bolt and washer assemblies in the
remaining holes (Figs. 23 and 24). Start at the center
arm and work outward. Tighten the bolts and nuts to
24 Nzm (18 ft. lbs.) torque.
(3) Raise the vehicle.
11 - 12
TORQUE SPECIFICATIONS
13 - 1
page
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUMPERS
FRONT BUMPER
REMOVAL/DISASSEMBLY
(1) If equipped, disconnect the fog lamp wire harness connectors.
(2) Remove the retainers and separate the air dam
seal (Fig. 1) from the closure panel.
INSTALLATION
(1) If removed, position the air dam on the bumper
and install the bumper-to-air dam bolts and retainers
(Fig. 1). Tighten the nuts with 11 Nzm (95 in. lbs.)
torque.
(2) Position and support the bumper at the front of
the vehicle. Align the bumper bolt holes with the
support bracket and brace holes (Fig. 1).
(3) Install the bumper retaining bolts and nuts at
the support brackets and braces (Fig. 1). Ensure that
the bumper is correctly aligned with the closure
panel and the front fenders. Tighten the nuts with 41
Nzm (30 ft. lbs.) torque.
(4) Attach the air dam to the front fenders with
the nuts/retainers (Fig. 1).
(5) Attach the air dam seal to the closure panel
with the retainers (Fig. 1).
(6) If equipped, connect the fog lamp wire harness
connectors.
REAR BUMPER
Dakota rear bumpers are attached to the frame
rails with support brackets, braces, bolts and nuts.
13 - 2
BUMPER INSTALLATION
(1) Attach the support brackets and braces to the
bumper (Fig. 2) with the attaching bolts and nuts.
Tighten the support bracket nuts with 68 Nzm (50 ft.
lbs.) torque and the brace nuts with 41 Nzm (30 ft.
lbs.) torque.
(2) Use a jack or similar lifting device and position
the step bumper assembly at the rear of the vehicle.
(3) Align the support bracket and brace holes with
frame rail holes and install the bracket attaching
bolts and nuts (Fig. 2). Tighten the support bracket
nuts with 68 Nzm (50 ft. lbs.) torque and the brace
nuts with 41 Nzm (50 ft. lbs.) torque.
(4) Ensure that the bumper is correctly aligned
with the cargo box rear corner panels.
(5) Connect the license plate lamp bulb sockets to
the lamps and attach the wire harness to the bumper
with the clip retainers (Fig. 3).
13 - 3
SNOW PLOW
INDEX
page
page
SERVICE INFORMATION
13 - 4
SYSTEM OPERATION
Refer to Figures 2 through 5 for voltage application
and hydraulic fluid flow for each snow plow function.
Each figure shows the components that are actuated
for each function.
13 - 5
13 - 6
Fig. 3 Lower & Float BladeVoltage Application & Hydraulic Fluid Flow
13 - 7
13 - 8
13 - 9
13 - 10
13 - 12
13 - 13
(23) Disassemble the three-way valve (Fig. 9). Discard the O-ring seal.
(24) Remove and clean solenoid valve C with special tool J-25399 (Fig. 9). Inspect the solenoid valve
for external damage.
(25) Disassemble the four-way valve (Fig. 12). Discard the O-ring seals (Fig. 12).
(26) Test solenoid valve B and C coils for electrical
continuity. The normal coil DC resistance is 3.7 ohms.
(27) Remove the pilot check valve plug, the spring
and the ball from the bottom of the valve block.
(28) Inspect the spring for damage and the ball
seat for nicks.
(29) Remove the acorn nut for access to the crossover valve components (Fig. 9).
(30) Remove the crossover valve components (Fig. 13).
Inspect for external damage. Discard the O-ring seals.
(31) Clean the block with compressed air to remove
all foreign material.
ASSEMBLY
Verify that all components are thoroughly clean
and free of foreign material. Use replacement gaskets
and seals during assembly. Petroleum jelly should
used for installing the rubber O-ring seals.
(1) Install the crossover valve components in the
valve block with replacement O-ring seals (Fig. 13).
(2) Install the ball, spring and pressure plug with
a replacement O-ring seal in the bottom of the valve
block (Fig. 13).
(3) Assemble solenoid valve C with replacement Oring seals and nylon retainer rings (Fig. 12).
(4) Install solenoid valve C with Tool J-25399 (Fig. 9).
(5) Assemble solenoid valve B with replacement Oring seals.
(6) Install the ball, spring and solenoid valve B
with Tool J-25399 (Fig. 9).
(7) Install the valve block and the replacement Oring seals on the pump base.
(8) Install the retainer, the spring, the ball, the insert valve and the pump housing with replacement
O-ring seals (Fig. 11). Tighten the pump housing
base nuts to 11.3 Nzm (100 in. lbs.) torque.
(9) Install the filters and the plugs with replacement O-ring seals (Fig. 9).
(10) Install solenoid valve A cartridge in the pump
base with replacement O-ring seals (Fig. 9).
(11) Install solenoid valve A coil (Fig. 9).
(12) Install the motor on the pump housing (Fig.
9). Engage the gear shaft tang with the notch in the
motor output shaft. Tighten the motor housing capscrews to 5 Nzm (45 in. lbs.) torque.
(13) Install the ram and piston with replacement
O-ring seals (Fig. 9).
(14) Position the cover on the reservoir. Secure it
with locknuts (Fig. 9). Tighten the locknuts to 11.3
Nzm (100 in. lbs.) torque.
13 - 14
13 - 15
13 - 16
INSTALLATION
(1) Position and support the snow plow frame at
the front of the vehicle frame with the bolt holes
aligned (Fig. 15).
(2) Install the snow plow frame attaching bolts,
washers and nuts finger-tight (Fig. 15).
(3) Install the support strap attaching bolts and
nuts finger-tight (Fig. 15).
(4) Install the bumper bracket attaching bolts and
nuts finger-tight (Fig. 15).
(5) Tighten all the attaching nuts to 68 Nzm (50 ft.
lbs.) torque.
(6) Remove the support from under the snow plow
frame.
13 - 17
INSTALLATION
(1) Position and support the pivot bracket at the
vehicle frame rails with the bolt holes aligned (Fig.
16).
(2) Install the pivot bracket attaching bolts, washers and nuts finger-tight (Fig. 16).
(3) Install the support strap attaching bolts and
nuts (Fig. 15). Tighten the nuts to 68 Nzm (50 ft. lbs.)
torque.
(4) Tighten the pivot bracket attaching nuts to 68
Nzm (50 ft. lbs.) torque.
(5) Remove the support from under the pivot
bracket.
13 - 18
ASSEMBLY/INSTALLATION
(1) Insert the auxiliary headlamp switch in the
switch cover opening. Carefully push inward until it
is completely seated against the cover face (Fig. 18).
13 - 19
13 - 20
page
Frame Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 21
Frame Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Frame Straightening . . . . . . . . . . . . . . . . . . . . . . . 20
General Information . . . . . . . . . . . . . . . . . . . . . . . 20
Safety Precautions and Warnings . . . . . . . . . . . . . 20
WARNING: USE EYE PROTECTION WHEN GRINDING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
BEFORE PROCEEDING WITH FRAME REPAIR INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
DO NOT ALLOW OPEN FLAME TO CONTACT PLASTIC BODY PANELS. FIRE OR EXPLOSION CAN RESULT.
WHEN WELDED FRAME COMPONENTS ARE REPLACED, 100% PENETRATION WELD MUST BE
ACHIEVED DURING INSTALLATION. IF NOT, DANGEROUS OPERATING CONDITIONS CAN RESULT.
STAND CLEAR OF CABLES OR CHAINS ON PULLING EQUIPMENT DURING FRAME STRAIGHTENING
OPERATIONS, PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect.
Do not drill holes in top or bottom frame rail
flanges, frame rail failure can result.
Do Not use softer than Grade 3 bolts to replace production fasteners, loosening or failure can result.
When using heat to straighten frame components do
not exceed 566C (1050F), metal fatigue can result.
Welding the joints around riveted cross members
and frame side rails can weaken frame.
GENERAL INFORMATION
Dakota vehicles have a ladder-type frame (Fig. 1)
that has:
A box-section front.
A dropped center.
Open-channel side rails in the rear.
As applicable, the frame crossmembers are securely
attached to the side rails by either rivets, welds or
bolts to form a ladder-shaped frame (Fig. 1). The cab
is attached from the frame with rubber load cushions
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566C (1050F).
The metal will have a dull red glow at the desired
temperature. Excessive heat will decrease the
strength of the metal and result in a weakened
frame.
Welding the joints around riveted cross members
and frame side rails is not recommended.
A straightening repair process should be limited to
frame members that are not severely damaged. The
replacement bolts, nuts and rivets that are used to
join the frame members should conform to the same
specifications as the original bolts, nuts and rivets.
FRAME REPAIRS
DRILLING HOLES
Do not drill holes in frame side rail top and bottom
13 - 21
WELDING
Use MIG, TIG or arc welding equipment to repair
welded frame components.
Frame components that have been damaged should
be inspected for cracks before returning the vehicle
to use. If cracks are found in accessible frame components perform the following procedures.
(1) Drill a hole at each end of the crack with a 3
mm (O.125 in.) diameter drill bit.
(2) Using a suitable die grinder with 3 inch cut off
wheel, V-groove the crack to allow 100% weld penetration.
(3) Weld the crack.
(4) If necessary when a side rail is repaired, grind
the weld smooth and install a reinforcement channel
(Fig. 2) over the repaired area.
If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches
narrower than the side rail flanges. Weld only
in the areas indicated (Fig. 2).
FRAME FASTENERS
Bolts, nuts and rivets can be used to repair frames
or to install a reinforcement section on the frame.
Bolts can be used in place of rivets. When replacing
rivets with bolts, install the next larger size diameter
bolt to assure proper fit. If necessary, drill the hole
out just enough to receive the bolt.
FRAME DIMENSIONS
Frame dimensions are listed in inch scale. All dimensions are from center to center of Principal Locating Point (PLP), or from center to center of PLP
and fastener location (Fig. 3, 4, 5, 6, 7, 8, 9, 10, 11,
12, 13, and 14).
13 - 22
FRAME AND BUMPERS
13 - 24
FRAME AND BUMPERS
13 - 26
FRAME AND BUMPERS
13 - 28
FRAME AND BUMPERS
13 - 30
FRAME AND BUMPERS
13 - 32
FRAME AND BUMPERS
13 - 34
page
Service Information . . . . . . . . . . . . . . . . . . . . . . . . 34
Skid Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SERVICE INFORMATION
It may be necessary to refer to the component removal procedure for service access.
INSTALLATION
(1) Position and support the skid plate at the front
crossmembers (Fig. 2).
(2) Install the screws to attach the skid plate to
the crossmembers (Fig. 2). Tighten the screws with
23 Nzm (200 in. lbs.) torque.
(3) Remove the support from under the skid plate.
INSTALLATION
(1) Position the splash shield/air deflector on the
side rails and crossmember (Fig. 1).
(2) Attach the splash shield/air deflector to the
side rails and crossmember with screws (Fig. 1).
Tighten the screws with 23 Nzm (200 in. lbs.) torque.
SKID PLATES
REMOVAL
(1) Position a support under the skid plate.
(2) Remove the screws that attach the skid plate to
the crossmembers (Fig. 3).
(3) Remove the support and the skid plate from
the crossmembers (Fig. 3).
13 - 35
INSTALLATION
(1) Position and support the skid plate at the
crossmembers (Fig. 3).
(2) Install the screws to attach the skid plate to
the crossmembers (Fig. 3). Tighten the screws with
23 Nzm (200 in. lbs.) torque.
(3) Remove the support from under the skid plate.
REMOVAL
(1) At each side of the vehicle, remove the nuts
and bolts that attach the support crossmember to the
frame side rail (Fig. 5).
13 - 36
FUEL SYSTEM
14 - 1
FUEL SYSTEM
CONTENTS
page
page
67
21
43
32
92
GENERAL INFORMATION
Throughout this group, references are made to particular vehicle models by alphabetical designation or
by the particular vehicle nameplate. A chart showing
a breakdown of the alphabetical designations is included in the Introduction section at the beginning of
this manual.
All vehicles are equipped with either: a 2.5L 4-cylinder, a 3.9L V-6 or a 5.2L (V-8) engine.
The Fuel System consists of: the fuel tank, an
electric (fuel tank mounted) fuel pump, a separate
frame mounted fuel filter (2.5L engine only), a combination fuel filter/pressure regulator (3.9L and 5.2L
engines only), the pressure relief/rollover valve and a
pressure-vacuum fuel filler cap. It also consists of
fuel tubes/lines/hoses, vacuum hoses, throttle body
and fuel injector(s).
The Fuel Delivery System consists of: the electric
fuel pump, fuel filter, fuel tubes/lines/hoses, fuel rail,
fuel injectors and fuel pressure regulator. On 3.9L
V-6 and 5.2L V-8 engines, a combination fuel filter
and fuel pressure regulator are mounted to the top of
the fuel pump module.
A Fuel Return System is used on all vehicles (all
engines). On the 2.5L 4-cylinder engine, the system
consists of a throttle body mounted fuel pressure regulator and the fuel tubes/lines/hoses that route fuel
from the engine and return it to the fuel tank. On
3.9L or 5.2L engines, fuel is returned through the
fuel pump module and back into the fuel tank
through the fuel filter/fuel pressure regulator. A separate fuel return line from the engine to the tank is
no longer used on any 3.9L V-6 or 5.2L V-8 engine.
The Fuel Tank Assembly consists of: the fuel
tank, the filler tube, a fuel gauge sending unit/electric fuel pump module, a combination fuel filter/pres-
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
materials that contain oxygen such as alcohol, MTBE
14 - 2
FUEL SYSTEM
MTBE/ETBE
Gasoline and MTBE (Methyl Tertiary Butyl Ether)
blends are a mixture of unleaded gasoline and up to
15 percent MTBE. Gasoline and ETBE (Ethyl Tertiary Butyl Ether) are blends of gasoline and up to
17 percent ETBE. Gasoline blended with MTBE or
ETBE may be used in your vehicle.
CLEAN AIR GASOLINE
Many gasolines are now being blended that contribute to cleaner air, especially in those areas of the
country where air pollution levels are high. These
new blends provide a cleaner burning fuel and some
are referred to as Reformulated Gasoline.
In areas of the country where carbon monoxide levels are high, gasolines are being treated with oxygenated materials such as MTBE, ETBE and ethanol.
Chrysler Corporation supports these efforts toward
cleaner air and recommends that you use these gasolines as they become available.
14 - 3
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
Fuel
page
page
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filter/Fuel Pressure Regulator . . . . . . . . . . . . . 5
Line with Latch Clip . . . . . . . . . . . . . . . . . . . . 13
Pressure Leak Down Test3.9L/5.2L Engine . . 9
Pump Capacity Test3.9L/5.2L Engine . . . . . . 9
Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump Module2.5L Engine . . . . . . . . . . . . . . 3
14 - 4
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE RELEASED.
CAUTION: Whenever the fuel pump module is serviced, the locknut and gasket must be replaced.
(1) Drain the fuel tank. Refer to Draining Fuel
Tank in the Fuel Tank section of this group.
(2) Remove fuel tank. Refer to the Fuel Tank section of this group.
The powertrain control module (PCM) computer energizes the fuel pump through the fuel pump relay.
Battery voltage is applied to the relay from the ignition switch. The coil in the relay is energized when a
ground is provided by the PCM. The relay is located
in the power distribution center (PDC) (Fig. 5). For
location of relay within the PDC, refer to label under
PDC cover.
14 - 5
FUEL FILTER
2.5L ENGINE ONLY
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL FILTER, THE FUEL
SYSTEM PRESSURE MUST BE RELEASED.
(1) Perform the Fuel System Pressure Release procedure.
(2) Disconnect negative battery cable from battery.
(3) Raise and support the vehicle.
(4) Remove filter retaining bolt and remove filter
assembly from mounting plate (Fig. 6).
(5) Loosen hose clamps on filter and hoses (Fig. 6).
(6) Wrap a shop towel around hoses to absorb fuel.
Remove hoses at filter and fuel tube and remove filter from vehicle.
(7) Discard hose clamps.
INSTALLATION
CAUTION: The tubes/hoses used on fuel injected
vehicles are of a special construction. This is due
to the higher fuel pressures and the possibility of
contaminated fuel in this system. If it is necessary
to replace these tubes/hoses, only tubes/hoses
marked EFM/EFI may be used.
CAUTION: The hose clamps used on fuel injected
vehicles are of a special rolled edge construction to
prevent the edge of the clamp from cutting into the
hose. Only these rolled edge type clamps may be
used in this system. All other types of clamps may
cut into the hoses and cause high-pressure fuel
leaks.
14 - 6
INSTALLATION
(1) Install a new clamp over the plastic fuel tube.
14 - 7
2.5L ENGINE
(1) Loosen fuel tank filler tube cap to release fuel
tank pressure.
(2) Disconnect fuel injector wiring harness from
engine harness.
(3) Connect one end of a jumper wire (18 gauge or
smaller) to ground terminal number-1 of the injector
harness (Fig. 13). Connect the other end of jumper to
engine ground.
(4) Connect one end of a jumper wire (18 gauge or
smaller) to the positive terminal number-2 of the injector harness (Fig. 13). Touch the other end of
jumper to positive battery post for no longer than 5
seconds. This releases fuel system pressure.
(5) Remove jumper wires.
(6) Continue fuel system service.
14 - 8
3.9L/5.2L ENGINE
(1) Disconnect negative battery cable.
(2) Remove the fuel tank filler tube cap to release
fuel tank pressure.
(3) Remove protective cap from pressure test port
on the fuel rail (Fig. 14).
14 - 9
14 - 10
MECHANICAL MALFUNCTIONS
Mechanical malfunctions are more difficult to diagnose with this system. The powertrain control module (PCM) has been programmed to compensate for
some mechanical malfunctions such as incorrect cam
timing, vacuum leaks, etc. If engine performance
problems are encountered and diagnostic trouble
codes are not displayed, the problem may be mechanical rather than electronic.
QUICK-CONNECT FITTINGS
Also refer to the previous Fuel Tubes/Lines/Hoses
and Clamps section.
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type.
SINGLE-TAB TYPE
This type of fitting is equipped with a single pull
tab (Fig. 17). The tab is removable. After the tab is
removed, the quick-connect fitting can be separated
from the fuel system component.
14 - 11
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
DISCONNECTION/CONNECTION
(1) Disconnect negative battery cable from the battery.
14 - 12
14 - 13
14 - 14
FUEL TANKS
FUEL TANKS
INDEX
page
Fuel
Fuel
Fuel
Fuel
Fuel
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16
16
16
15
15
page
Fuel Tank Pressure Relief/Rollover Valve
Fuel Tanks . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . .
Heat Shields . . . . . . . . . . . . . . . . . . . . .
No-Lead Fuel Tank Filler Tube . . . . . . . .
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16
15
14
15
14
GENERAL INFORMATION
These vehicles pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and vapor flow controls are required for all fuel tank connections.
All models are equipped with a pressure relief/rollover valve mounted in the top of the fuel pump module (Figs. 1 or 2). On 2.5L 4-cylinder engines, the
return line from the fuel pump to the fuel tank contains a one-way check valve.
FUEL TANKS
14 - 15
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE DRAINING THE FUEL TANK, THE FUEL
SYSTEM PRESSURE MUST BE RELEASED.
HEAT SHIELDS
The sheet metal heat shields must be removed
when servicing the fuel tank, fuel lines or vapor vent
line. The heat shields must be installed to protect the
lines and tank from the heat of the exhaust system.
Refer to Group 11, Exhaust System and Intake Manifold for proper installation.
FUEL TANKS
The standard equipment fuel tank on all models is
located between the left frame structure and the pro-
14 - 16
FUEL TANKS
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove fuel tank filler tube cap before disconnecting any fuel or vent lines. The fuel tank could be
under a small pressure.
(3) Drain fuel tank. Refer to Draining Fuel Tank in
this section.
WARNING: WRAP SHOP TOWELS AROUND FUEL
FILLER HOSES TO ABSORB ANY GASOLINE THAT
MIGHT SPILL.
(4) Raise vehicle on hoist and disconnect all vent
hoses and filler hose (Fig. 4). Remove the vent hoses
from hose routing bracket attached to the top of the
frame rail.
FUEL PUMPREMOVAL/INSTALLATION
The electric fuel pump is not serviceable. If the fuel
pump needs replacement, the complete fuel pump
module must be replaced. Refer to Fuel Pump Module in the Fuel Delivery System section of this group.
INSTALLATION
(1) Place fuel tank on top of transmission jack.
Raise tank up enough to connect the fuel tubes
(lines) to the fuel pump module. Refer to Quick-Connect Fittings in the Fuel Delivery System section.
FUEL RESERVOIR
The fuel reservoir (Fig. 6) is part of the lower end
of the fuel pump module. The purpose of the reservoir is to provide fuel at the pump intake during all
driving conditions. This is when low fuel levels are
present. The fuel return line directs fuel into the reservoir (2.5L engine only).
FUEL TANKS
14 - 17
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank draining
and removal in this section of the group.
INSTALLATION
(1) Install the rubber grommet in the fuel tank
and work it around the curled lip.
(2) Lubricate the grommet with power steering
fluid and push the valve downward into the grommet. Twist valve until properly positioned.
(3) Install fuel tank. Refer to Fuel Tank Installation in this section of the group.
14 - 18
page
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Information . . . . . . . . . . . . . . . . . . . . . . . 18
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
GENERAL INFORMATION
All engines are equipped with torsion return
springs located on the throttle body shaft. 3.9L V-6
and 5.2L V-8 engines equipped with a manual transmission have an additional pedal return spring (Fig.
1). All of these springs are designed to give positive
throttle return while meeting safety requirements.
ACCELERATOR PEDAL
CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables.
REMOVAL
(1) From inside the vehicle, hold up accelerator
pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 2).
Plastic cable retainer snaps into pedal arm.
INSTALLATION
(1) Position pedal/bracket assembly over the two
dash panel mounting studs and install retaining
nuts.
(2) Tighten nuts to 7 Nzm (65 in. lbs.) torque.
(3) From inside the vehicle, hold up the accelerator
pedal. Install the throttle cable core wire and plastic
cable retainer into the upper end of the pedal arm.
The plastic retainer is snapped into the pedal arm.
When installing the plastic retainer to the accelerator pedal arm, note the index tab on the pedal arm
(Fig. 3). Align the index slot (Fig. 3) on the plastic cable retainer to this index tab.
THROTTLE CABLE
14 - 19
CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables.
REMOVAL
(1) From inside the vehicle, hold up accelerator
pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 2).
Plastic cable retainer snaps into pedal arm.
(2) Remove the cable core wire at the pedal arm.
(3) From inside the vehicle, pinch both sides of the
cable housing retainer at the dash panel (Fig. 2). Remove cable housing from dash panel and pull into
the engine compartment.
(4) 2.5L Engine:
(a) Remove the cable slug from the throttle body
cam.
(b) Separate the cable mounting bracket with
wide-jaw pliers by compressing the end-fitting tabs
(Fig. 4).
3.9L/5.2L Engine:
(a) Remove the air cleaner housing.
(b) Operate the throttle body cam (by hand) to
the full open throttle position (Fig. 5).
(c) Slip the pin on the end of cable from the hole
in the throttle body cam (Fig. 5).
(d) Remove cable from cam.
(e) Remove cable housing at throttle body mounting bracket by pressing forward on release tab with
a small screwdriver (Fig. 6). To prevent cable
housing breakage, press on the tab only
enough to release the cable from the bracket.
(f) Lift the cable housing straight up from
bracket while pressing on release tab.
(g) Disconnect cable from radiator fan shroud
routing clip.
(5) Remove cable from vehicle.
14 - 20
14 - 21
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25
23
26
23
23
26
23
23
27
27
30
27
21
27
GENERAL INFORMATION
The Single-Port Electronic Fuel Injection System
(Fig. 1) used in vehicles equipped with the 2.5L engine is a computer regulated system. It provides a
precise air/fuel ratio for all driving conditions. Fuel is
supplied to the engine through a fuel injector located
in the throttle body.
The fuel injection system is controlled by the powertrain control module (PCM). The PCM was formerly referred to as the SBEC or engine controller.
The PCM is a pre-programmed, microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, engine
cooling fan, idle speed, air conditioning, fuel pump
and the tachometer. The PCM can adapt its programming to meet changing operating conditions.
Various sensors provide the inputs necessary for
the PCM to correctly regulate fuel flow at the injector. These include the manifold absolute pressure,
throttle position, exhaust gas oxygen content, engine
coolant temperature, throttle body temperature, engine speed and vehicle speed sensors. In addition to
the sensors, various switches and relays provide important information and system control. These include the air conditioning switch, brake switch and
automatic shutdown relay.
All inputs to the PCM are converted into signals.
Air-fuel ratio, ignition timing and other controlled
outputs are adjusted based on these inputs. The
PCM adjusts the air-fuel ratio by changing the injector pulse width. Injector pulse width is the period of
time that the injector is energized by the PCM.
page
Idle Air Control (IAC) MotorPCM Output . . . . .
Ignition CoilPCM Output . . . . . . . . . . . . . . . . .
Malfunction Indicator LampPCM Output . . . . .
Manifold Absolute Pressure (MAP) SensorPCM
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open Loop/Closed Loop Modes of Operation . . .
Oxygen (O2S) SensorPCM Input . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . . . . . . .
Radiator Cooling Fan RelayPCM Output . . . . .
Thermal Vacuum Valve (TVV) . . . . . . . . . . . . . .
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body Temperature SensorPCM Input .
Throttle Position Sensor (TPS)PCM Input . . . .
Vehicle Speed SensorPCM Input . . . . . . . . . .
. . 27
. . 28
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24
28
24
21
28
30
30
25
25
25
SYSTEM DIAGNOSIS
The powertrain control module (PCM) tests many
of its own input and output circuits. If a Diagnostic
Trouble Code (DTC) is found in a major system, this
information is stored in the PCM memory. Refer to
On-Board Diagnostics in the Single-Port Fuel InjectionGeneral Diagnosis2.5L Engine section of this
group for DTC information.
14 - 22
14 - 23
14 - 24
14 - 25
14 - 26
14 - 27
When the solenoid is energized by the PCM, it prevents vacuum from reaching the EGR valve transducer and EGR valve. The solenoid is energized
during engine warm-up, closed throttle (idle), wide
open throttle and rapid acceleration/deceleration. If
the solenoid wire connector is disconnected, the EGR
valve function will be operational at all times.
Refer to Group 25, Emission Control System for
more information.
GENERATORPCM OUTPUT
The powertrain control module (PCM) regulates the
charging system voltage within a range of 12.9 to
15.0 volts. Refer to Group 8A for charging system information.
14 - 28
MODES
Open Loop
Closed Loop
During Open Loop modes, the powertrain control
module (PCM) receives input signals and responds
only according to preset internal programming. Input
from the oxygen (O2S) sensor is not monitored during Open Loop modes.
During Closed Loop modes, the powertrain control
module (PCM) will monitor the oxygen (O2S) sensor
input. This input indicates to the PCM whether or
not the calculated injector pulse width results in the
ideal air-fuel ratio. This ratio is 14.7 parts air to 1
part fuel. By monitoring the exhaust oxygen content
through the O2S sensor, the PCM can fine tune the
14 - 29
14 - 30
DECELERATION MODE
This is a Closed Loop mode. During deceleration,
the following inputs are received by the powertrain
control module (PCM):
Engine coolant temperature
Manifold absolute pressure
Engine speed
Throttle position
Exhaust gas oxygen content
Vehicle speed sensor
Air Conditioning (A/C) control positions
A closed throttle input, along with an abrupt decrease in manifold pressure, indicates to the PCM
that the vehicle is in a hard deceleration. The PCM
may reduce injector firing to just once per engine
revolution to lean the air-fuel mixture. This is sensed
through the O2S sensor during hard deceleration.
The PCM grounds the EGR and EVAP purge solenoids. This stops EGR operation and EVAP canister
purge functions.
WIDE OPEN THROTTLE MODE
This is an Open Loop mode. During wide-openthrottle operation, the following inputs are received
by the powertrain control module (PCM):
Engine coolant temperature
Manifold absolute pressure
Engine speed
Throttle position
When the PCM senses wide open throttle condition
through the throttle position sensor (TPS), it will
provide a ground for the EGR solenoid. This will prevent any EGR functions.
The exhaust gas oxygen content input is not accepted by the PCM. It will adjust injector pulse
width to supply a predetermined amount of additional fuel.
IGNITION SWITCH OFF-MODE
This is an Open Loop mode. When the ignition
switch is turned to the Off position, the powertrain
control module (PCM) ceases to provide a ground for
the auto shutdown (ASD) relay. Battery voltage is
disconnected from the fuel pump, fuel injector, ignition coil and oxygen sensor heating element. This is
done when the ASD relay is not energized. All fuel
injection stops.
THROTTLE BODY
The throttle body assembly (Fig. 16) is mounted on
top of the intake manifold. It contains:
The fuel injector
The fuel pressure regulator
The throttle position sensor (TPS)
The idle air control (IAC) motor
The throttle body temperature sensor
Air flow through the throttle body is controlled by
a cable operated throttle blade. This throttle is located in the base of the throttle body. The throttle
body itself provides the chamber for metering, atomizing and mixing fuel with the air entering the engine.
14 - 31
14 - 32
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39
39
32
36
36
page
Oxygen (O2S) Sensor Heating Element Test
PCM System Schematics . . . . . . . . . . . . .
Throttle Body Minimum Air Flow Check . . .
Vehicle Speed Sensor Test . . . . . . . . . . . .
Visual Inspection . . . . . . . . . . . . . . . . . . . .
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35
36
36
35
32
GENERAL INFORMATION
VISUAL INSPECTION
The fuel injection system is managed by the powertrain control module (PCM). The PCM was formerly referred to as the SBEC or engine controller.
The PCM receives inputs from various switches and
sensors (Fig. 1). Based on these inputs, the PCM adjusts ignition timing and idle speed through output
devices. Refer to the previous section of this group
for system operation and component descriptions.
A visual inspection for loose, disconnected, or incorrectly routed wires and hoses should be made. This
should be done before attempting to diagnose or service the fuel injection system. A visual check will
help spot these faults and save unnecessary test and
diagnostic time. A thorough visual inspection will include the following checks:
14 - 33
(1) Verify that the 60-way connector is fully inserted into the socket on the powertrain control module (PCM). Also verify that the mounting screw is
tight (Fig. 2).
14 - 34
14 - 35
(21) Verify that 2-way connector is attached to engine coolant temperature Sensor (Fig. 11).
(22) Verify that negative battery ground eyelet is
mounted to the rear of the cylinder head (Fig. 11).
14 - 36
14 - 37
14 - 38
MONITORED CIRCUITS
The powertrain control module (PCM) can detect
certain problems in the fuel injection system.
Open or Shorted Circuit - The PCM can determine if sensor output (which is the input to PCM) is
within proper range. It also determines if the circuit
is open or shorted.
Output Device Current Flow - The PCM senses
whether the output devices are hooked up.
If there is a problem with the circuit, the PCM
senses whether the circuit is open, shorted to ground
(-), or shorted to (+) voltage.
Oxygen Sensor - The PCM can determine if the
oxygen sensor is switching between rich and lean.
This is, once the system has entered Closed Loop. Refer to Open Loop/Closed Loop Modes Of Operation in
the Component Description/System Operation section
for an explanation of the Closed (or Open) Loop operation.
NON-MONITORED CIRCUITS
The PCM does not monitor the following circuits,
systems or conditions that could have malfunctions
that result in driveability problems. A Diagnostic
Trouble Code (DTC) may not be displayed for these
conditions.
Fuel Pressure Fuel pressure is controlled by the
fuel pressure regulator. The PCM cannot detect a
clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply or return line. However,
these could result in a rich or lean condition causing
an oxygen sensor DTC to be stored in the PCM.
Secondary Ignition Circuit: The PCM cannot
detect an inoperative ignition coil, fouled or worn
spark plugs, ignition cross firing, or open circuited
spark plug cables.
Engine Timing: The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket or
crankshaft sprocket. The PCM also cannot detect an
incorrectly indexed distributor. However, these could
result in a rich or lean condition causing an oxygen
sensor DTC to be stored in the PCM.
14 - 39
could also indicate that battery voltage has been disconnected to the PCM. In either case, other DTCs
may have been erased.
If the lamp flashes 4 times, pauses and flashes 1
more time, a Diagnostic Trouble Code (DTC) number
41 is indicated.
If the lamp flashes 4 times, pauses and flashes 6
more times, a Diagnostic Trouble Code (DTC) number 46 is indicated.
After any stored DTC information has been observed, the display will end with a flashing DTC
number 55. This will indicate the end of all stored information.
Refer to the Diagnostic Trouble Code (DTC) charts
for DTC identification.
If the problem is repaired or ceases to exist, the
powertrain control module (PCM) cancels the DTC
after 51 engine starts.
Diagnostic Trouble Codes indicate the results of a
failure, but never identify the failed component directly.
14 - 40
Diagnostic
Trouble Code
11**
12*
Battery Disconnect
13**
14**
or
MAP Sensor Voltage Too High
15**
No vehicle distance (speed) sensor signal detected during road load conditions.
17*
21**
or
22**
or
23**
or
24**
or
Throttle Position Sensor Voltage Low
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle
Ignition key as described in manual and observe code flashed by Check Engine lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
14 - 41
25**
27*
or
Injector #2 Control Circuit
or
Injector #3 Control Circuit
or
Injector #4 Control Circuit
31**
32**
or
EGR System Failure
33*
34*
or
Speed Control Switch Always Low
or
Speed Control Switch Always High
35*
41**
42*
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle
Ignition key as described in manual and observe code flashed by Check Engine lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
14 - 42
Diagnostic
Trouble Code
44*
An open or shorted condition exists in the engine coolant temperature sensor circuit or a
problem exists in the PCMs battery temperature voltage circuit.
46**
47**
51**
52**
53*
or
PCM Failure SRI Communications
55*
62*
63*
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle
Ignition key as described in manual and observe code flashed by Check Engine lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
14 - 43
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43
43
43
43
43
44
44
44
44
45
46
46
46
46
46
page
Fuel Tubes/Lines/Hoses and Clamps . . . .
Idle Air Control (IAC) Motor . . . . . . . . . . .
Ignition Coil . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold . . . . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor
Oxygen (O2S) Sensor . . . . . . . . . . . . . . .
Park/Neutral Switch . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . .
Quick-Connect Fittings . . . . . . . . . . . . . .
Throttle Body . . . . . . . . . . . . . . . . . . . . .
Throttle Body Fittings . . . . . . . . . . . . . . .
Throttle Body Temperature Sensor . . . . . .
Throttle Position Sensor . . . . . . . . . . . . .
Vehicle Speed Sensor . . . . . . . . . . . . . . .
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46
46
47
47
47
47
47
48
48
48
49
49
50
50
REMOVAL/INSTALLATION
(1) Unsnap the four clips at the top of air cleaner
housing cover (Fig. 1).
(2) Lift the cover and remove the air cleaner element.
(3) Clean the inside of housing before installing
new element.
(4) Reverse the preceding steps for installation.
BRAKE SWITCH
Refer to Group 5, Brakes for removal/installation
procedures.
14 - 44
FUEL INJECTOR
REMOVAL
(1) Remove air cleaner assembly.
(2) Perform the fuel system pressure release procedure.
(3) Disconnect negative battery cable.
(4) Remove the Torx screw holding down the injector cap.
(5) With two small screwdrivers, lift the cap off the
injector using the provided slots(Fig. 4).
REMOVAL
(1) Partially drain cooling system. Refer to Group
7, Cooling System.
(2) Disconnect electrical connector from sensor
(Fig. 3).
(3) Remove sensor.
FUEL FILTER
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
14 - 45
INSTALLATION
(1) Place a new lower o-ring on the injector and a
new o-ring on the injector cap. The injector will have
the upper o-ring already installed (Fig. 6).
(2) Apply a light coating of clean engine oil on the
o-rings.
(3) Place assembly in the pod and align the injector wiring terminals with the injector cap fastener
hole (Fig. 7).
REMOVAL
(1) Remove air cleaner assembly.
(2) Perform Fuel System Pressure Release procedure.
(3) Disconnect negative battery cable at battery.
(4) Remove pressure regulator-to-throttle body
screws.
WARNING: PLACE A SHOP TOWEL AROUND FUEL
INLET CHAMBER TO ABSORB ANY RESIDUAL
FUEL REMAINING IN THE SYSTEM.
(5) Pull pressure regulator from the throttle body.
(6) Carefully remove o-ring from pressure regulator. Remove gasket.
14 - 46
FUEL TANKS
Fig. 10 Servicing Fuel Pressure Regulator
INSTALLATION
(1) Place new gasket on pressure regulator and
carefully install new o-ring.
(2) Position pressure regulator on throttle body.
Press into place. Install screws and tighten to 5 Nzm
(40 in. lbs.) torque.
(3) Connect battery cable to battery.
(4) Test for leaks using DRB scan tool. With key in
the Run position, use DRB Special Functions Test
ASD Fuel System Test. This will activate pump and
pressurize the system. Check for leaks.
(5) Install air cleaner assembly.
Refer to the Fuel Tank section of this group for removal/installation procedures.
REMOVAL
(1) Remove air cleaner.
(2) Disconnect negative battery cable at battery.
(3) Disconnect 4-pin connector on IAC motor.
(4) Remove throttle body temperature sensor from
throttle body housing.
(5) Remove IAC motor mounting screws (Torx head
screws 25 mm long).
(6) Remove IAC motor from throttle body housing,
making sure that o-ring remains on control motor.
14 - 47
INSTALLATION
(1) Be sure that the IAC motor pintle is in the retracted position. If pintle measures more than 1 inch
(25 mm) (Fig. 13) it must be retracted by using the
Actuate Outputs Test Idle Air Control Motor Open/
Close with the DRB scan tool. Refer to the appropriate Powertrain Diagnostic Procedures service manual
for operation of the DRB scan tool. Battery must be
connected for this operation.
IGNITION COIL
Refer to Group 8D, Ignition Systems for removal/
installation procedures.
INTAKE MANIFOLD
Refer to Group 11, Exhaust System and Intake
Manifold for removal/installation procedures.
REMOVAL
The oxygen sensor is installed in the exhaust manifold (Fig. 15).
CAUTION: When disconnecting the sensor electrical
connector, do not pull directly on wire going into
sensor. Damage to sensor may result. Use care in
working around sensor as the exhaust manifold
may be extremely hot.
(1) Disconnect O2S electrical connector (Fig. 15).
(2) Remove the O2S sensor from the exhaust manifold. Snap-On oxygen sensor wrench (number YA
8875) may be used for removal and installation.
(3) When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 +
6E tap.
INSTALLATION
If the same sensor is to be installed, the sensor
threads must be coated with an anti-seize compound
such as Loctite 771-64 or equivalent. New factory
sensors are packaged with compound on the threads.
Additional compound is not required. The sensor
must be tightened to 27 Nzm (20 ft. lbs.) torque.
PARK/NEUTRAL SWITCH
Refer to Group 21, Transmission and Transfer Case
for removal/installation procedures.
14 - 48
QUICK-CONNECT FITTINGS
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
THROTTLE BODY
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF)
OF APPROXIMATELY 100 KPA (14.5 PSI). BEFORE
SERVICING THE THROTTLE BODY OR FUEL INJECTOR THE FUEL SYSTEM PRESSURE MUST BE RELEASED.
(1) Remove air cleaner (Fig. 17).
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Remove air cleaner air duct from PCM.
(3) Remove 60-way wiring connector from module.
(4) Remove PCM mounting screws. Remove module.
REMOVAL
(1) Remove air cleaner.
(2) Disconnect throttle cables from throttle body
linkage.
(3) Remove throttle cable bracket mounting screws
and lay bracket aside.
(4) Disconnect throttle body temperature sensor
electrical connector.
(5) Unscrew sensor (Fig. 19).
INSTALLATION
(1) Apply heat transfer compound (provided with
new factory sensor) to tip portion of new sensor (Fig.
19).
(2) Install sensor and tighten to 9-13.5 Nzm
(80-120 in. lbs.) torque.
(3) Connect wiring connector.
(4) Install throttle cable bracket. Tighten mounting
screws.
(5) Connect throttle cables to throttle body linkage
and install clips.
(6) Install air cleaner.
14 - 49
REMOVAL
(1) Remove air cleaner assembly.
(2) Perform Fuel System Pressure Release.
(3) Disconnect negative battery cable at battery.
WARNING: DO NOT ALLOW FUEL TO SPILL ONTO
THE ENGINE INTAKE OR EXHAUST MANIFOLDS.
PLACE SHOP TOWELS UNDER THE FUEL SYSTEM
HOSES ABSORB ANY RESIDUAL FUEL WHEN DISCONNECTING THEM FROM THE FUEL FITTINGS.
(4) Loosen fuel intake and return hose clamps.
Wrap a shop towel around each hose. Twist and pull
on each hose for removal.
(5) Remove each fitting and note inlet diameter.
The fuel inlet fitting nipple diameter is larger than
the fuel inlet fittings (Fig. 20). Remove and discard
the copper washers on the fittings.
14 - 50
INSTALLATION
(1) Install new replacement washers on fuel fittings.
(2) Install fuel fittings in proper fuel passage ports.
Tighten to 20 Nzm (175 in. lbs.) torque.
(3) Using new original equipment type hose
clamps, install fuel return and supply hoses. Tighten
hose clamps to 1 Nzm (10 in. lbs.) torque.
(4) Connect battery cable.
(5) Test for leaks using Diagnostic Readout Box II
(DRB) scan tool. With key in the Run position, use
Special Functions Test ASD Fuel System Test. This
will activate pump and pressurize the system. Check
for leaks.
(6) Install air cleaner assembly.
14 - 51
(2) Tighten sensor mounting bolt. To prevent damage to sensor or speedometer adapter, be sure the
sensor is mounted flush to the adapter before tightening.
(3) Connect electrical connector to sensor.
14 - 52
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GENERAL INFORMATION
All 3.9L (V-6) and 5.2L (V-8) engines are equipped
with sequential Multi-Port Fuel Injection (MFI). The
MFI system provides precise air/fuel ratios for all
driving conditions.
The powertrain control module (PCM) operates the
fuel system. The PCM was formerly referred to as
the SBEC or engine controller. The PCM is a pre-programmed, dual microprocessor digital computer. It
regulates ignition timing, air-fuel ratio, emission control devices, charging system, speed control, air conditioning compressor clutch engagement and idle
speed. The PCM can adapt its programming to meet
changing operating conditions.
Powertrain Control Module (PCM) Inputs represent the instantaneous engine operating conditions.
Air-fuel mixture and ignition timing calibrations for
various driving and atmospheric conditions are preprogrammed into the PCM. The PCM monitors and
analyzes various inputs. It then computes engine fuel
and ignition timing requirements based on these inputs. Fuel delivery control and ignition timing will
then be adjusted accordingly.
Other inputs to the PCM are provided by the brake
switch, air conditioning select switch and the speed
control switches. All inputs to the PCM are converted
into signals.
page
Intake Manifold Air Temperature Sensor
PCM Input . . . . . . . . . . . . . . . . . . . . . . . .
Malfunction Indicator LampPCM Output . .
Manifold Absolute Pressure (MAP) Sensor
PCM Input . . . . . . . . . . . . . . . . . . . . . . . .
Open Loop/Closed Loop Modes of Operation
Overdrive/Override Switch . . . . . . . . . . . . . .
Oxygen (O2S) SensorPCM Input . . . . . . .
Park/Neutral SwitchPCM Input . . . . . . . . .
PCM System Schematics . . . . . . . . . . . . . .
Power Ground . . . . . . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . . . .
SCI ReceivePCM Input . . . . . . . . . . . . . .
SCI TransmitPCM Output . . . . . . . . . . . . .
Sensor ReturnPCM Input . . . . . . . . . . . . .
Shift IndicatorPCM Output . . . . . . . . . . . .
Speed ControlPCM Input . . . . . . . . . . . . .
Speed ControlPCM Output . . . . . . . . . . . .
TachometerPCM Output . . . . . . . . . . . . . .
Throttle Body . . . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor (TPS)PCM Input .
Vehicle Speed SensorPCM Input . . . . . . .
. . . . . 58
. . . . . 62
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SYSTEM DIAGNOSIS
The powertrain control module (PCM) tests many
of its own input and output circuits. If a Diagnostic
Trouble Code (DTC) is found in a major system, this
14 - 53
14 - 54
14 - 55
14 - 56
Brake switch
Engine coolant temperature sensor
Crankshaft position sensor
Ignition circuit sense (ignition switch in run position)
Manifold absolute pressure sensor
Overdrive/override switch
Oxygen sensor
Park/neutral switch (auto. trans. only)
SCI receive (DRB scan tool connection)
Speed control resume switch
Speed control set switch
Speed control on/off switch
Camshaft position sensor signal
Throttle position sensor
Vehicle speed sensor
Sensor return
Power ground
Signal ground
Powertrain Control Module (PCM) Outputs:
A/C clutch relay
Idle air control (IAC) motor
Auto shutdown (ASD) relay
Generator field
Malfunction Indicator lamp (Check Engine Lamp)
EGR valve control solenoid
Fuel injectors
Fuel pump relay
Ignition coil
EVAP canister purge solenoid
SCI transmit (DRB scan tool connection)
Shift indicator lamp (manual transmission only)
Speed control vacuum solenoid
Speed control vent solenoid
Tachometer (on instrument panel, if equipped)
The powertrain control module (PCM) contains a
voltage convertor. This converts battery voltage to a
regulated 8.0 volts. It is used to power the crankshaft
position sensor, camshaft position sensor and vehicle
speed sensor. The PCM also provides a five (5) volt
supply for the Manifold Absolute Pressure (MAP)
sensor and Throttle Position Sensor (TPS).
Refer to Camshaft Position Sensor in Group 8D, Ignition System for more information.
14 - 57
14 - 58
pulse width and ignition timing. As coolant temperature varies, the coolant temperature sensors resistance changes. The change in resistance results in a
different input voltage to the PCM.
When the engine is cold, the PCM will operate in
Open Loop cycle. It will demand slightly richer airfuel mixtures and higher idle speeds. This is done
until normal operating temperatures are reached.
14 - 59
The oxygen sensor is equipped with a heating element that keeps the sensor at proper operating temperature during all operating modes. Maintaining
correct sensor temperature at all times allows the
system to enter into closed loop operation sooner.
In Closed Loop operation, the powertrain control
module (PCM) monitors the O2S sensor input (along
with other inputs). It then adjusts the injector pulse
width accordingly. During Open Loop operation, the
PCM ignores the O2S sensor input and adjusts injector pulse width to a preprogrammed value (based on
other sensor inputs).
OVERDRIVE/OVERRIDE SWITCH
On vehicles equipped with an automatic transmission and overdrive, the powertrain control module
(PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. This solenoid is
located in the transmission. An overdrive/override
push-button switch is located on the instrument
panel.
The PCM circuit for overdrive is controlled by inputs from the engine coolant temperature sensor and
vehicle speed sensor. If coolant temperature and vehicle speed are not within the preset PCM specifications, the PCM will not allow the transmission to
shift into overdrive. These preset PCM specifications
must be met before the push-button switch will be allowed to control overdrive operation.
The overdrive/override push-button switch is normally closed (overdrive allowed) when the lamp is
not illuminated. It opens (overdrive not allowed)
when the operator presses the switch and the lamp is
illuminated. The switch will revert to its normally
closed position (lamp off) each time the ignition
switch in turned on. The transmission downshifts if
the operator presses the override switch while in
overdrive.
Refer to Group 21 for more transmission information.
14 - 60
POWER GROUND
The power ground is used to control ground circuits
for the following powertrain control module (PCM)
loads:
Generator Field Winding
8 volt (PCM) power supply
Fuel Injectors
Ignition Coil
14 - 61
14 - 62
14 - 63
TACHOMETERPCM OUTPUT
The powertrain control module (PCM) supplies engine rpm values to the instrument cluster tachometer. Refer to Group 8E for tachometer information.
THROTTLE BODY
Filtered air from the air cleaner enters the intake
manifold through the throttle body (Fig. 17). Fuel
does not enter the intake manifold through the throt-
FUEL RAIL
The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the intake
manifold (Fig. 19). The fuel pressure regulator is no
longer mounted to the fuel rail on the 3.9L V-6 or
5.2L V-8 engine. It is now located on the fuel tank
mounted fuel pump module. Refer to Fuel Filter/Fuel
Pressure Regulator in the Fuel Delivery System section of this group for information. The fuel rail is not
repairable.
14 - 64
MODES
Open Loop
Closed Loop
During Open Loop modes, the powertrain control
module (PCM) receives input signals and responds
only according to preset PCM programming. Input
from the oxygen (O2S) sensor is not monitored during Open Loop modes.
During Closed Loop modes, the PCM will monitor
the oxygen (O2S) sensor input. This input indicates
to the PCM whether or not the calculated injector
pulse width results in the ideal air-fuel ratio. This
ratio is 14.7 parts air-to-1 part fuel. By monitoring
the exhaust oxygen content through the O2S sensor,
the PCM can fine tune the injector pulse width. This
is done to achieve optimum fuel economy combined
with low emission engine performance.
The fuel injection system has the following modes
of operation:
Ignition switch ON
Engine start-up (crank)
Engine warm-up
Idle
Cruise
Acceleration
Deceleration
Wide open throttle (WOT)
Ignition switch OFF
The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide
open throttle modes are Open Loop modes. The idle
and cruise modes, (with the engine at operating temperature) are Closed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
This is an Open Loop mode. When the fuel system
is activated by the ignition switch, the following actions occur:
The powertrain control module (PCM) pre-positions the idle air control (IAC) motor.
The PCM determines atmospheric air pressure
from the MAP sensor input to determine basic fuel
strategy.
The PCM monitors the engine coolant temperature
sensor input. The PCM modifies fuel strategy based
on this input.
Intake manifold air temperature sensor input is
monitored
Throttle position sensor (TPS) is monitored
The auto shutdown (ASD) relay is energized by the
PCM for approximately three seconds.
14 - 65
IDLE MODE
When the engine is at operating temperature, this
is a Closed Loop mode. At idle speed, the powertrain
control module (PCM) receives inputs from:
Air conditioning select signal (if equipped)
Air conditioning request signal (if equipped)
Battery voltage
Crankshaft position sensor
Engine coolant temperature sensor
Intake manifold air temperature sensor
Manifold absolute pressure (MAP) sensor
Throttle position sensor (TPS)
Camshaft position sensor signal (in the distributor)
Battery voltage
Park/Neutral Switch (gear indicator signalauto.
trans. only)
Oxygen sensor
Based on these inputs, the following occurs:
Voltage is applied to the fuel injectors with the
powertrain control module (PCM). The PCM will
then control injection sequence and injector pulse
width by turning the ground circuit to each individual injector on and off.
The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It
also adjusts engine idle speed through the idle air
control (IAC) motor.
The PCM adjusts ignition timing by increasing
and decreasing spark advance.
The PCM operates the A/C compressor clutch
through the clutch relay. This happens if A/C has
been selected by the vehicle operator and requested
by the A/C thermostat.
CRUISE MODE
When the engine is at operating temperature, this
is a Closed Loop mode. At cruising speed, the powertrain control module (PCM) receives inputs from:
Air conditioning select signal (if equipped)
Air conditioning request signal (if equipped)
14 - 66
Battery voltage
Engine coolant temperature sensor
Crankshaft position sensor
Intake manifold air temperature sensor
Manifold absolute pressure (MAP) sensor
Throttle position sensor (TPS)
Camshaft position sensor signal (in the distributor)
Park/Neutral switch (gear indicator signalauto.
trans. only)
Oxygen (O2S) sensor
Based on these inputs, the following occurs:
Voltage is applied to the fuel injectors with the
PCM. The PCM will then adjust the injector pulse
width by turning the ground circuit to each individual injector on and off.
The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed
through the idle air control (IAC) motor.
The PCM adjusts ignition timing by turning the
ground path to the coil on and off.
The PCM operates the A/C compressor clutch
through the clutch relay. This happens if A/C has
been selected by the vehicle operator and requested
by the A/C thermostat.
ACCELERATION MODE
This is an Open Loop mode. The powertrain control
module (PCM) recognizes an abrupt increase in
throttle position or MAP pressure as a demand for
increased engine output and vehicle acceleration. The
PCM increases injector pulse width in response to increased throttle opening.
DECELERATION MODE
When the engine is at operating temperature, this
is an Open Loop mode. During hard deceleration, the
powertrain control module (PCM) receives the following inputs.
Air conditioning select signal (if equipped)
Air conditioning request signal (if equipped)
Battery voltage
Engine coolant temperature sensor
Crankshaft position sensor
Intake manifold air temperature sensor
Manifold absolute pressure (MAP) sensor
Throttle position sensor (TPS)
Camshaft position sensor signal (in the distributor)
Park/Neutral switch (gear indicator signalauto.
trans. only)
If the vehicle is under hard deceleration with the
proper rpm and closed throttle conditions, the PCM
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VISUAL INSPECTION
A visual inspection for loose, disconnected, or incorrectly routed wires and hoses should be made. This
should be done before attempting to diagnose or service the fuel injection system. A visual check will
help spot these faults and save unnecessary test and
diagnostic time. A thorough visual inspection will include the following checks:
(1) Verify that the 60-way connector is fully inserted into the connector of the powertrain control
module (PCM) (Fig. 1). Verify that the connector
mounting screw is tightened to 4 Nzm (35 in. lbs.)
torque.
page
Oxygen (O2S) Sensor Heating Element Test
Powertrain Control Module (PCM) 60-Way
Connector . . . . . . . . . . . . . . . . . . . . . . .
Powertrain Control Module Testing . . . . . . .
RelaysOperation/Testing . . . . . . . . . . . .
Starter Motor Relay Test . . . . . . . . . . . . . .
System Schematics . . . . . . . . . . . . . . . . . .
Throttle Body Minimum Air Flow Check . . .
Throttle Position Sensor (TPS) Test . . . . . .
Vehicle Speed Sensor Test . . . . . . . . . . . .
Visual Inspection . . . . . . . . . . . . . . . . . . . .
. . . . . 72
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power distribution center (PDC) (Fig. 2). For the location of the relays within the PDC, refer to label under PDC cover.
14 - 68
14 - 69
14 - 70
SYSTEM SCHEMATICS
Refer to PCM Schematics in the Multi-Port Fuel
Injection (MFI)Component Description/System Operation3.9L/5.2L Engine section of this group.
tor terminal. Also test continuity of wire harness terminal 4 to the sensor connector terminal. Repair the
wire harness if an open circuit is indicated.
(4) After tests are completed, connect electrical
connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor
in either direction.
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14 - 73
14 - 74
RELAYSOPERATION/TESTING
Fig. 22 Idle Purge Line
(6) Connect the DRB scan tool to the data link connector (Fig. 23) on the vehicle. Refer to the appropriate Powertrain Diagnostic Procedures service manual
for DRB operation.
(7) Start the engine.
OPERATION
The following operations/tests apply to these
relays only: Automatic Shutdown (ASD) and Fuel
Pump. For operations/tests on all other relays, refer
to the appropriate section of this service manual.
These relays are located in the power distribution
center (PDC) (Fig. 24). For the location of the relay
within the PDC, refer to label under PDC cover.
14 - 75
tion. Terminal number 87 then supplies battery voltage to the component being operated.
Terminal number 86 is connected to a switched (+)
power source.
Terminal number 85 is grounded by the powertrain control module (PCM).
TESTING
(1) Remove relay before testing.
(2) Using an ohmmeter, perform a resistance test
between terminals 85 and 86. Resistance value
(ohms) should be 75 65 ohms for resistor equipped
relays.
(3) Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this
time.
(4) Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at
this time.
(5) Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12
Volt power source.
(6) Attach the other jumper wire to the positive
side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
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14 - 77
14 - 78
MONITORED CIRCUITS
The powertrain control module (PCM) can detect
certain problems in the fuel injection system.
Open or Shorted Circuit - The PCM can determine if sensor output (which is the input to PCM) is
within proper range. It also determines if the circuit
is open or shorted.
Output Device Current Flow - The PCM senses
whether the output devices are hooked up.
If there is a problem with the circuit, the PCM
senses whether the circuit is open, shorted to ground
(-), or shorted to (+) voltage.
Oxygen Sensor - The PCM can determine if the
oxygen sensor is switching between rich and lean.
This is, once the system has entered Closed Loop. Refer to Open Loop/Closed Loop Modes Of Operation in
the Component Description/System Operation section
for an explanation of Closed (or Open) Loop operation.
NON-MONITORED CIRCUITS
The PCM does not monitor the following circuits,
systems or conditions that could have malfunctions
that result in driveability problems. A Diagnostic
Trouble Code (DTC) may not be displayed for these
conditions.
Fuel Pressure: Fuel pressure is controlled by the
vacuum assisted fuel pressure regulator. The PCM
cannot detect a clogged fuel pump inlet filter, clogged
in-line fuel filter, or a pinched fuel supply or return
line. However, these could result in a rich or lean
condition causing an oxygen sensor DTC to be stored
in the PCM.
Secondary Ignition Circuit: The PCM cannot
detect an inoperative ignition coil, fouled or worn
spark plugs, ignition cross firing, or open circuited
spark plug cables.
Engine Timing: The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket or
crankshaft sprocket. The PCM also cannot detect an
incorrectly indexed distributor. However, these could
result in a rich or lean condition causing an oxygen
sensor DTC to be stored in the PCM.
Cylinder Compression: The PCM cannot detect
uneven, low, or high engine cylinder compression.
Exhaust System: The PCM cannot detect a
plugged, restricted or leaking exhaust system.
Fuel Injector Malfunctions: The PCM cannot determine if the fuel injector is clogged, or the wrong
injector is installed. However, these could result in a
rich or lean condition causing an oxygen sensor DTC
to be stored in the PCM.
14 - 79
After any stored DTC information has been observed, the display will end with a flashing DTC
number 55. This will indicate the end of all stored information.
Refer to the Diagnostic Trouble Code (DTC) charts
for DTC identification.
If the problem is repaired or ceases to exist, the
powertrain control module (PCM) cancels the DTC
after 51 engine starts.
Diagnostic trouble codes indicate the results of a
failure, but never identify the failed component directly.
The circuits of the data link connector are shown in
(Fig. 30).
14 - 80
Diagnostic
Trouble Code
11**
12*
Battery Disconnect
13**
14**
or
MAP Sensor Voltage Too High
15**
No vehicle distance (speed) sensor signal detected during road load conditions.
17*
21**
or
22**
or
23**
or
24**
or
25**
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle
Ignition key as described in manual and observe code flashed by Check Engine lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
14 - 81
27*
or
Injector #2 Control Circuit
or
Injector #3 Control Circuit
or
Injector #4 Control Circuit
or
Injector #5 Control Circuit
or
Injector #6 Control Circuit
or
Injector #7 Control Circuit
or
Injector #8 Control Circuit
31**
32**
or
EGR System Failure
33*
34*
or
Speed Control Switch Always Low
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle
Ignition key as described in manual and observe code flashed by Check Engine lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
14 - 82
Diagnostic
Trouble Code
or
Speed Control Switch Always High
41**
42*
44*
An open or shorted condition exists in the engine coolant temperature sensor circuit or a
problem exists in the PCMs battery temperature voltage circuit.
46**
47**
51**
52**
53*
or
PCM Failure SRI Communications
54*
55*
62*
63*
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle
Ignition key as described in manual and observe code flashed by Check Engine lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
14 - 83
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83
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84
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85
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86
86
86
page
Fuel System Pressure Release Procedure
Fuel Tank Pressure Relief/Rollover Valve .
Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tubes/Lines/Hoses and Clamps . . . .
Idle Air Control (IAC) Motor . . . . . . . . . . .
Ignition Coil . . . . . . . . . . . . . . . . . . . . . .
Intake Manifold . . . . . . . . . . . . . . . . . . . .
Intake Manifold Air Temperature Sensor . .
Manifold Absolute Pressure (MAP) Sensor
Oxygen (O2S) Sensor . . . . . . . . . . . . . . .
Park/Neutral Switch . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . .
Quick-Connect Fittings . . . . . . . . . . . . . .
Throttle Body . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor (TPS) . . . . . . . .
Vehicle Speed Sensor . . . . . . . . . . . . . . .
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87
87
87
87
88
88
88
84
88
89
89
89
89
89
90
91
INSTALLATION
(1) Position air cleaner housing to throttle body.
(2) If housing-to-throttle body mounting stud (Fig.
3) is being installed, tighten to 10 Nzm (90 in. lbs.)
torque.
(3) Tighten wingnut to 1.5 Nzm (15 in. lbs.) torque.
(4) Push crankcase breather/filter into valve cover.
(5) Install air intake tube to housing.
14 - 84
BRAKE SWITCH
Refer to Group 5, Brakes for removal/installation
procedures.
INSTALLATION
(1) Install sensor to intake manifold. Tighten to 28
Nzm (20 ft. lbs.) torque.
(2) Install electrical connector.
(3) Install air cleaner.
14 - 85
FUEL FILTER
3.9L and 5.2L Engine: The fuel filter and fuel
pressure regulator are one combined part. A separate
in-line fuel filter is not used with the 3.9L or 5.2L engine. Refer to Fuel Filter/Fuel Pressure Regulator in
the Fuel Delivery System section of this group for removal and installation procedures.
FUEL INJECTOR(S)
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE
TURNED OFF). BEFORE SERVICING THE FUEL INJECTOR(S), THE FUEL SYSTEM PRESSURE MUST
BE RELEASED.
To release fuel pressure, refer to the Fuel Delivery
System section of this group. See Fuel System Pressure Release.
To remove one or more fuel injectors, the fuel rail
assembly must be removed from engine.
REMOVAL
(1) Remove air cleaner assembly.
(2) Remove fuel rail assembly. Refer to Fuel Rail
removal in this section.
INSTALLATION
(1) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(2) Install injector(s) and injector clip(s) to fuel
rail.
(3) Install fuel rail assembly. Refer to Fuel Rail installation.
(4) Install air cleaner.
(5) Start engine and check for leaks.
14 - 86
Fuel Filter/Fuel Pressure Regulator in the Fuel Delivery System section of this group for removal and
installation procedures.
(4) Remove throttle body from intake manifold. Refer to Throttle Body removal in this group.
(5) If equipped with air conditioning, remove the
A/C compressor-to-intake manifold support bracket
(three bolts) (Fig. 9).
FUEL RAIL
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE
TURNED OFF). BEFORE SERVICING THE FUEL
RAIL ASSEMBLY, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED.
To release fuel pressure, refer to the Fuel Delivery
System section of this group. See Fuel System Pressure Release.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate the rail
halves at the connecting hose (Fig. 8). Due to the
design of this connecting hose, it does not use any
clamps. Never attempt to install a clamping device
of any kind to the hose. When removing the fuel rail
assembly for any reason, be careful not to bend or
kink the connecting hose.
(7) 3.9L engine only: Disconnect electrical connector at intake manifold air temperature sensor. Do not
remove sensor.
(8) Remove EVAP canister purge solenoid/bracket
assembly (Fig. 11) from intake manifold (one nut on
3.9L, one bolt on 5.2L).
INSTALLATION
(1) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(2) Install injector(s) and injector clip(s) to fuel
rail.
14 - 87
FUEL TANKS
Refer to the Fuel Tank section of this group for removal/installation procedures.
14 - 88
IGNITION COIL
The IAC motor is located on the back of the throttle body (Fig. 13).
INTAKE MANIFOLD
Refer to Group 11, Exhaust System and Intake
Manifold for removal/installation procedures.
REMOVAL
WARNING: THE EXHAUST MANIFOLD BECOMES
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Raise and support the vehicle.
(2) Disconnect the wire connector from the O2S
sensor.
14 - 89
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Carefully remove 60-way wiring connector from
PCM (one screw) (Fig. 17).
(3) Remove three mounting screws (Fig. 17).
(4) Remove PCM from vehicle.
INSTALLATION
(1) Install PCM to inner fender.
(2) Check inside of 60-way wiring harness connector for bent pins or corrosion. Repair as necessary.
(3) Install 60-way connector to PCM. Tighten
mounting screw to 4 Nzm (35 in. lbs.). torque.
(4) Install battery cable to battery.
QUICK-CONNECT FITTINGS
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
THROTTLE BODY
Fig. 16 Oxygen Sensor
INSTALLATION
Threads of new oxygen sensors are factory coated
with anti-seize compound to aid in removal. DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) Install the O2S sensor into the exhaust manifold. Tighten to 30 Nzm (22 ft. lbs.) torque.
(2) Connect the O2S sensor wire connector.
(3) Lower the vehicle.
PARK/NEUTRAL SWITCH
Refer to Group 21, Transmission and Transfer Case
for removal/installation procedures.
A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle
plate. Never attempt to adjust the engine idle
speed using this screw. All idle speed functions are
controlled by the powertrain control module (PCM).
REMOVAL
(1) Remove the air cleaner.
(2) Disconnect throttle body electrical connectors at
MAP sensor, IAC motor and TPS (Fig. 18).
(3) Remove vacuum line at throttle body.
(4) Remove all control cables from throttle body
(lever) arm. Refer to the Accelerator Pedal and Throttle Cable section of this group for additional information.
(5) Remove four throttle body mounting bolts (Fig.
19).
(6) Remove throttle body from intake manifold.
(7) Discard old throttle body-to-intake manifold
gasket.
14 - 90
INSTALLATION
The throttle shaft end of the throttle body slides
into a socket in the TPS (Fig. 21). The TPS must be
installed so that it can be rotated a few degrees. If
the sensor will not rotate, install the sensor with the
throttle shaft on the other side of the socket tangs.
The TPS will be under slight tension when rotated.
14 - 91
REMOVAL
INSTALLATION
(1) Install new sensor into speedometer gear
adapter.
(2) Tighten sensor mounting bolt. To prevent damage to sensor or speedometer adapter, be sure the
sensor is mounted flush to the adapter before tightening.
(3) Connect electrical connector to sensor.
14 - 92
GENERAL INFORMATION
The following specifications are published from the
latest information available at the time of publication. If anything differs between the specifications found on the Vehicle Emission Control
Information (VECI) label and the following
specifications, use specifications on VECI label.
The VECI label is located in the engine compartment.
SENSOR
14 - 93
PROPELLER SHAFTS
16 - 1
PROPELLER SHAFTS
CONTENTS
page
page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
PROPELLER SHAFT REPLACEMENT . . . . . . . . . . 8
SERVICE DIAGNOSIS/PROCEDURES . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 15
UNIVERSAL JOINT REPLACEMENT . . . . . . . . . 10
GENERAL INFORMATION
PROPELLER SHAFTS
The propeller shaft transmits power from one point
to another in a smooth and continuous action. The
shaft is designed to send torque through an angle
from the transmission (transfer case on 4WD vehicles) to the axle.
The propeller shaft must operate through constantly changing relative angles between the transmission and axle. It must also be capable of changing
length while transmitting torque. The axle rides suspended by springs in a floating motion. This means
the propeller shaft must be able to contract, expand
and change operating angles when going over various
road surfaces. This is accomplished through universal joints, which permit the propeller shaft to operate
at different angles. The slip joints (or yokes) permit
contraction or expansion.
Tubular propeller shafts are balanced by the manufacturer with weights spot welded to the tube.
The propeller shaft is designed and built with the
yoke lugs in line with each other. This is called phasing. This design produces the smoothest running condition. Out of phase shafts can cause a vibration.
Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered. This
will prevent the undercoating from causing an
unbalanced condition.
CAUTION: Use exact replacement hardware on propeller shafts and tighten fasteners to specified
torque. This will ensure proper operation.
16 - 2
PROPELLER SHAFTS
CENTER BEARINGS
Vehicles equipped with a two-piece propeller shaft
uses a rubber insulated center bearing. The bearing
is used to support the shafts where they are joined
together.
UNIVERSAL JOINTS
The rear propeller shaft uses a 7290 series cardan
joint. This joint is used on 2WD and 4WD vehicles.
The 4WD front shaft uses a 1310 series double cardan joint at the transfer case end. At the front axle
end a 1310/7260 hybrid joint is used.
Two different types of universal joints systems are
used:
Single cardan universal joint (Fig. 2).
Double cardan universal joint (Fig. 3).
LUBRICATION
The slip yoke on the front shaft is equipped with a
zerk type lubrication fitting. Use a multi-purpose
NLGI Grade 2 EP lubricant. Refer to Group 0, Lubrication and Maintenance for additional information.
The factory installed U-joints are lubricated for the
life of the vehicle and do not need re-lubrication. All
PROPELLER SHAFTS
16 - 3
SERVICE DIAGNOSIS/PROCEDURES
INDEX
page
page
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PRECAUTIONS
Propeller shaft vibration will increase as the vehicle speed is increased. A vibration that occurs within
a specific speed range is not caused by propeller
shaft unbalance. Defective U-joints or an incorrect
propeller shaft angle are usually the cause.
VIBRATION
Tires that are out-of-round or wheels that are unbalanced will cause a low frequency vibration. Refer
to Group 22, Tires And Wheels for service information.
Brake drums that are unbalanced will cause harsh,
low frequency vibration. Refer to Group 5, Brakes for
service information.
Driveline vibration can also result from loose or
damaged engine mounts. Refer to Group 21, Transmissions for additional information.
UNBALANCE
If propeller shaft unbalance is suspected, it can be
verified with the following procedure.
Removing and re-indexing the propeller shaft
180 may eliminate some vibrations.
(1) Raise and support the vehicle.
(2) Clean all foreign material from propeller shaft
and U-joints.
(3) Inspect propeller shaft for missing balance
weights, broken welds, and bent areas. If the propeller shaft is bent, it must be replaced.
(4) Ensure the U-joints are not worn and are properly installed.
(5) Check the U-joint clamp screws torque.
(6) Remove wheels and tires. Install wheel lug
nuts to retain brake drums in place.
DRIVELINE VIBRATION
16 - 4
PROPELLER SHAFTS
RUNOUT
(1) Clean propeller shaft surface where the dial indicator contacts the shaft.
(2) Measure propeller shaft runout at the center
and ends of the shaft.
(3) Mount a dial indicator perpendicular to the
shaft surface.
(4) Rotate shaft several times and not reading. Refer to Runout Specifications chart.
(5) Replace the propeller shaft if the runout exceeds the limit.
RUNOUT SPECIFICATIONS
INFORMATION
When two shafts intersect at any common universal joint, the bend that is formed is called the working or operating angle. The larger the operating
angle, the larger the amount of acceleration and deceleration of the joint. This speeding up and slowing
down of the joint must be cancelled to produce a
PROPELLER SHAFTS
smooth power flow. This is done through phasing and
proper universal joint working angles.
A propeller shaft is properly phased when the yoke
ends are on the same plane or in line. A twisted shaft
will throw the yokes out of phase and cause a noticeable vibration.
When taking universal joint angle measurements or
checking phasing with two piece shafts, consider each
shaft separately. On 4WD vehicles, the front shaft input
(pinion shaft) angle has priority over the caster angle.
Ideally the driveline system should have:
Angles that are in equal or opposite within 1
degree of each other
Have a 3 degree maximum operating angle
Have at least a 1/2 degree continuous operating (propeller shaft) angle
Engine speed (R.P.M.) is the main factor though in
determining maximum allowable operating angles.
As a guide to maximum normal operating angles refer to the chart listed (Fig. 4).
16 - 5
(3) Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft (Fig.
6). Center bubble in sight glass and record measurement. This measurement can also be taken at the
rear end of the shaft.
This measurement will give you the PROPELLER SHAFT ANGLE (C).
16 - 6
PROPELLER SHAFTS
PROPELLER SHAFTS
16 - 7
16 - 8
PROPELLER SHAFTS
PROPELLER SHAFT REPLACEMENT
PRECAUTIONS
Use exact replacement hardware for attaching the
propeller shafts. Exact replacement will ensure safe
operation. The specified torque must always be applied when tightening the fasteners.
Mark propeller shaft yoke and axle or transmission
yoke before removal or component service (Fig. 1).
This will assure correct phasing and eliminate possible vibration.
FRONT
REMOVAL
(1) Shift the transmission and transfer case (if applicable) to their Neutral positions. Raise the vehicle.
Remove skid plates (if equipped) from frame, refer to
Group 13, Frames.
(2) Scribe alignment marks on the yokes at the
transfer case. Place marks at the pinion shaft and at
each end of the propeller shaft. These marks will be
used for installation reference (Fig. 2).
(3) Remove the U-joint strap bolts at the pinion
shaft yoke.
(4) Remove bolts from transfer case yoke and remove the propeller shaft.
INSTALLATION
(1) Position the propeller shaft with the yoke reference marks aligned. Install the propeller shaft (Fig.
2).
Replacement U-joint straps and bolts must be
installed.
(2) Tighten the U-joint strap bolts at the pinion
shaft to 19 Nzm (14 ft. lbs.) torque. Tighten the transfer case bolts to 27 Nzm (20 ft. lbs.) torque.
(3) Install skid plates (if equipped), refer to Group
13, Frames. Lower the vehicle.
REAR
REMOVAL
(1) Shift the transmission and transfer case (if applicable) to their Neutral positions. Raise the vehicle.
(2) Scribe alignment marks at the pinion yoke and
at each end of the propeller shaft.
(3) Remove the U-joint strap bolts at the pinion
shaft yoke.
(4) Slide the slip yoke off of the transmission/
transfer case output shaft and remove the propeller
shaft (Fig. 3).
INSTALLATION
(1) Slide the slip yoke on the transmission/transfer
case output shaft. Align the installation reference
marks at the axle yoke and install the propeller shaft
(Fig. 3).
Replacement U-joint straps and bolts must be
installed.
PROPELLER SHAFTS
16 - 9
REARTWO PIECE
REMOVAL
(1) Shift the transmission and transfer case (if applicable) to their Neutral positions. Raise the vehicle.
(2) Scribe alignment marks at the pinion yoke and
at each end of the propeller shaft.
(3) Remove the universal joint strap bolts at the
pinion shaft yoke.
(4) Scribe alignment marks at the frame crossmember for reference. Remove the bolts that attach
the center bearing to the support bracket (Fig. 4).
INSTALLATION
(1) Slide the slip yoke on the transmission/transfer
case output shaft. Align the installation reference
marks at the axle yoke and install the propeller
shaft.
(2) Align and install the center bearing to the support bracket. Install the bolts and tighten to 68 Nzm
(50 ft. lbs.) torque.
Replacement U-joint straps and bolts must be
installed.
(3) Tighten the U-joint strap bolts to 19 Nzm (14 ft.
lbs.) torque.
(4) Lower the vehicle.
REMOVAL
(1) Remove rear two-piece shaft. Refer to two-piece
removal.
(2) Remove slip joint boot clamp and separate the
two shafts. The slip joints are master splined.
(3) Use hammer and punch to tap slinger away
from shaft to provide room for bearing splitter.
(4) Position Bearing Splitter Tool 1130 between
slinger and shaft.
Caution: Do not damage shaft spline during removal of center bearing.
(5) Set shaft in press and press bearing off the
shaft.
INSTALLATION
(1) Install new slinger on shaft and drive into position with suitable size pipe.
(2) Install new center bearing on shaft with Bearing Installer Tool 6052. Drive on shaft with hammer
until bearing is seated.
(3) Clean shaft splines and apply a coat of multipurpose grease.
(4) Align master splines and slide front and rear
shafts together. Reposition slip yoke boot and install
new clamp.
(5) Install two-piece shaft in vehicle. Refer to installation two-piece shaft.
16 - 10
PROPELLER SHAFTS
UNIVERSAL JOINT REPLACEMENT
PRECAUTIONS
It is important to put reference marks on the yokes
before removal or component service. This will assure
correct phasing and eliminate possible vibration.
REMOVAL/DISASSEMBLY
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
(2) Score alignment marks on the yokes/flanges
and propeller shaft for installation reference.
(3) Using a soft drift, tap the outside of the bearing assembly to loosen snap ring.
(4) Remove snap rings from both sides of yoke (Fig. 1).
ASSEMBLY/INSTALLATION
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to aid in installation.
PROPELLER SHAFTS
(2) Position the cross in the yoke with its lube fitting (if equipped) pointing up (Fig. 4).
16 - 11
16 - 12
PROPELLER SHAFTS
(6) Flip assembly and repeat steps 4 and 5 for removing the opposite side bearing. This will then allow removal of the cross centering kit assembly and
spring (Fig. 9).
PROPELLER SHAFTS
(2) Place a bearing assembly in a tube yoke hole
and over a trunnion. Keep the needle bearings upright in the bearing assembly (Fig. 11). A needle
roller lying at the bottom will prevent proper assembly. Be sure to remove any lube fittings that may interfere with removal.
16 - 13
(4) Flip the tube yoke and bearing assembly installation on the opposite trunnion. Install a snap ring
(Fig. 13).
(5) Fit the center yoke on the remaining two trunnions and press bearing assemblies in place, both
sides (Fig. 14). Install a snap ring.
16 - 14
PROPELLER SHAFTS
(9) Tap the snap rings to allow them to set into the
grooves (Fig. 18).
PROPELLER SHAFTS
16 - 15
TORQUE SPECIFICATIONS
PROPELLER SHAFT AND UNIVERSAL JOINT
DESCRIPTION ................................................TORQUE
Center Bearing
Support Bolts...............................68 Nzm (50 ft. lbs.)
Transfer Case
Yoke Bolts ....................................27 Nzm (20 ft. lbs.)
Axle Yoke
Clamp Bolts .................................19 Nzm (14 ft. lbs.)
STEERING
19 - 1
STEERING
CONTENTS
page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 12
POWER STEERING SYSTEM DIAGNOSIS . . . . . . 3
RACK AND PINION STEERING GEAR . . . . . . . . 33
page
19
36
17
42
GENERAL INFORMATION
STEERING SYSTEM COMPONENTS
Dakota vehicles can have either manual or power
steering system (Fig. 1). A power assisted recirculating-ball type steering gear is used with four wheel
drive. Two wheel drive vehicles use either a manual
or power assisted rack and pinion steering gear.
Power steering systems use:
Recirculating-ball steering gear on 4WD vehicles
Rack and pinion steering gear on 2WD vehicles
Steering linkage
Belt driven hydraulic steering pump with fluid
reservoir
Pump pressure and return hoses and fittings
Intermediate shaft between column and gear
STEERING LINKAGE4WD
The steering linkage consists of a pitman arm,
idler arm, tie rods, and center link. Adjustment
sleeves are used on the tie rods for toe and steering
19 - 2
STEERING
wheel alignment. For additional wheel alignment information refer to Group 2, Front Suspension.
Fig. 5 PumpP-Series
STEERING COLUMNS
Two types of steering columns are installed on Dakota vehicles: a fixed, non-tilt column and a tilt column.
The ignition key/lock cylinder and the ignition
switch are located in the steering column. When the
key/lock cylinder is turned to the LOCK position, the
ignition switch and the steering shaft cannot be operated.
The column to gear intermediate shaft is equipped
with universal joints. A Rubber isolator is built into
the shafts to absorb noise and vibration from the
steering system.
Both types of steering columns have anti-theft provisions. They are energy-absorbing (collapse from impact in the event of a front-end collision).
STEERING
19 - 3
19 - 4
STEERING
POWER STEERING SYSTEM DIAGNOSIS
STEERING
POWER STEERING SYSTEM DIAGNOSIS
19 - 5
19 - 6
STEERING
POWER STEERING SYSTEM DIAGNOSIS
STEERING
POWER STEERING SYSTEM DIAGNOSIS
19 - 7
19 - 8
STEERING
POWER STEERING SYSTEM DIAGNOSIS
STEERING
POWER STEERING SYSTEM DIAGNOSIS
19 - 9
19 - 10
STEERING
PUMP LEAKAGE DIAGNOSIS
STEERING
GEAR LEAKAGE DIAGNOSIS
19 - 11
19 - 12
STEERING
POWER STEERING PUMP
INDEX
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15
16
12
13
page
Pump Replacement V-6 and V-8 . . . . . . . . . . . . 13
Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . 15
Service Information . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE INFORMATION
The power steering pump internal components are
not serviced or adjusted. If a malfunction or an internal fluid leak occurs, the complete unit must be replaced.
A power steering pump oil cooler is available on
some vehicles (Figs 1 and 2).
REMOVAL
(1) Place a drain pan under the pump and gear.
INSTALLATION
(1) Wipe hose ends, pump and gear unions clean.
(2) Connect hose at steering gear and pump. Route
hose while avoiding extreme bends or kinks. The
hose must be kept away from exhaust system
components. Do not distort hose tube ends by bending, kinking or over tightening.
(3) When used, the protective foam sleeves must be
properly positioned on the hose to prevent chafing.
(4) Tighten fittings at pump and gear to 35 Nzm
(25 ft. lbs.) torque.
(5) Install clamps on return hose on gear and
pump.
(6) After installation, inspect and test for fluid
leaks.
STEERING
19 - 13
INSTALLATION
(1) If removed, attach the front mounting bracket
to the pump.
(2) Position the pump in the rear mounting
bracket. Install the retaining bolts/nuts and tighten
to 28 Nzm (21 ft. lbs.) torque.
(3) Install front bracket-to-engine bolts and tighten
to 28 Nzm (21 ft. lbs.) torque.
(4) Connect fluid hoses to pump.
(5) Install and adjust drive belt. Refer to Group 7,
Cooling for additional information.
(6) Fill reservoir with MOPARt Power Steering
Fluid. If necessary, refer to Power Steering Pump
Initial Operation.
REMOVAL
WARNING: DO NOT ATTEMPT TO REMOVE THE
PUMP WITHOUT REMOVING THE BELT FIRST. THE
AUTOMATIC BELT TENSIONER IS UNDER A HIGH
SPRING LOAD.
(1) Remove the serpentine drive belt. Rotate tensioner clock-wise and hold in place, slide belt from
tensioner pulley (Fig. 7).
(2) Clamp the fluid return hose and disconnect the
hoses from the power steering pump. Cap the fittings.
(3) Remove battery ground cable. Remove the
bracket to engine block attaching bolts (Fig. 8). The
steering pump (with pulley) and mounting
bracket will be removed from engine as an assembly.
19 - 14
STEERING
INSTALLATION
(1) Install the bracket to pump attaching bolts
(Fig. 9). Tighten the screws to 54 Nzm (40 ft. lbs.)
torque.
STEERING
19 - 15
INSTALLATION
Service replacement for plastic pulley will be a
metal pulley. Install the replacement metal pulley accordingly.
(1) Install the pulley with Installer C-4063-B (Fig.
11). Do not use the tool adapters.
RESERVOIR REPLACEMENT
REMOVAL
(1) Remove the drive pulley with Puller C-4333
(Fig. 10).
REMOVAL
(1) Remove power steering pump. Refer to Pump
Replacement in this section.
(2) Remove the filler cap and drain the fluid from
reservoir before removing parts.
(3) Remove mounting studs and pressure fitting
(Fig. 12). Rock reservoir by hand or use a soft face
mallet to remove.
(4) Remove O-ring seals from housing and reservoir (Fig. 12).
(5) Remove flow control valve and spring from
housing.
INSTALLATION
(1) Install flow control valve and spring (Fig. 13).
(2) Lubricate and install new O-ring seals in housing (Fig. 13). Tighten mounting studs to 48 Nzm (35
ft. lbs.) torque.
(3) Install fitting in flow control valve bore.
Tighten the fitting to 75 Nzm (55 ft. lbs.) torque.
(4) Install power steering pump. Refer to Pump
Replacement in this section.
19 - 16
STEERING
STEERING
19 - 17
page
Center Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Idler Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pitman Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service Information . . . . . . . . . . . . . . . . . . . . . . . . 17
Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SERVICE INFORMATION
(3) If necessary, loosen the end clamp bolts and remove the tie rod ends from the tube.
The steering linkage consists of a pitman arm, center link, tie rod, and idler arm. Adjustment sleeves
are used on the tie rods for toe and steering wheel
alignment.
Refer to Group 2, Front Suspension and Axle
for additional information.
The tie-rod end ball stud seals should be inspected
during all oil changes.
A damaged ball stud seal requires removal of the
seal. Inspect the tie-rod end ball stud at the throat
opening. Check for lubricant loss, contamination, ball
stud wear or corrosion. If these conditions exist, replace the tie-rod. A replacement seal can be installed
if lubricant is in good condition. Otherwise, a complete replacement ball stud end should be installed.
Lubricate the tie-rod end with MOPARt Multi-Mileage Lubricant, or equivalent product.
Use Puller C-3894-A for tie rod removal. Failure to use this tool could damage the ball stud
and seal (Fig. 1).
INSTALLATION
(1) If necessary, install the tie rod ends in the tube
(Fig. 2). Position the tie rod clamp. Tighten to 30 Nzm
(22 ft. lbs.) torque.
(2) Install the tie rod on the center link and steering knuckle. Install the retaining nuts.
(3) Tighten the ball stud nut on the steering
knuckle to 54 Nzm (40 ft. lbs.) torque. Tighten the
ball stud nut to center link to 75 Nzm (55 ft. lbs.)
torque. Install new cotter pins.
(4) Set the wheel toe pattern. Refer to Group 2,
Front Suspension and Axle for Alignment adjustment.
PITMAN ARM
REMOVAL
(1) Remove the cotter pin and nut from the pitman
arm at the center link.
(2) Remove the pitman arm from the center link
with a puller.
(3) Remove the nut and washer from the steering
gear shaft. Mark the pitman shaft and pitman arm
for installation reference. Remove the pitman arm
from steering gear with Puller C-4150-A (Fig. 3).
INSTALLATION
(1) Align and install the pitman arm on steering
gear shaft.
(2) Install the washer and nut on the shaft.
Tighten the nut to 251 Nzm (185 ft. lbs.) torque.
(3) Install center link on the pitman arm ball stud.
Install and tighten nut to 54 Nzm (40 ft. lbs.) torque.
Install a new cotter pin.
TIE ROD
REMOVAL
(1) Remove the cotter pins and nuts at the steering
knuckle and center link (Fig. 2).
(2) Loosen the ball studs with puller tool to remove
the tie rod.
IDLER ARM
REMOVAL
(1) Remove the cotter pin and nut from the idler
arm at the center link.
(2) Remove the idler arm from the center link with
a puller.
(3) Remove the bolts from the right frame rail and
remove idler arm.
19 - 18
STEERING
CENTER LINK
REMOVAL
(1) Remove the tie rods from the center link (Fig.
2). Refer to Tie Rod Removal in this section.
(2) Remove the idler arm from the center link. Refer to Idler Arm Removal in this Section.
(3) Remove the pitman arm from the center link.
Refer to Pitman ArmRemoval in this Section.
(4) Remove the link from the steering knuckle with
a puller tool. Remove the same for tie rod and pitman arm.
INSTALLATION
(1) Install the drag link adjustment sleeve and tie
rod end. Position clamp bolts.
(2) Position the drag link at the steering linkage
(Fig. 2).
Install the drag link to the steering knuckle nut.
Do the same for the tie rod and pitman arm.
(3) Tighten the nut at the steering knuckle to 54
Nzm (40 ft. lbs.) torque. Tighten the pitman and tie
rod ball stud nuts to 75 Nzm (55 ft. lbs.) torque. Install new cotter pins.
STEERING
19 - 19
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25
31
22
24
31
24
19
SERVICE INFORMATION
A recirculating-ball steering gear is used with the
power (assisted) steering system. The power steering
gear can be adjusted and internally serviced.
page
Pitman Shaft Seals and Bearing Replacement
Rack Piston and Worm Shaft Replacement . .
Service Information . . . . . . . . . . . . . . . . . . . .
Steering Gear Adjustments . . . . . . . . . . . . . .
Steering Gear Replacement . . . . . . . . . . . . .
Valve Replacement . . . . . . . . . . . . . . . . . . . .
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30
28
19
21
32
26
INSTALLATION
(1) Install single lip seal with Installer or a suitable size deep socket (Fig. 2).
(2) Coat the double lip seal and washer with grease.
(3) Install the backup washer.
(4) Install the double lip seal.
(5) Install the backup washer.
(6) Install the retainer ring with snap ring pliers.
(7) Center the steering gear.
(8) Install the pitman arm. Refer to Pitman Arm
Installation in Steering Linkage.
(9) Add power steering fluid. Refer to Power Steering Initial Operation.
19 - 20
STEERING
STEERING
19 - 21
OVER-CENTER ADJUSTMENT
(1) Rotate the stub shaft from stop to stop and
count the number of turns.
(2) Starting at either stop turn the stub shaft back
1/2 the total number of turns. This is the center of
the gear travel (Fig. 8).
19 - 22
STEERING
STEERING
19 - 23
19 - 24
STEERING
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this group.
STEERING
CAUTION: Do not turn stub shaft any further than
necessary. The recirculating balls will drop out of
the rack piston circuit and fall inside the rack piston chamber.
(3) Remove O-ring seal (Fig. 13).
19 - 25
19 - 26
STEERING
(4) Remove bearing spacer, races and thrust bearing (Fig. 17).
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
ASSEMBLE
VALVE REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
STEERING
19 - 27
DISASSEMBLE
(1) Remove adjuster plug, refer to Adjuster Plug
Assembly Replacement.
(2) Remove stub shaft and valve assembly (Fig.
21).
ASSEMBLE
(1) Install valve spool O-ring seal to valve spool.
(2) Lubricate valve spool and O-ring seal with
power steering fluid.
(3) Install valve spool to valve body by pushing
and rotating. Hole in valve spool for stub pin must be
accessible from opposite end of valve body.
(4) Assemble stub shaft to valve spool, if necessary
and insert pin (Fig. 25).
Notch in stub shaft cap MUST fully engage valve
body pin and seat against valve body shoulder.
(5) Install O-ring seals and teflon rings to valve
body.
19 - 28
STEERING
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
STEERING
19 - 29
19 - 30
STEERING
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
ASSEMBLE
(1) Install needle bearing into housing (Fig. 34).
(2) Install single lip seal with Installer or a suitable size socket (Fig. 35).
(3) Coat the double lip seal and washer with
grease.
(4) Install the backup washer.
(5) Install the double lip seal.
(6) Install the backup washer.
(7) Install the retainer ring with snap ring pliers.
STEERING
19 - 31
ASSEMBLE
(1) Install the valve into the housing with a 3/8inch diameter piece of tubing 100 mm (4 inches) long.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
REMOVAL
The new easy slide shaft does not pullapart at
the center. Shaft is a single assembly that collapses
for removal and installation.
(1) Place the front wheels in the straight ahead position.
(2) Remove the bolt at the steering gear and column (Fig. 36).
(3) Collapse the intermediate shaft to remove.
INSTALLATION
(1) Align and install the intermediate (coupler)
shaft to the steering column. Install the bolt and
tighten to 49 Nzm (36 ft. lbs.).
(2) Slide the lower coupler down onto steering gear.
Install the bolt and tighten to 49 Nzm (36 ft. lbs.).
19 - 32
STEERING
INSTALLATION
(1) Align the column coupler shaft to steering gear.
Refer to Column Coupler installation in this section.
(2) Position the steering gear on the frame rail and
install the bolts. Tighten the bolts to 95 Nzm (70 ft.
lbs.) torque.
(3) Align and install the pitman arm. Refer to Pitman Arm Installation in the Steering Linkage section.
(4) Connect fluid hoses to steering gear. Refer to
Pressure and Return Hose Replacement in this group.
STEERING
19 - 33
Use Puller C-3894-A for tie rod removal. Failure to use this tool could damage the tie rod
and seal (Fig. 3).
A damaged ball stud seal requires removal of the
seal. Inspect the tie-rod end ball stud at the throat
opening. Check for lubricant loss, contamination, ball
stud wear or corrosion. If these conditions exist, replace the tie-rod. A replacement seal can be installed
if lubricant is in good condition. Otherwise, a complete replacement tie-rod end should be installed. Lubricate the tie-rod end with MOPARt Multi-Mileage
Lubricant, or an equivalent product.
(3) Install Puller C-3894-A on the tie-rod end stud
and steering arm (Fig. 3). Loosen the tie-rod end stud
from steering knuckle arm.
(4) Remove the hoses from the pump (power steering only). If necessary, refer to the hose removal procedure.
(5) Disconnect the steering shaft coupler from the
pinion gear shaft by collapsing shaft (Fig. 1).
(6) Remove the bolts (Fig. 2) that attach the gear
to the front crossmember. Remove the gear.
INSTALLATION
(1) Position the gear at the front crossmember. Install the attaching bolts (Fig. 1).
For manual rack and pinion gears, ensure
that the master serration is aligned.
(2) Tighten the steering gear-to-crossmember bolts
to 203 Nzm (150 ft. lbs.) torque.
(3) Connect the steering shaft coupler to the pinion
gear shaft and tighten bolt to 49 Nzm (36 ft. lbs.).
19 - 34
STEERING
(4) Loosen the jam nut and un-thread the tie-rod
(Fig. 4).
TIE-ROD END
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the cotter pin and nut from the tie-rod
end stud at the steering knuckle arm (Fig. 3).
Use Puller C-3894-A for tie rod removal. Failure to use this tool could damage the tie rod
and seal (Fig. 3).
A damaged ball stud seal requires removal of the
seal. Inspect the tie-rod end ball stud at the throat
opening. Check for lubricant loss, contamination, ball
stud wear or corrosion. If these conditions exist, replace the tie-rod. A replacement seal can be installed
if lubricant is in good condition. Otherwise, a complete replacement tie-rod end should be installed. Lubricate the tie-rod end with MOPARt Multi-Mileage
Lubricant, or an equivalent product.
(3) Install Puller C-3894-A on the tie-rod end stud
and steering arm (Fig. 3). Loosen the tie-rod end stud
from steering knuckle arm.
INSTALLATION
(1) Thread the replacement tie-rod end onto the tie
rod. Do not tighten the jam nut.
(2) Use pliers to expand the protective rubber boot
outer clamp and remove it from the boot. Leave it
loose around the tie rod.
(3) Connect the tie-rod end stud to the steering
knuckle arm. Tighten the nut to 54 Nzm (40 ft. lbs.)
torque. Install a new cotter pin.
(4) Adjust the wheel toe position, refer to Group 2,
Wheel Alignment. Do not twist the protective rubber
boot.
(5) Tighten the locknut to 75 Nzm (55 ft. lbs.)
torque. Lubricate the boot outer groove (tie rod end)
with silicone type lubricant. Ensure that the protective rubber boot is not twisted.
BOOT SEAL
Servicing the rubber boot must be done with
the steering gear removed from the vehicle
(Fig. 5).
REMOVAL
(1) Loosen the locknut and remove the tie-rod.
(2) Remove the outer clamp from the rubber boot.
(3) Remove the boot inner clamp.
(4) Mark the vent tube location on steering gear
before removing the rubber boot.
STEERING
INSTALLATION
(1) Align the vent tube with the reference mark on
the steering gear.
(2) Position and align the new boot over the housing.
(3) Install inner clamp on the rubber boot.
(4) Position outer clamp on the inner tie rod.
(5) Install the tie-rod end.
(6) Lubricate the boot outer groove (tie rod end)
with silicone type lubricant. Ensure that the protective rubber boot is not twisted.
(7) Install the outer clamp on the boot.
19 - 35
19 - 36
STEERING
STEERING COLUMN
INDEX
page
page
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Column Assembly Replacement . . . . . . . . . . . . . . 39
Component Service . . . . . . . . . . . . . . . . . . . . . . . . 41
Service Information . . . . . . . . . . . . . . . . . . . . . . . . 36
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SERVICE INFORMATION
STEERING
19 - 37
STEERING WHEEL
REMOVAL
When removing a deployed air bag module Refer to
Group 8M.
(1) Make sure the front wheels are in the straight
ahead position.
(2) Disconnect battery negative cable and isolate.
(3) From underside of steering wheel, remove
speed control switch or trim piece mounting screws
(Fig. 4).
(4) Pull switches from wheel and unplug connector
(Fig. 5).
(5) Using a small screwdriver remove right rear
steering wheel cover (Fig. 6).
(6) Remove 4 nuts attaching AirBag Module (Fig.
7).
(7) Remove AirBag Module from steering wheel
and unplug squib connector from airbag module.
(8) Remove the steering wheel retaining nut.
Steering wheel and shaft are master splined for installation reference.
INSTALLATION
(1) Pull speed control and air bag wires through
the lower hole in the steering wheel. Pull the horn
wire through the smaller hole at the top (Fig. 8). Ensure the wires are NOT pinched.
(2) Install the steering wheel with the scored
marks or master splines aligned.
(3) Install the retaining nut and tighten to 61 Nzm
(45 ft. lbs.) torque. Force the steering wheel down
on the shaft with the retaining nut only. Do not
hammer or shock the column with sudden impact to install the wheel.
(4) Connect the wires to the horn buttons, speed
control switch and air bag module.
(5) Connect clockspring wiring connector to the
module, by pressing straight in on the connector. The
connector should latch securely beneath module locking clip to assure positive connection.
19 - 38
STEERING
INSTALLATION
(1) Snap clockspring assembly onto column. If
clockspring is not properly positioned, follow the centering procedures before installing steering wheel.
(2) Connect the wire connector to the clockspring.
WARNING: ENSURE CLOCKSPRING WIRE CONNECTION IS COMPLETELY SEATED. THE LATCHING
CLIP ARMS MUST BE PROPERLY ENGAGED ON
THE MODULE.
(3) Install upper and lower steering column
shrouds. Be sure wiring is inside of shrouds and not
pinched.
(4) Install the steering wheel and, refer to Steering
Wheel Installation.
CLOCKSPRING
REMOVAL
(1) Place the front wheels in the straight ahead position before starting the repair.
(2) Disconnect battery negative cable and isolate.
CENTERING PROCEDURE
If the rotating tape within the clockspring is not
positioned properly, the clockspring may fail during
use. The following procedures MUST BE USED to
center the clockspring.
(1) Place the front wheels in the straight ahead position before starting the procedure.
(2) Depress the 2 locking tabs to disengage the
locking mechanism (Fig. 9).
(3) Keeping the mechanism disengaged, rotate the
clockspring rotor in the CLOCKWISE DIRECTION
to the end of the travel. Do not apply excessive
torque.
STEERING
19 - 39
Fig. 9 ClockspringAuto-Locking
(4) From the end of travel, rotate the rotor 2 1/2
full turns in the COUNTER CLOCKWISE direction.
The horn wire should end up at the top and the
squib wire at the bottom (Fig. 9).
(5) Install the steering wheel, refer to Steering
Wheel Installation.
19 - 40
STEERING
INSTALLATION
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
STEERING
(3) Remove the shipping lock pin (Fig. 1), if necessary.
(4) Install column through floor pan.
(5) Position the column bracket shear pins on the
attaching studs. Install, but loose assemble the two
upper bracket washers and nuts.
(6) With the front wheels in the straight-ahead position. Align and install the upper and lower coupler.
Do not apply force at the top of the steering
column shaft.
(7) Install the coupler bolt and tighten to 48 Nzm
(36 ft. lbs.) torque.
(8) Clip the wiring harness on the steering column.
Connect the multi-function switch wiring.
(9) Install the upper fixed shroud (Fig. 1).
(10) Be sure both spacers are fully seated in the
column support bracket by pulling column upwards.
Tighten the upper column bracket support nuts to 12
Nzm (105 in. lbs.) torque (DO NOT OVER TORQUE).
(11) Tighten the toe plate attaching bolts/nuts (Fig.
1) to 23 Nzm (200 in. lbs.) torque.
(12) Install the wiring connections to the column.
Install the lower fixed shroud.
(13) Column shift vehicles, install the gear position
indicator cable.
(14) Install the lock housing shrouds. Install the
tilt lever (if equipped).
(15) Install the lower dash panel column cover.
(16) Install hood release cable bracket.
(17) Install steering wheel on column, refer to
Steering Wheel-Installation.
(18) Column shift vehicles, connect the shift link
rod to the transmission shift lever. Use MOPARt
Multipurpose Lubricant, or an equivalent product, to
aid the installation.
(19) Check operation of the transmission shift linkage and adjust as necessary. Refer to Group 21,
Transmission for the shift linkage adjustment.
(20) Slowly move the gear shift selector lever from
1 or L (low) to P (PARK). The indicator pointer must
align with each indicator position.
(21) Connect the battery ground (negative) cable.
COMPONENT SERVICE
The Acustar columns (Fig.1) have been designed to
be serviced as an assembly; less wiring, switches,
shrouds, steering wheel, etc. Most steering column
components can be serviced without removing the
column from the vehicle. For additional information
refer to Group 8H, Electrical.
(1) The gear shift lever (if equipped) can be serviced. Use a drift and a suitable size socket to drive
out the pin (Fig. 18).
(2) The gear position indicator driver can be removed by drilling out the rivets (Fig. 19). Use care
when installing a new driver. Use the correct replacement rivets. Install with a hand rivet gun (Fig. 20).
19 - 41
19 - 42
STEERING
TORQUE SPECIFICATIONS
STEERING COLUMN
STEERING LINKAGE
STEERING GEAR
STEERING PUMP
21 - 1
page
AX 15 MANUAL TRANSMISSION
INDEX
page
Gear Ratios . . . . . . . . . .
General Information . . . .
Identification . . . . . . . . . .
Recommended Lubricant
Shift Pattern . . . . . . . . . .
Specifications . . . . . . . . .
Speedometer Service . . .
Switch and Plug Locations
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2
1
2
2
2
3
3
2
GENERAL INFORMATION
The AX 15 is a five speed, synchromesh, manual
transmission. Fifth gear is an overdrive range with a
ratio of 0.789:1. The AX 15 is used with 2.5L and
3.9L engines.
page
Transmission Assembly and Adjustment . . . . . . . . . 24
Transmission Diagnosis . . . . . . . . . . . . . . . . . . . . . 3
Transmission Disassembly and Overhaul . . . . . . . . . 8
Transmission Installation2-Wheel Drive . . . . . . . . 6
Transmission Installation4-Wheel Drive . . . . . . . . 7
Transmission Removal2-Wheel Drive . . . . . . . . . . 4
Transmission Removal4-Wheel Drive . . . . . . . . . . 5
The AX 15 is a top loader style transmission with the
entire shift mechanism located in the shift tower
(Fig. 1).
21 - 2
AX 15 MANUAL TRANSMISSION
IDENTIFICATION
The AX 15 identification code numbers are on the
bottom surface of the transmission gear case (Fig. 2).
The first number represents year of manufacture (5
= 1995, 4 = 1994). The second and third numbers indicate month of manufacture (01 = January, 02 = february, etc.). The remaining numbers represent the
transmission serial number.
Correct lubricant refill or top-off level is to the bottom edge of the fill plug hole.
Lubricant dry fill capacity is approximately 3.10 liters (3.27 U.S. quarts) in 4-wheel drive models.
SHIFT PATTERN
GEAR RATIOS
RECOMMENDED LUBRICANT
Recommended lubricant for the AX 15 transmission
is Mopar 75W-90, API Grade GL-5 gear lubricant, or
equivalent.
AX 15 MANUAL TRANSMISSION
SPECIFICATIONS
AX 15 transmission specifications are located at
the end of Group 21. Recommended lubricant, gear
ratios, and overhaul information are all provided in
this section.
TRANSMISSION DIAGNOSIS
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an incorrect lubricant level check.
Leaks can occur at the mating surfaces of the gear
case, intermediate plate and adapter or extension
housing, or from the front/rear seals. A suspected
leak could also be the result of an overfill condition.
Leaks at the rear of the extension or adapter housing will be from the housing oil seals. Leaks at component mating surfaces will probably be the result of
inadequate sealer, gaps in the sealer, incorrect bolt
tightening, or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either a loose or damaged, front bearing retainer or
retainer seal. Lubricant may also drip from the
clutch housing after extended operation. If the leak is
severe, it will contaminate the clutch disc causing
slip, grab and chatter.
Transmissions filled from air or electrically powered lubricant containers can be underfilled. This
generally happens when the container delivery mechanism is improperly calibrated. Always check the lubricant level after filling to avoid an under fill
condition.
A correct lubricant level check can only be
made when the vehicle is level; use a drive-on
hoist to ensure this. Also allow the lubricant to
settle for a minute or so before checking. These
recommendations will ensure an accurate
check and avoid an under-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by: low lubricant
level; improper or contaminated lubricants; transmission component damage; faulty clutch linkage; or
damaged clutch cover or disc.
Substantial lubricant leaks can result in gear, shift
rail, synchro and bearing damage. If a leak goes undetected for an extended period, the first indications
of a problem are usually hard shifting and noise.
Incorrect or contaminated lubricants can also contribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear,
internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. A loose, worn, or damaged pressure plate,
disc, or clutch linkage can cause incorrect release. If
the clutch problem is advanced, gear clash during
shifts can result.
21 - 3
TRANSMISSION NOISE
Most manual transmissions make some noise during normal operation. Rotating gears can generate a
mild whine that may only be audible at extreme
speeds.
Severe, obviously audible transmission noise is
generally the result of a lubricant problem. Insufficient, improper, or contaminated lubricant can promote rapid wear of gears, synchros, shift rails, forks
and bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine pinion
gear requirements. If the gear must be replaced, refer to the parts catalogue information for the correct
gear.
21 - 4
AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
21 - 5
21 - 6
AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
(6) Install and tighten clutch housing bolts to 68
Nzm (50 ft. lbs.) torque. Be sure housing is fully
seated before tightening bolts. Install housing dust
cover after tightening housing bolts.
(7) Lower transmission for access to shift tower.
(8) Reach up and around transmission and insert
shift lever into shift tower. Press lever retainer downward and turn it clockwise to lock it in place. Then
install lever dust boot on shift tower.
(9) Fill transmission with Mopar 75W-90, or equivalent API grade GL 5 gear lubricant. Correct fill level
is to bottom edge of fill plug hole.
(10) Connect backup light switch wires.
(11) Connect transmission harnesses to clips on
case.
(12) Install crossmember. Tighten crossmember-toframe bolts to 68 Nzm (50 ft. lbs.) torque.
(13) Tighten crossmember-to-transmission insulator nuts to 68 Nzm (50 ft. lbs.) torque.
(14) Install slave cylinder. Tighten cylinder nuts to
23 Nzm (200 in. lbs.) torque.
(15) Remove jack used to support transmission.
(16) Install strut bolts/nuts, if removed. Also install oil filter if removal was necessary.
(17) If speedometer was removed, install pinion
and adapter. Then index adapter and install speed
sensor (Fig. 6). Connect wires to speed sensor.
(18) Connect exhaust pipes.
(19) Align and install remaining exhaust components that were loosened, or removed. Tighten all
clamp and bracket bolts and nuts securely. Be sure
exhaust components are clear of all chassis and driveline components.
(20) Align and install propeller shaft. Tighten
U-joint clamp bolts to 19 Nzm (170 in. lbs.) torque.
(21) Verify that all linkage components, hoses and
electrical wires have been connected.
(22) Remove any remaining support stands and
lower vehicle.
(23) Install crankshaft position sensor.
21 - 7
21 - 8
AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
(7) Remove shift arm shaft plug (Fig. 6).
(8) Remove shift arm shaft with large magnet (Fig.
7).
(9) Remove shift arm (Fig. 8).
21 - 9
21 - 10
AX 15 MANUAL TRANSMISSION
(13) Remove backup light switch from adapter/extension housing.
(14) On 2-wheel drive models, remove distance
sensor, speedometer adapter and driven gear if not
removed previously.
(15) Remove adapter/extension housing bolts (Fig.
12).
(16) Loosen adapter/extension housing with rubber
mallet (Fig. 13).
(17) Remove housing after loosening it (Fig. 14)
AX 15 MANUAL TRANSMISSION
21 - 11
21 - 12
AX 15 MANUAL TRANSMISSION
(5) Loosen gear case by tapping it away from intermediate plate with rubber mallet (Fig. 20).
AX 15 MANUAL TRANSMISSION
21 - 13
21 - 14
AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
(14) Remove fifth spline gear (Fig. 33).
(15) Remove fifth gear synchro ring (Fig. 34).
(16) Remove fifth gear synchro and sleeve assembly (Fig. 35).
21 - 15
21 - 16
AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
21 - 17
(2) Remove 1-2 and 3-4 shift rail C-rings with two
screwdrivers of equal size and length (Fig. 42).
21 - 18
AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
(12) Remove reverse shift rail C-ring with two
equal length and size screwdrivers (Fig. 51).
21 - 19
(15) Position shift rails, shift forks, lock balls, interlock plugs and interlock pins on the workbench in
order of removal. This will help in identifying components during inspection and assembly.
21 - 20
AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
21 - 21
21 - 22
AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
21 - 23
21 - 24
AX 15 MANUAL TRANSMISSION
Check clearance between the shift forks and synchro sleeves with a feeler gauge (Fig. 68). Clearance
should not exceed 1.0 mm (0.039 in.). Replace the
synchro sleeve (and matching hub) if clearance exceeds the stated limit.
(2) Press front bearing on cluster gear. Then secure bearing with thickest snap ring that will fit in
ring groove on gear (Fig. 71).
(3) Install new oil seals in front bearing retainer
and adapter housing (Fig. 72). Installation depth for
bearing retainer seal is 10.5 - 11.5 mm (0.414 - 0.453
in.).
(4) Install reverse shaft and shaft retaining pin in
adapter housing. Then install access hole plug with
torx bit (Fig. 73).
(5) Lubricate reverse shaft and gear components
with Mopar 75W-90 gear lubricant.
AX 15 MANUAL TRANSMISSION
21 - 25
21 - 26
AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
21 - 27
(3) Install cluster gear rear bearing in intermediate plate (Fig. 81). Be sure snap ring groove in bearing is rearward as shown.
21 - 28
AX 15 MANUAL TRANSMISSION
bly. The jelly will hold the interlock components in place making installation easier. Use a
pencil magnet to hold and insert the interlocks.
Then use a small screwdriver to push the interlock components into place.
AX 15 MANUAL TRANSMISSION
21 - 29
21 - 30
AX 15 MANUAL TRANSMISSION
(6) Coat 1-2 shift rail interlock plug with petroleum jelly and install it in intermediate plate bore
(Fig. 90).
AX 15 MANUAL TRANSMISSION
21 - 31
21 - 32
AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
(9) Install reverse shift head and rail (Fig. 105).
Then install lock ball in shift head.
21 - 33
through fork, shift head, intermediate plate and reverse shift fork. Be sure interlock ball is not displaced during installation.
(12) Align screw holes in shift fork and rail and install set screw (Fig. 108). Tighten screw to 20 Nzm
(15 ft. lbs.) torque.
21 - 34
AX 15 MANUAL TRANSMISSION
(7) Clean gear case and front bearing retainer sealing surfaces with wax and grease remover. Then
wipe dry with a clean cloth.
(8) Install new seal in front bearing retainer. Then
lubricate seal lip with petroleum jelly. Installation
depth for seal is 10.5 - 11.5 mm (0.413 - 0.453 in.).
(9) Apply a 3 mm (1/8 in.) wide bead of Mopar
Gasket Maker to front bearing retainer sealing surface.
(10) Align and install front bearing retainer (Fig.
114). Be sure retainer is properly seated on case and
bearings.
(11) Install and tighten front bearing retainer bolts
to 17 Nzm (12 ft. lbs.) torque.
(12) On 2-wheel drive models, install speedometer
gear, lock ball and retaining rings (Fig. 115). Be sure
lock ball is engaged in gear.
AX 15 MANUAL TRANSMISSION
21 - 35
21 - 36
AX 15 MANUAL TRANSMISSION
(23) Align shift arm with shaft and push shaft into
arm.
(24) Rotate shift arm shaft until set screw holes in
shaft and arm are aligned.
(25) Install and tighten shift arm set screw to 38
Nzm (28 ft. lbs.) torque (Fig. 125).
AX 15 MANUAL TRANSMISSION
(26) Install and tighten restrictor pins to 19 Nzm
(14 ft. lbs.) torque (Fig. 125).
(27) Install and tighten shift arm shaft access plug
to 19 Nzm (14 ft. lbs.) torque (Fig. 126).
21 - 37
21 - 38
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40
38
41
60
41
56
41
45
page
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Transmission
Gear Ratios . . . . . . . . . . . .
Installation (2-Wheel Drive) .
Installation (4-Wheel Drive) .
Lubricant . . . . . . . . . . . . . .
Lubricant Level and Capacity
Removal (2-Wheel Drive) . .
Removal (4-Wheel Drive) . .
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40
44
45
40
40
42
43
Roller bearings are used to support the transmission shafts in the two housings. The transmission
gears all rotate on caged type needle bearings.
The NV3500 has only one shift shaft; all three shift
forks are mounted on the single shaft. The shaft is
supported in the front and rear housings by bushings
and one bearing. Internal shift components consist of
the forks, shaft, shift lever socket, anti-rotation
bracket, bias spring and detent components (Fig. 2).
21 - 39
21 - 40
TRANSMISSION LUBRICANT
Required lubricant for the NV3500 is Mopar Manual Transmission Lubricant P/N 4761526. This is the
only lubricant recommended for use in NV3500
transmissions.
TRANSMISSION CHANGES
The shift lever assembly and shift mechanism are
new for 1995. The new design self-biasing shift lever
is mounted in a lightweight shift tower. The lever
and tower are serviced as an assembly.
The shift socket and shift shaft are basically unchanged. However, the bias spring, and anti-rotation
bracket and rollers are no longer necessary and have
been eliminated. This is made possible by the new
self-biasing shift lever assembly.
TRANSMISSION DIAGNOSIS
LOW LUBRICANT LEVEL
A low transmission lubricant level is generally the
result of a leak, inadequate lubricant fill, or an incorrect lubricant level check.
Leaks can occur at the mating surfaces of the housings, or from the front/rear seals. A suspected leak
could also be the result of an overfill condition.
Leaks at component mating surfaces will probably
be the result of inadequate sealer, gaps in the sealer,
incorrect bolt tightening, or use of a non-recommended sealer.
A leak at the front of the transmission will be from
either a loose or damaged, front bearing retainer or
retainer seal. Lubricant may also drip from the
transmission clutch housing after extended operation. If the leak is severe, it will contaminate the
clutch disc causing slip, grab and chatter.
Transmissions filled from air or electrically powered lubricant containers can be underfilled. This
generally happens when the container delivery mechanism is improperly calibrated. Always check the lubricant level after filling to avoid an under fill
condition.
A correct lubricant level check can only be
made when the vehicle is level; use a drive-on
hoist to ensure this. Also allow the lubricant to
settle for a minute or so before checking. These
recommendations will ensure an accurate
check and avoid an under-or-overfill condition.
21 - 41
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, transmission component damage, clutch linkage malfunction,
or by a damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
component, synchro and bearing damage. If a leak
goes undetected for an extended period, the first indications of a problem are usually hard shifting and
noise.
Incorrect or contaminated lubricants can also contribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear,
internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. If
the clutch problem is advanced, gear clash during
shifts can result.
Worn or damaged synchro rings can cause gear
clash when shifting into any forward gear. In some
new or rebuilt transmissions, new synchro rings may
tend to stick slightly causing stiff and/or noisy shifts.
In most cases, this condition will decline as the rings
wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise during normal operation. Rotating gears can generate a
mild whine that may only be audible at extreme
speeds.
Severe, obviously audible transmission noise is
generally the result of a lubricant problem. Insufficient, improper, or contaminated lubricant can promote rapid wear of gears, synchros, shift rails, forks
and bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine pinion
gear requirements. If the gear must be replaced, refer to the parts catalogue information for the correct
gear.
21 - 42
21 - 43
21 - 44
(28) If transmission will be disassembled for service, remove release bearing and fork.
21 - 45
21 - 46
side of plate goes toward driver side of transmission and rubber coated side faces upward.
21 - 47
21 - 48
21 - 49
21 - 50
21 - 51
21 - 52
21 - 53
21 - 54
(7) Remove second speed synchro ring. Then remove 1-2 synchro hub snap ring (Fig. 43).
21 - 55
21 - 56
Component Cleaning
Clean the gears, shafts, shift components and
transmission housings with a standard parts cleaning solvent. Do not use acid or corrosive base solvents. Dry all parts except bearings with compressed
air.
Clean the shaft bearings with a mild solvent such
as Mopar degreasing solvent, Gunk, or similar solvents. Do not dry the bearings with compressed air.
Allow the bearings to either air dry, or wipe them dry
with clean shop towels.
Shift Lever Assembly
The shift lever assembly is not serviceable. Replace
the lever and shift tower as an assembly if the tower,
lever, lever ball, or internal components are worn, or
damaged.
21 - 57
21 - 58
21 - 59
21 - 60
TRANSMISSION ASSEMBLY
Assembly Information
Gaskets are not used in the NV3500 transmission.
Sealers are used at all flange joints. Recommended
sealers are Mopar Gasket Maker (or Loctite 518) for
all flange joints and Loctite Ultra, heavy body silicone (black) sealer (or Mopar equivalent) for the input shaft bearing retainer. Apply these products as
indicated in the reassembly procedures.
It is very important that the transmission
shift components be in Neutral position during
assembly. This is necessary to prevent damaging synchro and shift components when the
housings are installed.
Transmission gears, shafts, and synchro components should all be lubricated with recommended
gear lubricant during assembly operations. Petroleum jelly can be used to prelubricate bearings and
to hold parts in place during assembly. Only petroleum jelly should be used. Do not use chassis or
bearing grease. This type of heavy grease will
plug oil channels in the housings and gears resulting in failure.
The 3-4, 1-2 and fifth-reverse synchro hub snap
rings can be fitted selectively. New snap rings are
available in 0.05 mm (0.0019 in.) thickness increments. Use the thickest snap ring that will fit in
each snap ring groove.
Proper reassembly of the NV3500 requires some
special service tools. Geartrain Assembly Fixture
6747 is especially important. The entire geartrain
and shift mechanism must be assembled in this fixture before either transmission housing can be properly installed. The tools are needed to avoid
damaging the gears, housing, or shift components.
21 - 61
(5) Lubricate and install reverse gear needle bearing on shaft (Fig. 59). Slide bearing up against shoulder on output shaft as shown.
21 - 62
21 - 63
21 - 64
21 - 65
21 - 66
21 - 67
21 - 68
21 - 69
21 - 70
21 - 71
21 - 72
21 - 73
21 - 74
21 - 75
21 - 76
21 - 77
21 - 78
21 - 79
21 - 80
21 - 81
21 - 82
page
GENERAL INFORMATION
INDEX
page
Fourth Gear Overdrive Components
Gear Ratios . . . . . . . . . . . . . . . . .
Recommended Fluid . . . . . . . . . . .
Torque Converter . . . . . . . . . . . . .
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86
83
86
82
TRANSMISSION DESCRIPTION
Chrysler 42RH and 46RH automatic transmissions
are 4-speed, fully automatic units with an overdrive
fourth gear range.
The 42RH is used with 3.9L V6 engines. The 46RH
is used with 5.2L (V8) engines.
The 42RH/46RH are dual unit designs. The assembly consists of a three speed automatic transmission
with an overdrive unit attached at the rear (Figs. 1
and 2). The overdrive unit provides a fourth gear
overdrive ratio of 0.69 to 1.
First through third gear ranges are provided by the
clutches, bands, overrunning clutch and planetary
gear set in the transmission. The overdrive unit contains an overdrive clutch, direct clutch, compound
planetary gear set and overrunning clutch.
The 42RH/46RH valve body has an additional housing. This housing contains the extra valving and electrical solenoid that provide overdrive fourth gear range.
The governor and park lock assemblies are located
inside the overdrive unit. The overdrive unit must be
removed and disassembled for service access to the
park lock and governor components.
Fourth gear is selected by a switch in the instrument panel. The switch is a signal device for the
powertrain control module (PCM). When the switch
is turned ON, it signals the PCM that overdrive
range has been selected. The PCM will then energize
the overdrive solenoid for a 3-4 upshift.
page
Transmission Changes and Parts Interchangeability . . 87
Transmission Description . . . . . . . . . . . . . . . . . . . . 82
Transmission Identification . . . . . . . . . . . . . . . . . . 86
The transmission must be in D range, third gear
before a 3-4 upshift will occur. The overdrive solenoid
will not be energized by the PCM when the switch is
in the OFF position.
TORQUE CONVERTER
A three element torque converter is used for all applications. The converter consists of an impeller, stator, and turbine. The converter also contains an
overrunning clutch and converter clutch mechanism.
A new converter is used with 42RH transmissions.
It has new design drive flats in the hub instead of
the square drive lugs used in previous models. The
oil pump inner gear was also changed to accept the
new drive flats. This converter is not interchangeable with older style converters and oil
pump gears.
The converter clutch consists of a piston, damper,
and disc. The clutch provides optimum torque transfer and economy when applied.
The clutch disc is located in the converter front
cover. The piston and damper are attached to the turbine hub. The damper helps to smooth engine firing
impulses and loads during converter clutch engagement.
Clutch engagement is controlled by the converter
clutch valve. The valve is located in the transmission
valve body. Clutch engagement occurs in drive range at
speeds above approximately 72-80 km/h (45-50 mph).
21 - 83
21 - 84
42RH/46RH AUTOMATIC TRANSMISSION
21 - 86
RECOMMENDED FLUID
The recommended (and preferred) fluid for 42RH/
46RH transmissions is Mopar ATF Plus, type 7176.
Dexron II is not really recommended and should
only be used when ATF Plus is not available.
TRANSMISSION IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan gasket surface (Fig. 3).
The first letter/number group is the transmission
part number. The next number group is the build
date and the last number group is the serial number.
Refer to this information when ordering replacement
parts.
21 - 87
21 - 88
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88
89
90
90
89
88
page
Overdrive Selector Switch . . . .
Pressure Regulation . . . . . . . .
Quick Fill Valve Operation . . . .
Shift Valve Flow Control . . . . .
Transmission Hydraulic Controls
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88
89
89
89
88
GEARSHIFT MECHANISM
The gear shift mechanism provides six shift positions which are:
park (P)
reverse (R)
neutral (N)
drive (D)
manual second (2)
manual low (1)
Manual low (1) range provides first gear only.
Overrun braking is also provided in this range. Manual second (2) range provides first and second gear
only.
Drive range provides first, second third and overdrive fourth gear ranges. The shift into overdrive
fourth gear range occurs only after the transmission
has completed the shift into D third gear range. No
further movement of the shift mechanism is required
to complete the 3-4 shift.
The fourth gear upshift occurs automatically when
the overdrive selector switch is in the ON position.
21 - 89
PRESSURE REGULATION
The pressure regulator valve maintains line pressure. The amount of pressure developed is controlled
by throttle pressure which is dependent on the degree of throttle opening. The regulator valve is located in the valve body.
The throttle valve determines line pressure and
shift speed. The throttle valve controls upshift and
downshift speeds by regulating pressure according to
throttle position.
21 - 90
engine speed
vehicle speed
throttle position
manifold vacuum (MAP sensor)
21 - 91
page
Fluid Contamination . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . .
Hydraulic Pressure Test . . . . . . . . . . . . . . .
Overdrive Fourth Gear Electrical Controls . .
Preliminary Diagnosis . . . . . . . . . . . . . . . . .
Road Testing . . . . . . . . . . . . . . . . . . . . . . .
Stall Test Analysis . . . . . . . . . . . . . . . . . . . .
Transmission Cable and Linkage Adjustment
GENERAL INFORMATION
VEHICLE IS DISABLED
(1) Check fluid level and condition.
(2) Check for broken, disconnected shift linkage.
(3) Check for cracked, leaking cooler lines, or loose,
missing pressure port plugs.
(4) Raise vehicle, start engine, shift transmission
into gear and note following:
(a) If propeller shaft turns but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shaft does not turn and transmission is noisy, stop engine. Remove oil pan, and
check for debris. If pan is clear, remove transmission and check for damaged drive plate, converter,
oil pump, input shaft, planetary gear, clutches.
(c) If propeller shaft does not turn and transmission is not noisy, perform hydraulic pressure test to
determine if problem is hydraulic or mechanical.
PRELIMINARY DIAGNOSIS
Two basic procedures are required. One procedure
for vehicles that are driveable and an alternate procedure for disabled vehicles (will not back up or move
forward).
VEHICLE IS DRIVEABLE
(1) Check fluid level and condition.
(2) Check throttle cable and gearshift linkage adjustments if complaint was based on delayed, erratic,
or harsh shifts.
(3) Road test vehicle and note how transmission
engages, upshifts, downshifts.
(4) Perform stall test if complaint is based on sluggish acceleration or if abnormal throttle opening is
needed to maintain normal speeds with a properly
tuned engine.
(5) Perform hydraulic pressure test if shift problems were noted during road test.
(6) Perform air pressure test to check clutch-band
operation if hydraulic pressure test is inconclusive.
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92
91
94
93
91
93
96
93
21 - 92
either case, air bubbles cause fluid overheating, oxidation and varnish buildup which interferes with
valve, clutch and servo operation.
Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or
fill tube. Fluid overflow can easily be mistaken for a
leak if inspection is not careful.
FLUID CONTAMINATION
ROAD TESTING
Before road testing, be sure the fluid level and all
linkage adjustments have been checked and adjusted
if necessary. Observe engine performance during the
road test. A poorly tuned engine will not allow an accurate analysis of transmission operation.
Operate the transmission in all gear ranges. Check
for shift variations and engine flare, which indicates
slippage. Note if shifts are harsh, spongy, delayed,
early, or if part throttle downshifts are sensitive.
21 - 93
21 - 94
21 - 95
(3) Move selector lever to D range. This is two detents rearward from full forward position.
(4) Read pressures on both gauges as transmission
throttle lever is moved from full forward to full rearward position.
(5) Line pressure should be 54-60 psi (372-414
kPa) with throttle lever forward and gradually increase as lever is moved rearward.
(6) Front servo is pressurized only in D range and
should be same as line pressure within 3 psi (21 kPa)
up to downshift point.
Test FourTransmission In Reverse
This test checks pump output, pressure regulation and the front clutch and rear servo circuits. Use 300 psi Test Gauge C-3293-SP for this
test.
(1) Connect 300 psi gauge to rear servo port (Fig.
3).
(2) Start and run engine at 1600 rpm for test.
(3) Move valve body selector lever four detents
rearward from the full forward position. This is Reverse range.
(4) Move throttle lever all way forward then all
way rearward and note gauge readings.
(5) Pressure should be 145 - 175 psi (1000-1207
kPa) with lever forward and increase to 230 - 280 psi
(1586-1931 kPa) as lever is moved rearward.
Test FiveGovernor Pressure
This test checks governor operation by measuring governor pressure response to changes
in engine speed. It is usually not necessary to
check governor operation unless shift speeds
are incorrect or if the transmission will not
downshift.
(1) Connect 100 psi Test Gauge C-3292 to governor
pressure port (Fig. 3).
(2) Move shift lever to D range.
(3) Start and run engine at curb idle speed and
note pressure. At idle and with vehicle stopped, pressure should be zero to 1-1/2 psi maximum. If pressure exceeds this figure, governor valve or weights
are sticking open.
(4) Slowly increase engine speed and observe
speedometer and pressure test gauge. Governor pressure should increase in proportion to vehicle speed.
Or approximately 1 psi for every 1 mph.
(5) Pressure rise should be smooth and drop back
to 0 to 1-1/2 psi when wheels stop rotating.
(6) Compare results of pressure tests with analysis
chart (Fig. 4).
Test SixTransmission In Overdrive Fourth Gear
This test checks line pressure at the overdrive clutch in fourth gear range. Use 300 psi
Test Gauge C-3292 for this test.
(1) Raise vehicle on hoist.
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21 - 97
21 - 98
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21 - 100
DIAGNOSIS CHARTS
The diagnosis charts provide additional reference
when diagnosing a transmission fault. The charts
provide general information on a variety of transmission, overdrive and converter fault conditions.
The hydraulic flow charts outline fluid flow and hydraulic circuitry. Circuit flow is provided for all gear
ranges. Approximate working pressures are also supplied for each gear range.
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AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING
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136
134
125
125
129
127
125
125
130
129
125
RECOMMENDED FLUID
Recommended (and preferred) fluid for 42RH/46RH
transmissions is Mopar ATF Plus, type 7176.
Dexron II is not really recommended and should
only be used when ATF Plus is not available.
page
Refilling After Overhaul or Fluid/Filter Change
Shift Linkage Adjustment . . . . . . . . . . . . . . .
Slip Yoke Seal Replacement (2-Wheel Drive
Models) . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Service . . . . . . . . . . . . . . . . .
Transmission Cooler Flow Testing . . . . . . . .
Transmission Cooler Line and Fitting Service
Transmission Cooler Replacement . . . . . . . .
Transmission Cooler Reverse Flushing . . . .
Transmission Throttle Valve Cable Adjustment
Valve Body Service . . . . . . . . . . . . . . . . . . .
. . . 126
. . . . 127
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130
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133
136
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(7) Drive vehicle until transmission fluid is at normal operating temperature. Then recheck fluid level
as described in next step.
(8) Leave engine running at curb idle speed, shift
into Neutral, and check fluid level again. This time,
add just enough fluid to bring level up to MAX arrow mark but do not overfill.
(9) When fluid level is correct, shut engine off, release park brake, remove funnel, and reseat dipstick
in fill tube.
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21 - 129
ADJUSTMENT PROCEDURE
(1) Raise vehicle.
(2) Loosen band adjusting screw locknut. Then
back locknut off 4-5 turns.
(3) Be sure adjusting screw turns freely in case.
Lubricate screw threads with Mopar spray lube, LPS
all purpose spray lube, or equivalent quality product.
(4) Tighten band adjusting screw to 8 Nzm (72 in.
lbs.) torque with inch pound Torque Wrench
C-3380-A, a 3-in. extension and 5/16 socket (Fig. 9).
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw (Fig. 10), tighten the screw to only
5 Nzm (47-50 in. lbs.) torque.
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SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine pinion
gear requirements. If the gear must be replaced, refer to the parts catalogue information for the correct
gear.
The center terminal of the switch is the starter circuit terminal. It provides the ground for the starter
solenoid circuit through the selector lever in Park
and Neutral positions only. The outer terminals on
the switch are for the backup lamp circuit.
SWITCH TEST
(1) Verify that gearshift linkage is correctly adjusted before testing. Switch will not operate properly if linkage adjustment is incorrect.
(2) To test switch, remove wiring connector. Then
test continuity between center terminal and trans-
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(8) Position cooler on radiator and install cooler attaching U-nuts and screws.
(9) Tighten cooler hose clamps securely.
(10) Install grille and air conditioning condenser.
(11) Check and adjust transmission fluid level.
(12) If air conditioning condenser lines were disconnected during service, evacuate and recharge system.
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140
137
139
144
145
143
GENERAL INFORMATION
The entire transmission assembly must be removed in
order to service the torque converter, driveplate, and oil
pump. The overdrive unit can be removed and serviced
separately. It is not necessary to remove the entire
transmission assembly to service the overdrive unit.
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid component damage. The converter drive plate, pump
bushing, or oil seal can be damaged if the converter is left attached to the driveplate during removal. Be sure to remove the transmission and
converter as an assembly.
page
Overdrive Unit Removal4-Wheel Drive
Transmission Installation2-Wheel Drive
Transmission Installation4-Wheel Drive
Transmission Removal2-Wheel Drive .
Transmission Removal4-Wheel Drive .
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140
142
137
139
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(1) Mount transmission on transmission jack. Secure transmission to jack with safety chains.
(2) Check torque converter hub for sharp edges,
burrs, scratches, or nicks. Polish hub and notches
with crocus cloth or 400 grit paper if necessary. Hub
must be smooth to avoid damaging pump seal.
(3) Lubricate converter hub and pump seal lip with
transmission fluid or petroleum jelly.
(4) Position converter hub so drive slots will be
aligned with pump gears. Then remove aligning tool
and carefully insert converter hub into pump and
gears.
(5) Verify that converter is fully seated. Use
straight edge and steel ruler to check seating (Fig. 6).
Surface of converter lugs should be 12.7 mm (1/2 in.)
to rear of straight edge when converter is fully
seated.
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(2) If original case gasket is in good condition, proceed to step (6). If overdrive piston retainer was not
removed during service and original case gasket is
not reusable, prepare new gasket as described in
steps (3) through (5).
(3) Cut out old case gasket around piston retainer
with razor knife.
(4) Use old gasket as template and trim new gasket to fit.
(5) Position new gasket over piston retainer and on
transmission case. Use petroleum jelly to hold gasket
in place if necessary. Do not use any type of
sealer to secure gasket. Use petroleum jelly
only.
(6) Install selective spacer on intermediate shaft, if
removed. Spacer goes in groove just rearward of
shaft rear splines.
(7) Install overdrive piston in retainer, if removed.
Lubricate piston seals with Mopar Door Ease, RuGlyde, or petroleum jelly to ease installation. Be sure
piston locating lugs are aligned in piston retainer.
(8) Install thrust bearing in overdrive clutch hub.
Use liberal quantity of petroleum jelly to hold bearing in position.
CAUTION: Be sure the shoulder on the inside diameter of the bearing is facing forward.
(9) Install thrust plate in overdrive piston hub.
Use liberal amount of petroleum jelly to hold thrust
plate in position.
(10) Verify that splines in overdrive planetary gear
and overrunning clutch hub are aligned with Tool
6227-2. Overdrive unit cannot be fully installed
if splines have rotated out of alignment. If misaligned has occurred, overdrive will have to be
disassembled in order to realign splines.
(11) Raise overdrive unit and carefully slide it
straight onto intermediate shaft. Insert park rod into
21 - 147
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159
168
154
153
. . 154
page
Rear Clutch Overhaul . . . . . . . . . . . . . . . .
Rear Servo and Band Overhaul . . . . . . . . .
Transmission Assembly and Adjustment . . .
Transmission Case Cleaning and Inspection
Transmission Disassembly . . . . . . . . . . . .
Valve Body Cleaning and Inspection . . . . .
Valve Body Service and Adjustment . . . . . .
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161
169
183
154
147
176
170
. . 164
TRANSMISSION DISASSEMBLY
(1) Remove torque converter if not previously removed.
(2) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning operations.
(3) Remove shift and throttle levers from valve
body manual lever shaft.
(4) Remove bolts attaching overdrive unit to transmission (Fig. 1). Note bolt locations as some attaching bolts are different lengths.
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OVERRUNNING CLUTCHLOW-REVERSE
DRUMOVERDRIVE PISTON RETAINER
INSPECTION AND OVERHAUL
If the overrunning clutch and cam came out with
the low-reverse drum, remove the cam and clutch
from the drum as follows: Thread two clutch cam
bolts into the cam. Then lift the clutch and cam out
of the drum with the bolts (Fig. 32). Rotate the cam
back and forth to ease removal if necessary.
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(6) Remove seals from clutch piston and clutch retainer hub. Discard both seals as they are not reusable.
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(12) Remove solenoid connector from 3-4 accumulator housing (Fig. 99). Note that connector is attached to housing with shoulder-type screw.
Keep this screw with accumulator housing to
avoid losing it.
(13) Note routing of solenoid wires for assembly
reference (Fig. 100).
(14) Remove screws attaching solenoid assembly to
valve body lower housing and remove solenoid and
connector assembly (Fig. 101).
(15) Remove 3-4 accumulator housing attaching
screws and remove housing from valve body (Fig.
102).
(16) Remove following parts from valve body lower
housing: 3-4 shift valve and spring, pressure regula-
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The kickdown valve spring must be fully compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
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(22) Coat intermediate shaft thrust washer with petroleum jelly. Then install washer in rear clutch hub
(Fig. 148). Use enough petroleum jelly to hold washer
in place. Be sure grooved side of washer faces
rearward as shown. Also note that washer only
fits one way in clutch hub.
21 - 189
(38) Install new seals on overdrive piston. Then lubricate seals with Ru-Glyde, Door-Eze or petroleum
jelly.
(39) Install overdrive piston in retainer. Align locating lugs on piston in locating bores in retainer (Fig. 156). Use thin plastic strip or feeler
gauge to help guide piston outer seal into retainer.
(40) Install spacer on intermediate shaft, if not
previously installed.
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203
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203
201
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page
Planetary Geartrain Overhaul . . . . . . . . . . . . . . . .
Rear Clutch Overhaul . . . . . . . . . . . . . . . . . . . . .
Rear Servo Overhaul . . . . . . . . . . . . . . . . . . . . .
Transmission Assembly . . . . . . . . . . . . . . . . . . . .
Transmission Case Cleaning and Inspection . . . .
Transmission Disassembly . . . . . . . . . . . . . . . . .
Valve Body Cleaning and Inspection . . . . . . . . . .
Valve Body Service and Adjustment . . . . . . . . . . .
211
210
204
229
200
193
223
217
TRANSMISSION DISASSEMBLY
(1) Remove torque converter, if not previously removed.
(2) Clean transmission exterior with steam gun or
solvent. Wear safety goggles while cleaning transmission.
(3) Remove shift and throttle levers from shaft of
valve body manual lever.
(4) Remove bolts attaching overdrive unit to transmission case (Fig. 1).
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(26) Remove intermediate shaft thrust washer. Triangular shaped washer will either be on shaft pilot
hub or in rear clutch retainer (Fig. 26).
(27) Remove thrust plate from intermediate shaft
hub (Fig. 27).
(28) Remove
intermediate
shaft-planetary
geartrain assembly (Fig. 28). Set assembly aside for
disassembly and inspection later in procedure.
21 - 199
21 - 200
parts. These inserts are available from most automotive jobbers. Stainless steel inserts are preferred.
The use of crocus cloth is permissible where necessary, providing it is used carefully. When used on
valves, use extreme care to avoid rounding off sharp
edges. Sharp edges are vital as they prevent foreign
matter from getting between the valve and valve
bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or Eclips that are bent or distorted. Replace these parts
as well.
Lubricate transmission parts with Mopar ATF
Plus, Type 7176 transmission fluid during assembly.
Use Mopar Door Ease, or Ru-Glyde to lubricate piston seals and O-rings. Use petroleum jelly on thrust
washers and to hold parts in place during reassembly.
21 - 201
Inspect condition of the clutch cam, cage-type retainer, rollers, springs and clutch race.
Replace the clutch cam if worn or damaged. Also
check fit of the cam in the transmission case. If the
cam is loose, the case may be worn, or cracked.
The clutch race is permanently pressed onto the
low-reverse drum hub. If either the drum or race are
worn or damaged, replace the drum and race as an
assembly. Check fit of the race on the low-reverse
21 - 202
21 - 203
ACCUMULATOR OVERHAUL
Inspect the accumulator piston and seal rings (Fig.
48). Replace the seal rings if worn or cut. Replace the
piston if chipped or cracked.
21 - 204
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21 - 206
(5) Tap bushing into place until Installer Tool SP5118 bottoms in pump cavity. Keep tool and bushing
square with bore. Do not allow bushing to become
cocked during installation.
(6) Stake pump bushing in two places with blunt
punch. Remove burrs from stake points with knife
blade (Fig. 58).
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(2) Remove E-clip that secure shuttle valve secondary spring on valve stem (Fig. 112).
(3) Remove governor plug and shuttle valve covers
(Fig. 113).
(4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 113).
(5) Remove boost valve retainer, spring and valve
if not previously removed.
21 - 222
21 - 223
21 - 224
21 - 225
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21 - 227
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21 - 229
TRANSMISSION ASSEMBLY
Assembly Tips
Do not allow dirt, grease, or foreign material to enter the case or transmission components during assembly. Keep the transmission case and components
clean. Also make sure the tools and workbench area
used for reassembly operations are equally clean.
Shop towels used for wiping off tools and your
hands must be made from lint free materials. Lint
will stick to transmission parts and could interfere
with valve operation or even restrict fluid passages.
Lubricate transmission clutch and gear components
with Mopar ATF Plus during reassembly. Soak clutch
discs in transmission fluid before installation.
Use Mopar Door Ease, or Ru-Glyde on piston seals
and O-rings to ease installation. Petroleum jelly can
also be used to lubricate and hold thrust washers
and plates in position during assembly.
Do not use chassis grease, bearing grease,
white grease, or similar lubricants on any part.
These types of lubricants can eventually block or restrict fluid passages and valve operation. Use petroleum jelly only.
Do not force parts into place. The transmission
components and sub-assemblies are easily installed
by hand when properly aligned. If a part seems difficult to install, it is either misaligned or incorrectly
assembled. Verify that thrust washers, thrust plates
and seal rings are correctly positioned. These parts
will prevent proper assembly is mispositioned (or
left out by accident).
The planetary geartrain, front/rear clutch assem-
21 - 230
21 - 231
(2) Install overdrive piston retainer. Be sure governor tube bores in retainer are aligned with governor
feed passages in gasket and case (Fig. 135). Install
and tighten retainer bolts to 17 Nzm (13 ft. lbs.)
torque.
21 - 232
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21 - 234
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21 - 238
page
page
. . . 250
. . . 246
. . . 257
. . 245
21 - 239
21 - 240
21 - 241
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21 - 243
(16) Remove overrunning clutch assembly with external type snap ring pliers (Fig. 27). Insert pliers
into clutch hub. Expand pliers to grip hub splines
and remove clutch with counterclockwise, twisting
motion.
21 - 244
21 - 245
21 - 246
bushings can be installed with tools from an all purpose installer kit such as the Snap-On A257 bushing
driver set.
GOVERNOR OVERHAUL
Governor Changes
1992 and later overdrive units have an aluminum
governor valve and different output shaft; the shaft
is spotfaced for valve end clearance. The aluminum
21 - 247
GOVERNOR DISASSEMBLY
(1) Remove snap ring and washer that retain governor weight assembly in governor body (Fig. 38).
(2) Remove governor weight assembly from governor body.
(3) Note position of governor body on drive for installation reference.
21 - 248
GOVERNOR ASSEMBLY
(1) Lubricate governor components with Mopar
ATF Plus transmission fluid during assembly.
(2) Install new seal rings on governor drive as follows:
(a) Compress (squeeze) each seal over center before installation (Fig. 41); this provides tighter ring
fit on drive.
(b) Carefully work seal into each groove of drive.
Avoid overspreading seals during installation to ensure tight fit.
Governor Inspection
Check condition of the governor components. Check
operation of the governor valve, weights and shaft.
The valves and weights should slide freely in the
governor body.
Check condition of the governor drive seal rings.
Replace the seal rings only if they exhibit wear or
damage. Be sure the seal ring grooves in the drive
are in good condition as well.
Inspect the governor support and oil pressure tubes.
The tubes must not be pinched, kinked, collapsed, or
distorted. Blow them out with compressed air to clear
them. The tubes are designed to be a slip fit in the piston retainer boss. Do not modify the tube ends in an effort to make them fit tighter. Both tubes are an
integral part of the support. Do not attempt to re-
21 - 249
(c) Verify that diagonally cut ring ends are properly interlocked (Fig. 42).
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21 - 255
(5) Install retainer washer and snap ring that secure governor weight assembly in governor body (Fig.
67).
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21 - 257
21 - 258
(4) Install
(5) Install
plate.
(6) Install
same order.
(7) Install
(8) Install
(Fig. 77).
21 - 259
(b) Measure distance to clutch hub thrust bearing seat at four points 90 apart. Then average
measurements by adding them and dividing by 4.
(c) Select and install required thrust plate from
information in thrust plate chart (Fig. 81).
(12) Leave Alignment Tool 6227-2 in place. Tool
will keep planetary and clutch hub splines in alignment until overdrive unit is ready for installation on
transmission.
21 - 260
General Information . . . .
NP31 Service Diagnosis
Operating Ranges . . . . .
Recommended Lubricant
Shift Linkage Adjustment
Shift Mechanism . . . . . .
Speedometer Service . .
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260
263
261
262
264
261
264
GENERAL INFORMATION
The NP231 is a part-time transfer case with a low
range reduction gear system (Fig. 1). The NP231 has
page
Transfer
Transfer
Transfer
Transfer
Transfer
Transfer
Transfer
Case Assembly . . . . . . . . . . . .
Case Disassembly and Overhaul
Case Identification . . . . . . . . . .
Case In-Vehicle Service . . . . . .
Case Installation . . . . . . . . . . .
Case Removal . . . . . . . . . . . . .
Case Specifications . . . . . . . . .
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273
267
261
265
266
266
262
21 - 261
OPERATING RANGES
Transfer case operating ranges are:
2-wheel drive high (2H)
4-wheel drive high (4H)
4-wheel drive low (4H)
The 2H range is for use on all road surfaces. The
4H and 4L ranges are for off-road use only. Use these
ranges on low traction surfaces such as sand, dirt, or
snow covered roads only.
SHIFT MECHANISM
Operating ranges are selected with a floor mounted
shift lever (Fig 2). The shift lever is connected to the
transfer case range lever by an adjustable linkage
rod.
A straight line shift pattern is used. Range positions are marked on the shifter knob and bezel cover
plate. A synchronizer assembly in the transfer case
allows the unit to be shifted between two and four
high ranges while in motion.
21 - 262
RECOMMENDED LUBRICANT
Recommended lubricants are Mopar Dexron II, or
ATF Plus automatic transmission fluid. Do not use
21 - 263
21 - 264
SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine pinion
gear requirements. If the gear must be replaced, refer to the parts catalogue for the correct gear.
21 - 265
(3) Disconnect propeller shaft (or shafts) and secure them to the underside of the vehicle with mechanics wire.
(4) Remove speed sensor, speedometer adapter and
pinion. Refer to procedure in this section.
(5) Remove extension housing bolts.
(6) Tap extension housing in clockwise direction to
break sealer bead and remove housing (Fig. 7). Use
plastic mallet only to loosen housing.
21 - 266
(1) Install transfer case (Fig. 10). Align and position transfer case with transmission jack or with aid
of helper. Tilt case upward and work into position on
transmission mounting studs.
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21 - 268
21 - 269
21 - 270
21 - 271
21 - 272
(33) Remove front bearing retainer. Position screwdrivers in retainer slots and lift upward to loosen
and remove retainer (Fig. 23).
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21 - 278
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21 - 284
AX 15 TORQUE SPECIFICATIONS
21 - 285
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22 - 1
page
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 12
VEHICLE VIBRATION . . . . . . . . . . . . . . . . . . . . . 10
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TIRES
INDEX
page
Cleaning of Tires .
General Information
Pressure Gauges .
Repairing Leaks . .
Replacement Tires
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2
1
2
3
2
GENERAL INFORMATION
Tires are designed for each specific vehicle. They
provide the best overall performance for normal operation. The ride and handling characteristics match
the vehicles requirements. With proper care they
will give excellent reliability, traction, skid resistance, and tread life. These tires have specific load
carrying capacities. When correctly inflated, they will
operate properly.
Tires used in cool climates, and with light loads
will have a longer life than tires used in hot climates
with heavy loads. Abrasive road surfaces will accelerate tire wear.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain much
greater mileage than careless drivers.
Driving habits that shorten the life of any tire;
Rapid acceleration and deceleration
Severe application of brakes
High-speed driving
Taking turns at excessive speeds
Striking curbs and other obstacles
Longer wearing tires are more susceptible to irregular tread wear. It is very important to follow the
tire rotation interval
IDENTIFICATION
Tire type, size, aspect ratio and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the chart to decipher
the tire identification code (Fig. 1).
Performance tires will have a speed rating letter
after the aspect ratio number. The speed rating is not
page
Rotation . . . . . . . . . . .
Tire Inflation Pressures
Tire Noise or Vibration
Tire Wear Patterns . . .
Tread Wear Indicators .
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3
2
4
4
3
always printed on the tire sidewall. The letter S indicates that the tire is speed rated up to 112 mph.
Q up to 100 mph
T up to 118 mph
U up to 124 mph
H up to 130 mph
V up to 149 mph
Z more than 149 mph (consult the tire manufacturer for the specific speed rating)
An All Season type tire will have either M + S, M
& S or MS (indicating mud and snow traction) imprinted on the side wall.
RADIAL-PLY TIRES
Radial-ply tires improve handling, tread life, ride
quality and decrease rolling resistance.
Radial-ply tires must always be used in sets of
four. Under no circumstances should they be used on
the front only. They may be mixed with temporary
spare tires when necessary, but reduced speeds are
recommended.
Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They use
the same recommended inflation pressures.
SPARE TIRE (COMPACT)
The compact spare tire is designed for emergency
use only. The original tire should be repaired and reinstalled at the first opportunity. Refer to Owners
Manual for complete details.
TIRE CHAINS
Tire snow chains may be used on certain models.
Refer to Owners Manual for more information.
22 - 2
CLEANING OF TIRES
Steam cleaning may be used for cleaning.
DO NOT use gasoline or wire brush for cleaning.
DO NOT use mineral oil or an oil-based solvent.
PRESSURE GAUGES
High-quality, dial-type, air-pressure gauges are recommended. After checking with the gauge, replace
valve caps and tighten finger tight.
REPLACEMENT TIRES
OEM tires provide a proper balance of many features such as;
Ride
Noise
Handling
22 - 3
Tire replacement is necessary when indicators appear in two or more grooves, or if localized balding
occurs (Fig. 5).
ROTATION
Tires on the front and rear axles operate at different loads and perform different steering, driving, and
braking functions. For these reasons;
They wear at unequal rates
Tend to develop irregular wear patterns
These effects can be reduced by timely rotation of
tires. The benefits of rotation are especially worthwhile. Rotation will:
Increase tread life
Help to maintain mud, snow, and wet traction levels
Contribute to a smooth, quiet ride
The suggested method of tire rotation is the same
side front to rear pattern (Fig. 4). Other rotation
methods can be used, but they will not provide all
the tire longevity benefits.
REPAIRING LEAKS
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
puncture is in the tread area (Fig. 6). If outside the
tread area the tire should be replaced.
22 - 4
22 - 5
22 - 6
GENERAL INFORMATION
Original equipment wheels are designed for all
loads up to the specified Maximum Vehicle Capacity.
All models use steel or cast aluminum drop center
wheels. The safety rim wheel (Fig. 1) has raised sections between the rim flanges and the rim well.
tightened just snug. Gradually tighten them in sequence to 129 Nzm (95 ft. lbs.) torque (Fig. 2). Never
use oil or grease on studs or nuts.
WHEEL INSTALLATION
The wheel studs and nuts are designed for specific
applications. They must be replaced with equivalent
parts. Do not use replacement parts of lesser quality
or a substitute design. All aluminum and some steel
wheels have wheel stud nuts which feature an enlarged nose. This enlarged nose is necessary to ensure proper retention of the aluminum wheels.
CAUTION: Models equipped with chrome plated
wheels come with chrome plated lug nuts. Under no
circumstances substitute these lug nuts, use only
the factory specified lug nuts.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces.
Ensure wheels are installed with good metal-to-metal
contact. Improper installation could cause loosening
of wheel nuts. This could affect the safety and handling of your vehicle.
To install the wheel, first position it properly on
the mounting surface. All wheel nuts should then be
WHEEL REPLACEMENT
Wheels must be replaced if they have:
Excessive runout
Bent or dented
Leak air through welds
Have damaged bolt holes
Wheel repairs employing hammering, heating, or
welding are not allowed.
Original equipment wheels are available through
your dealer. Replacement wheels from any other
source should be equivalent in:
Load carrying capacity
Diameter
Width
Offset
Mounting configuration
Failure to use equivalent replacement wheels may
affect the safety and handling of your vehicle. Replacement with used wheels is not recommended.
Their service history may have included severe treatment.
Refer to the Specifications Chart for information regarding above requirements.
22 - 7
WHEEL ORNAMENTATION
WARNING: HANDLE ALL WHEEL ORNAMENTATION
WITH EXTREME CARE DURING REMOVAL AND INSTALLATION. SHARP EDGES ON THE COVERS OR
CAPS CAN CAUSE PERSONAL INJURY.
22 - 8
MATCH MOUNTING
Wheels and tires are match mounted at the factory.
This means that the high spot of the tire is matched
to the low spot on the wheel rim. This technique is
used to reduce run-out in the wheel/tire assembly.
The high spot on the tire is marked with a paint
mark or a bright colored adhesive label on the outboard sidewall. The low spot on the rim is at the
valve stem location on the wheel rim.
Before dismounting a tire from its wheel, a reference mark should be placed on the tire at the valve
stem location. This reference will assure that it is remounted in the original position on the wheel.
(1) Measure the total indicator runout on the center of the tire tread rib. Record the indicator reading.
Mark the tire to indicate the high spot. Place a mark
on the tire at the valve stem location (Fig. 5).
22 - 9
22 - 10
VIBRATION TYPES
There are two types of vehicle vibration:
Mechanical
Audible.
Mechanical vehicle vibration can be felt through
the seats, floor pan and/or steering wheel.
Audible vehicle vibration is heard above normal
background noise. The sound can be a droning or
drumming noise.
Vibrations are sensitive to change in engine torque,
vehicle speed or engine speed.
VIBRATION DIAGNOSIS
A vibration diagnosis should always begin with a
10 mile (16 km) trip (to warm the vehicle and tires).
Then a road test to identify the vibration. Corrective
action should not be attempted until the vibration
type has been identified via a road test.
During the road test, drive the vehicle on a smooth
surface. If vibration exists, note and record the following information:
22 - 11
VIBRATION DIAGNOSIS
22 - 12
BODY COMPONENTS
23 - 1
BODY COMPONENTS
CONTENTS
page
page
Follow the instructions included with each replacement label, decal or plate to affix it to a panel or
component.
23 - 2
BODY COMPONENTS
BODY COMPONENTS
23 - 3
EXTERIOR COMPONENTS
INDEX
page
page
Battery Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Body Mouldings, Nameplates and Decals . . . . . . . 10
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cab and Cargo Box Stripes . . . . . . . . . . . . . . . . . . 13
Cargo Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cowl Grille and Screen . . . . . . . . . . . . . . . . . . . . . . 7
Exterior Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GRILLE
GRILLE REMOVAL
(1) Remove screws that attach the headlamp bezels
(Fig. 1) to the grille and the closure panel.
GRILLE INSTALLATION
(1) Position the grille on the closure panel and
loosely install the attaching screws (Fig. 2).
(2) Install the headlamps in the bezels.
(3) Position the headlamp bezels on the closure
panel and loosely install the attaching screws (Fig.
2).
(4) Correctly align the grille and the headlamp bezels, and then tighten the screws with 2 Nzm (17 in.
lbs.) torque.
CLOSURE PANEL REMOVAL
(1) Raise and support the hood. Remove the battery.
(2) Remove the headlamps from the headlamp receptacles in the closure panel and from the bezels.
(3) Remove the headlamp bezels and the grille
from the closure panel. If necessary, refer to the removal procedure.
(4) Drain the engine coolant from the radiator in a
clean container for reuse. Remove the radiator from
the closure panel. If necessary, refer to Group
7Cooling System for the procedure.
(5) Detach battery tray from the closure panel. If
necessary, refer to the removal procedure.
(6) Separate Ambient Temperature Sensor harness
connector, if equipped.
(7) Remove the horns from the closure panel.
(8) Remove the retaining screws, and the hood
latch and the reinforcement plate from the closure
panel.
(9) Detach the latch release cable from the retaining clip on the.
(10) Remove the screws that attach the fender liners (Fig. 3) to the closure panel.
(11) Remove the screws that attach the fenders
(Fig. 3) to the closure panel.
(12) Remove the nuts/retainers and separate the
air dam from the front fenders.
23 - 4
BODY COMPONENTS
CAUTION: Use care to avoid damage to the fender
panels and the cowl panel when pivoting the fender
panels at the cowl.
(16) Move both fender panels outward at the front
and remove the closure panel from the frame rails
and the vehicle.
BODY COMPONENTS
23 - 5
POSITION ADJUSTMENT
The hood hinge screw holes are oversize and elongated to ease hood up/down and fore/aft position adjustment. Loosen the hinge-to-fender panel screws for
up/down adjustment (in relation to the fenders).
Loosen the hinge arm-to-hood bolts for fore/aft adjustment (in relation to the cowl).
INSTALLATION
If a replacement hood latch is also being installed, ensure that it is thoroughly lubricated.
(1) From inside the vehicle, route the hood release
cable through the hole in the dash panel.
(2) Position the release cable handle at the bottom
of the instrument panel (Fig. 6) and install the attaching screws. Tighten the screws with 1 Nzm (12
in. lbs.) torque.
(3) Install the cable grommet in the dash panel
hole (Fig. 5).
HOOD
23 - 6
BODY COMPONENTS
REMOVAL
(1) Raise and support the hood at the full-open position.
(2) If equipped, disconnect the underhood lamp
wire harness connector from the lamp connector and
remove the wire harness from the hood (Fig. 8).
(3) With the aid of an assistant, remove the hinge
arm-to-hood bolts (Fig. 7) at each side of the hood.
Remove the hood from vehicle.
(4) If a replacement hood is being installed, transfer the underhood lamp (Fig. 8) and the insulator
panel (Fig. 9).
(5) Inspect/test the hood hinges for correct operation and clean them with an appropriate solvent.
INSTALLATION
(1) With the aid of an assistant, position the hood
on the vehicle and align the hood bolt holes with the
hinge arm holes (Fig. 7). Install and finger-tighten
the bolts.
(2) Align the hood, the latch, and the striker (refer
to Fore/Aft And Latch/Striker Adjustment).
HINGE REPLACEMENT
REMOVAL
If both hinges are being replaced, remove the
hood and both hinges as a unit. If only one
hinge is being replaced, use the following procedure.
BODY COMPONENTS
23 - 7
LATCH STRIKER
REMOVAL
(1) Raise and support the hood.
(2) Remove the attaching screws and the latch
striker from the hood (Fig. 7).
INSTALLATION
(1) Position the striker on the hood.
(2) Install and finger-tighten the attaching screws.
ADJUSTMENT
Align the latch and the striker (refer to Fore/Aft
And Latch/Striker Adjustment).
INSTALLATION
(1) Position the screen and grille on the cowl plenum (Fig. 12) and engage the rear of grille with the
windshield weatherstrip seal.
(2) Attach windshield washer hoses to the nozzles
and the retaining clips (Fig. 11).
(3) Install the grille attaching screws (Fig. 12).
Tighten the screws with 2 Nzm (17 in. lbs.) torque.
(4) Remove the support and close the hood.
(5) Install the windshield wiper arms (Fig. 11).
23 - 8
BODY COMPONENTS
(3) Remove the screws that attach the battery tray
to the fender liner, inner fender panel and the closure panel.
(4) Remove the battery tray from the vehicle.
(5) If necessary, remove the U-nuts and the holddown rods from the battery tray.
INSTALLATION
(1) If removed, install the U-nuts and the holddown rods on the battery tray.
(2) Position the battery tray against the inner
fender panel and on the fender liner.
(3) Attach the battery tray to the inner fender
panel, the fender liner and the closure panel with the
screws. Tighten the screws with 23 Nzm (200 in. lbs.)
torque.
(4) Install the battery in the tray.
(5) Position the holddown bracket over the holddown rods.
(6) Install the retaining nuts on the holddown
rods. Tighten the nuts with 2 Nzm (20 in. lbs.)
torque.
FRONT FENDERS
Fig. 12 Cowl Grille, Screen & Seals
BATTERY TRAY
REMOVAL
(1) Remove the nuts and holddown bracket from
the holddown rods (Fig 13).
REMOVAL
(1) Raise and support the hood. Remove the battery for left fender removal only.
(2) Remove the headlamps from the headlamp receptacles in the closure panel and from the bezels.
BODY COMPONENTS
(3) Remove the headlamp bezels closure panel. If
necessary, refer to the grille removal procedure.
(4) Remove the battery tray for left fender removal
only. If necessary, refer to the removal procedure.
(5) Remove the screws that attach the fender (Fig.
15) to the closure panel.
23 - 9
(11) Remove the fender and the liner from the cab
(Fig. 15).
(12) Remove the screws that attach the fender
liner to the fender panel (Fig. 15). Remove the liner
from the fender.
INSTALLATION
(1) Position the liner on the fender. Install the
screws to attach the fender liner to the fender panel
(Fig. 15). Tighten the screws with 23 Nzm (200 in.
lbs.) torque.
(2) Position the fender and the liner on the cab
(Fig. 15).
(3) Install the screws to attach the fender and the
liner (Fig. 15) to the closure panel. Tighten the
screws with 23 Nzm (200 in. lbs.) torque.
(4) Install nut/retainer to attach the air dam to the
front fender.
(5) Install the screw that attaches the fender liner
(Fig. 16) to the dash panel. Tighten the screw with
23 Nzm (200 in. lbs.) torque.
(6) Install the nuts to attach the bottom of the
fender (Fig. 14) to the cowl. Tighten the nuts with 23
Nzm (200 in. lbs.) torque.
(7) Install the bolts to attach the top of the fender
(Fig. 14) to the cowl. Tighten the bolts with 23 Nzm
(200 in. lbs.) torque.
(8) If removed, install the battery tray. If necessary, refer to the installation procedure. Tighten the
screws with 23 Nzm (200 in. lbs.) torque.
(9) If removed, install the battery and the holddown bracket. Tighten the holddown rod nuts with 2
Nzm (20 in. lbs.) torque.
(10) Install the headlamp bezels on the closure
panel (if necessary, refer to the grille installation procedure).
(11) Install the headlamps in the bezels and in the
headlamp receptacles.
(12) Remove the support and close the hood.
SPLASH SHIELDS
FRONT FENDER WHEELHOUSE2WD
VEHICLES
REMOVAL
(1) Remove the plastic retainers that attach the
splash shield to the wheelhouse liner and to the
frame rail (Fig. 17).
(2) Remove the screws that attach the splash deflector to the frame rail.
(3) Remove the splash shield and the splash deflector from the wheelhouse.
INSTALLATION
(1) Position the splash shield on the wheelhouse
liner.
23 - 10
BODY COMPONENTS
CARGO BOX WHEELHOUSE
REMOVAL
(1) Remove the screws that attach the front splash
shield to the wheelhouse liner.
BODY COMPONENTS
23 - 11
NAMEPLATES/BADGES
REMOVAL
(1) Soften the nameplate/badge tape adhesive (Fig.
21) with a heat gun.
(2) Lift one edge of the nameplate/badge with a
putty knife (or a similar thin-blade tool) and peel the
23 - 12
BODY COMPONENTS
moulding and tape from the cab panel. Apply additional heat to any location where the tape remains
adhered to the panel.
(3) Remove the residual tape adhesive from the
panel.
(4) If the original nameplate/badge is being installed, remove the original tape and all the residual
adhesive from it.
SURFACE PREPARATION
The painted panel area that will be covered by the
nameplate/badge must be cleaned with an appropriate cleaning solution.
(1) Clean the painted panel surface with a commercial wax and silicone removal solution. Wipe the
surface with a clean cloth and allow it to dry.
(2) Freshly painted surfaces must be thoroughly
dry. If not, the residual solvent in the paint could adversely affect the nameplate/badge tape adhesive.
INSTALLATION
(1) Install 3M 06379 double-sided tape on the
nameplate/badge.
(2) For vertical alignment, use masking tape to indicate the upper position for the nameplate/badge on
the cab panel.
(3) Remove the backing from the double-sided
tape, align the nameplate/badge with the alignment
reference tape, and position it on the cab panel.
(4) Verify that the nameplate/badge is properly
aligned and remove the alignment reference tape.
(5) Press the nameplate/badge onto the cab panel
with a roller (or use hand pressure) to ensure complete adhesion.
TAILGATE DECAL
The tailgate is covered with a durable decal (Fig.
22).
REMOVAL
The key to successful decal removal is to apply heat only to the immediate area and slowly
peel the decal away from the tailgate panel.
Slow peeling will ensure that a maximum
amount of adhesive remains with the decal as it
is removed.
(1) Soften the decal adhesive with a heat gun.
(2) Lift one edge of the decal with a putty knife (or
a similar thin-blade tool). Slowly peel the decal from
the tailgate panel.
(3) Apply additional heat to any location where the
decal remains adhered to the panel.
(4) Remove the residual decal adhesive from the
panel.
SURFACE PREPARATION
The painted area that will be covered by the decal
must be cleaned with an appropriate cleaning solution.
BODY COMPONENTS
ROOF MOULDING
REMOVAL
(1) Remove the interior trim panel for access to the
moulding retainer stud nuts. If necessary, refer to the
removal procedure (Fig. 24).
23 - 13
REPAIR
Small nicks and scratches in a tape stripe can be
touched-up with paint in a manner similar to that
used for painted surfaces. A correct color match can
be obtained by blending small amounts of appropriate paint colors and then spot-painting the damaged
area(s) in the stripe.
To eliminate blisters and air bubbles, pierce them
with a needle or pin. Force the trapped air out of the
hole and press the stripe firmly against the cab/cargo
box panel. It could be necessary to slightly pre-heat
the stripe/panel with a heat gun to soften the adhesive.
A heat gun can also be used to remove small wrinkles in a stripe.
23 - 14
BODY COMPONENTS
BODY COMPONENTS
of wetting solution by thoroughly mixing two or three
teaspoons of dish detergent with 1 gallon of water.
Do not use soap.
Too much detergent will reduce the effectiveness of the mixture.
REMOVAL
The key to successful tape stripe removal is
to apply heat only to the immediate area and
slowly peel the stripe from the panel. Slow
peeling will ensure that a maximum amount of
adhesive remains with the stripe as it is removed.
(1) Start at one end of the tape stripe and apply
heat with a heat gun. Slowly peel the stripe from the
panel by pulling it back, in-line with the stripe affixed to the panel.Do not pull the tape stripe outward from the panel.
WARNING: USE THE TAPE STRIPE REMOVAL SOLUTION IN A WELL-VENTILATED AREA ONLY.
(2) A commercial tape stripe removal solution can
be used for stripe removal at areas where the heat
gun is ineffective.
(3) After the tape stripe is removed, remove any
adhesive remaining on the panel.
(4) Wipe the panel with a cloth saturated with a
general purpose adhesive cleaning solution.
SURFACE PREPARATION
(1) The panel area that will be covered by the tape
stripe must be cleaned with an appropriate cleaning
solution to remove any paint residue.
(2) Freshly painted surfaces must be thoroughly
dry. If not, the residual solvent in the paint could
cause the tape stripe to blister.
(3) Clean the painted surface with a commercial
wax and silicone removal solution. Wipe the surface
with a clean cloth and allow it to dry.
INSTALLATION
(1) Use a clean sponge and apply ample wetting
solution to the tape stripe adhesive and to the
painted panel surface. The wetting solution will permit ease of tape stripe movement when positioning it
on the panel.
(2) Immediately position the wetted adhesive side
of the replacement tape stripe on the panel. The bottom of the carrier should align with the panel character line (Fig. 25). Where applicable:
align the end of the replacement tape stripe with
the end of the existing tape stripe, and
correctly align the index darts and index notches
(Fig. 25).
(3) If a complete replacement tape stripe is not being installed:
23 - 15
23 - 16
BODY COMPONENTS
EXTERIOR MIRRORS
Service information for manual exterior rear view
mirrors is provided below.
REMOTE/MANUAL MIRROR
REMOVAL
(1) Loosen the mirror toggle control setscrew at the
bezel (Fig. 31).
NOZZLE/TUBES
REMOVAL
(1) Remove the fuel filler door.
(2) Remove the cap from the nozzle.
(3) Loosen the clamps and separate the hoses from
the tubes.
(4) Remove the screws that attach the nozzle to
the cargo box panel.
The fuel cap tether is also attached to the
cargo box panel with one of the screws.
(5) Remove the nozzle/tubes from the cargo box
panel (Fig. 30).
INSTALLATION
(1) Position the fuel filler nozzle/tubes and the fuel
cap tether at the opening in the cargo box panel.
(2) Install the screws to attach the nozzle and
tether to the panel. Tighten the screws with 4 Nzm
(35 in-lbs) torque.
(3) Attach the hoses to the tubes with the clamps.
Tighten the clamp screws with 4 Nzm (35 in-lbs)
torque.
(4) Install the cap on the nozzle.
(5) Install the fuel filler door.
BODY COMPONENTS
(3) Install the mirror retaining nuts. Tighten the
nuts with 7 Nzm (65 in. lbs.) torque.
(4) Install the mirror seal in the door aperture.
(5) Position the mirror bezel over the toggle control
and tighten the setscrew with 1 Nzm (9 in. lbs.)
torque.
(6) Install the mirror bezel retaining screw.
Tighten the screw with 2 Nzm (17 in. lbs.) torque.
(7) Install the mirror bezel retaining screw cover
plug.
23 - 17
CAB
The cab is attached to the vehicle front frame
structure with bolts (Figs. 33 and 34). If necessary,
the cab can be removed for repair or service access.
REMOVAL
(1) Disconnect the battery cables from the terminals and remove the battery from the tray.
(2) As necessary, disconnect the wire harness connectors from the engine-related components and from
the frame.
(3) Disconnect the parking brake cable and the
brake lines.
(4) Disconnect the engine controls.
(5) Disconnect the heater and A/C hoses.
(6) Disconnect the cable from the starter motor.
(7) Disconnect the transmission and transfer case
(if equipped) shift linkage.
(8) Disconnect the tubing from the clutch master
cylinder (if equipped).
(9) Disconnect the steering shaft from the steering
gear.
(10) Disconnect all remaining connections between
the cab and the frame-attached components.
(11) Remove the restraint cable (Fig. 33) from the
cab.
(12) Remove the retaining screws and the floor
panel-to-holddown bracket plate (Fig. 33) from the
cab.
(13) Remove the cab holddown bolts (Figs. 33 and
34). The bolts are accessible from the underside of
the cab.
(14) Separate and remove the cab from the frame
(Figs. 33 and 34).
INSTALLATION
(1) Ensure that the isolators and spacers are correctly positioned on the frame holddown brackets
(Figs. 33 and 34).
(2) Position the cab on the frame (Figs. 33 and 34).
(3) Install the cab holddown bolts (Figs. 33 and
34). Tighten the bolts with 81 Nzm (60 ft. lbs.) torque.
(4) Position the floor panel-to-holddown bracket
plate (Fig. 33) on the cab floor panel and install the
retaining screws. Tighten the screws with 23 Nzm
(200 in. lbs.) torque.
(5) Position the restraint cable ends (Fig. 33) on
the cab rear seat belt anchor bolts and install the retaining nuts. Tighten the nuts with 45 Nzm (33 ft.
lbs.) torque.
(6) Connect the steering shaft to the steering gear.
(7) Connect the tubing to the clutch master cylinder (if equipped).
(8) Connect the transmission and transfer case (if
equipped) shift linkage.
(9) Connect the cable to the starter motor.
(10) Connect the heater and A/C hoses.
(11) Connect the engine controls.
23 - 18
BODY COMPONENTS
BODY COMPONENTS
(16) Thoroughly inspect the installation of the cab
on the frame and ensure that:
All connecting hardware is correctly tightened.
All fluids and lubricants are at an acceptable level.
All electrical, engine, drivetrain and chassis components are functionally operational.
TAILGATE
REMOVAL
(1) Open the tailgate.
(2) Position the tailgate at an angle that will allow
the restraint/support cable eyelets to be removed
from the tailgate cable pivots (Fig. 35).
(3) Separate connector for Center High Mounted
Stop Lamp (CHMSL).
INSTALLATION
(1) Position the tailgate at the cargo box.
(2) On the left side, insert the tailgate hinge-half
into the cargo box hinge-half by moving the tailgate
to the left.
(3) On the right side, insert the tailgate hinge-half
into the slot in cargo box hinge-half.
(4) Position the tailgate at an angle that will allow
the restraint/support cable eyelets to be installed on
the tailgate cable pivots (Fig. 35).
(5) Connect CHMSL electrical connector.
23 - 19
(6) Test the handle and latches for correct operation. If necessary, adjust the strikers to eliminate
tailgate looseness and noise.
(7) Close the tailgate.
DISASSEMBLY
(1) Remove the screws that attach the cover plate
to the tailgate inside panel. Remove the cover plate
from the panel (Fig. 35).
(2) Disconnect the plastic clips that attach the
handle-to-latch rods to the rod retainer at the handle.
(3) Remove the nuts that attach the handle and
the rod retainer to the tailgate inner panel.
(4) Remove the rod retainer from the opening at
the inside of the tailgate.
(5) Lower the handle and remove it from the tailgate opening.
(6) Support the tailgate. Remove the latches and
the restraint/support cables from the ends of the tailgate.
ASSEMBLY
(1) Lubricate the latches, the handle and the rod
retainer before assembly.
(2) Install the latches and the restraint/support cables at the ends of the tailgate. Remove the support.
(3) Insert the handle in the tailgate opening.
(4) Position the rod retainer in the opening at the
inside of the tailgate.
(5) Install the nuts to attach the handle and the
rod retainer to the tailgate inner panel.
(6) Connect the handle-to-latch rods to the rod retainer at the handle and retain them with the plastic
clips.
(7) Position the cover plate over the opening in the
tailgate inside panel and install the attaching screws
(Fig. 35).
(8) Test the handle and latches for correct operation. If necessary, adjust the strikers to eliminate
tailgate looseness and noise.
23 - 20
BODY COMPONENTS
(2) Remove the support and lower the vehicle.
(3) Attach the spare tire and wheel to the winch.
CAUTION: Operate the spare tire winch manually
only. Air or electrically powered tools can cause
damage to the internal mechanism.
(4) Insert a lug wrench into the rear bumper access hole and into the winch actuator.
(5) Rotate and force the lug wrench inward to engage it with the winch actuator slot.
(6) Rotate the lug wrench clockwise and raise the
spare tire and wheel until the tire is flush against
the bottom of the cargo box. When this occurs, the
winch mechanism will slip. Allow the mechanism to
slip 2 or 3 times to ensure that the tire is tightly
seated against the cargo box.
(7) Remove the lug wrench from the winch actuator and the rear bumper access hole.
INSTALLATION
(1) Position the spare tire winch under the cargo
box and install the retaining bolts. Tighten the bolts
with 23 Nzm (200 in. lbs.) torque.
CARGO BOX
REMOVAL
The cargo box is attached to the vehicle rear frame
structure with screws (Fig. 37). If necessary, the box
can be removed for repair, service access, or replacement.
(1) Disconnect the battery cables from the terminals.
BODY COMPONENTS
(2) Disconnect tail lamp wire harness connectors.
(3) Support the exhaust tail pipe and disconnect
the support hanger from the cargo box.
(4) Loosen the clamps and disconnect the fuel and
vent hoses from the nozzle tubes (Fig. 38).
23 - 21
LIGHT BAR
REMOVAL
(1) Disconnect off road lamp wire connectors.
(2) Remove nuts and support plates holding light
bar to cargo box top rails (Fig. 39).
(3) Separate light bar from side support cover.
(4) Remove nuts holding side support cover to
cargo box top rails.
INSTALLATION
(1) Position cargo box on the frame (Fig. 37).
(2) If used, insert the shims and install the holddown screws (Fig. 37). Tighten the screws with 41
Nzm (30 ft. lbs.) torque.
(3) Position the spare tire winch tube support
bracket at the bottom of the cargo box and install the
retaining screws. Tighten the screws securely.
(4) Connect the fuel and vent hoses to the nozzle
tubes (Fig. 38). Tighten the fuel hose clamp screw
with 4 Nzm (35 in. lbs.) torque. Tighten the vent hose
clamp screw with 2 Nzm (14 in. lbs.) torque.
(5) Connect the tail pipe to the support hanger on
the cargo box and remove the support.
(6) Connect tail lamp wire harness connectors.
(7) Connect the battery cables to the terminals.
(8) Thoroughly inspect the installation of the cargo
box on the frame and ensure that:
All connecting hardware is correctly tightened.
All electrical system components are functionally
operational.
23 - 22
BODY COMPONENTS
(2) Install light bar on side support cover.
(3) Install nuts and support plates holding light
bar to cargo box top rails. Torque to 25 Nzm. (239 in.
lbs.).
(4) Connect off road lamp wire connectors.
BODY COMPONENTS
23 - 23
DOORS
INDEX
page
Blind Rivet Removal . . . . . . . . . . . . . . . .
Complete Door . . . . . . . . . . . . . . . . . . . .
Door Adjustment . . . . . . . . . . . . . . . . . . .
Door Latch . . . . . . . . . . . . . . . . . . . . . . .
Door Latch Linkage . . . . . . . . . . . . . . . . .
Door Latch Striker . . . . . . . . . . . . . . . . . .
Door Trim Panel/Waterdam/Noise Insulator
Hinge Replacement . . . . . . . . . . . . . . . . .
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SERVICE INFORMATION
The door (Fig. 1) service procedures include:
Complete door.
Component removal/installation.
Component replacement.
Adjustments.
page
Inside Door Handle . . .
Key Lock Cylinder . . . .
Mirror Support Bracket
Outside Door Handle . .
Power Door Lock Motor
Rearview Mirror . . . . .
Service Information . . .
Window Glass and Door
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Weatherstrip
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Seals
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23
29
HINGE REPLACEMENT
REMOVAL
(1) Support the door with a padded floor jack.
(2) Use a wax pencil to mark the outline of the
hinge-halves on the door and the cab pillar for installation alignment reference.
(3) Remove the hinge-to-cab pillar screws.
When removing a door hinge, DO NOT discard the shims (if equipped).
(4) Remove the hinge-to-door screws and remove
the hinge from the door and the cab (Fig. 1).
INSTALLATION
(1) Clean the hinge in an appropriate solvent and
blow dry with compressed air.
(2) Color coat the hinge to match the vehicle color.
(3) Lubricate the hinge with engine oil.
(4) Position the hinge on the door and install the
hinge-to-door screws finger-tight.
(5) Install the hinge-to-cab pillar screws fingertight.
(6) Align the hinge-halves with the installation reference outlines on the door and the cab.
(7) Tighten the hinge screws with 35 Nzm (26 ft.
lbs.) torque.
(8) Remove the floor jack from the door.
DOOR ADJUSTMENT
The doors are adjusted at the hinge attaching locations at either the cab pillar or the door, as applicable. Enlarged screw holes are located in the cab pillar
for fore, aft and tilt adjustments. Enlarged screw
holes are located in the door for up/down and in/out
adjustments.
Prior to door adjustment, the door latch must be
removed to allow the door to close freely and be properly aligned without interference.
23 - 24
BODY COMPONENTS
UP AND DOWN
(1) Support the door with a padded floor jack.
(2) Loosen hinge-to-door screws at both hinges,
and move the door to the required up/down position.
(3) Tighten the hinge screws with 35 Nzm (26 ft.
lbs.) torque.
(4) Remove the floor jack from the door.
IN AND OUT
In/out door adjustment should be made by loosening the screws for one hinge at a time and then moving the door to the correct position.
(1) Support the door with a padded floor jack.
(2) Loosen the applicable hinge-to-door screws and
move the door to the required in/out position.
(3) If necessary, loosen the other hinge-to-door
screws and move the door to the required in/out position.
(4) Tighten the hinge screws with 35 Nzm (26 ft.
lbs.) torque.
(5) Remove the floor jack from the door.
DOOR LATCH STRIKER
The door latch striker can be adjusted either in or
out to position it correctly for the door latch to be
completely engaged when the door is closed. When
closed, the door should be flush with the adjacent
body panels.
INSTALLATION
(1) Position the noise insulator on the door inner
panel and install the retainers (Fig. 5).
(2) Apply an appropriate adhesive/sealant to the
waterdam edges before installing it (Fig. 4).
(3) Position the waterdam on the door inner panel
and press it inward at the areas with the adhesive
(Fig. 4) to attach it to the inner panel.
(4) Position the trim on the door inner panel and
press around the perimeter of the panel to attach the
inner panel.
(5) Install the armrest (if removed) and the window glass regulator handle (Fig. 3), or (if equipped)
the power switch housing (Fig. 2). Tighten the armrest retaining screws with 3 Nzm (20 in. lbs.) torque.
Tighten the housing retaining screw with 2 Nzm (17
in. lbs.) torque.
BODY COMPONENTS
23 - 25
COMPLETE DOOR
REMOVAL
(1) For doors equipped with a power window,
power door lock, power mirror and radio speaker, remove the door trim panel/waterdam/noise insulator.
If necessary, refer to the removal procedure.
(2) Disconnect the component wire harness connectors from the main wire harness (Fig. 6). Remove the
main wire harness retainer from the door panel and
then remove the main wire harness from the door.
DOOR INSTALLATION
(1) If a replacement front door is being installed,
coat the door interior with anti-corrosion wax. Also,
seal the door hem flange with sealant.
(2) Before installing a replacement door, as applicable, transfer:
Original window glass and regulator.
Electric motors.
Key lock cylinder.
Latch handles.
Trim panel.
Any remaining components to the replacement
door.
Refer to the applicable removal/installation procedures.
(3) Lubricate the hinges with engine oil.
(4) Position the door in the cab opening.
23 - 26
BODY COMPONENTS
INSTALLATION
(1) If removed, position the glass rear channel/
track in the door (Fig. 7) and install the retaining
screws. Tighten the screws securely.
BODY COMPONENTS
(2) Install the lift channel and gaskets on the window glass with 1/4-20 x 1/2 bolts and nuts. Tighten
the nuts with 10 Nzm (90 in. lbs.) torque.
(3) Install replacement edge sliders on the window
glass rear edge (Fig. 8).
(4) Position the window glass regulator in the door
and install the retaining screws (Fig. 9). Tighten the
screws securely.
(5) Install the window glass in the door:
Insert the window glass into the door.
Slide it forward and downward at a 45 angle.
Engage the window glass edge sliders with the
glass rear track (Fig. 8).
Engage the lift channel with the regulator roller.
(6) Position the beltline weatherstrip moulding on
the door panel and install the retaining screws (Fig.
7). Tighten the screws securely.
(7) Install the noise insulator, the waterdam and
the door trim panel (or, if applicable, the access panel). If necessary, refer to the installation procedure.
23 - 27
INSTALLATION
(1) Install the lock cylinder in the door hole. Retain the lock cylinder with the clip retainer.
23 - 28
BODY COMPONENTS
DOOR LATCH
REMOVAL
(1) Raise the window glass to the completely closed
position.
(2) Remove the door trim panel, the waterdam and
the noise insulator from the door inner panel. If necessary, refer to the removal procedure.
(3) Disconnect the:
Outside handle-to-latch rod from the latch.
Key lock cylinder-to-latch rod from the latch.
Inside handle-to-latch rod from the latch (Fig. 11).
Lock knob-to-latch rod from the latch (Fig. 11), if
equipped.
Lock motor-to-latch rod from the latch (Fig. 11).
(4) Remove the door latch retaining screws from
the door inner panel face (Fig. 12).
(5) Remove the door latch from the door via the access hole in the panel (Fig. 12).
INSTALLATION
(1) Install the latch striker, if removed.
(2) Insert the door latch through the access hole in
the panel, position it at the door face panel and connect the rods to it (Fig. 11).
(3) Install the latch retaining screws in the door
panel face (Fig. 12). Tighten the screws with 9 Nzm
(7 ft-lbs) torque.
(4) Test and ensure that the latch operates correctly.
BODY COMPONENTS
DOOR LATCH STRIKER
REPLACEMENT
(1) Remove the striker and spacer from the B-pillar (Fig. 12).
(2) Install the spacer and replacement striker on
the B-pillar (Fig. 12).
(3) Adjust the door latch striker either in or out to
position it correctly for the door latch to be completely engaged when the door is closed. When
closed, the door should be flush with the adjacent
body panels.
23 - 29
INSTALLATION
(1) Insert the motor in the access hole in the inner
panel and position it at the location of the retaining
screw holes (Fig. 13).
(2) Connect the lock motor-to-latch rod to the motor (Fig. 13).
(3) Install the lock motor retaining screws. Tighten
the screws with 11 Nzm (95 in. lbs.) torque.
(4) Connect the lock motor wire harness connector
to the door wire harness connector.
23 - 30
BODY COMPONENTS
BODY COMPONENTS
(3) The top of the seal must fit tight against the
roof to provide a proper water-tight seal and to have
good appearance (Fig. 14).
SECONDARY WEATHERSTRIP SEAL
(1) Clean the door sill contact surface (Fig. 15)
with a 50/50 solution of isopropyl alcohol and clean
water.
(2) Remove the backing from the tape at the front
of the seal.
(3) Position the seal on the door sill with the screw
holes aligned. The inner edge of the seal must be located under the door primary weatherstrip seal bulb,
but must not contact or interfere with the bulb (Fig.
15).
(4) Apply pressure to seal at the area of the tape to
adhere the tape to the rocker panel/door sill (Fig. 15).
(5) Attach the seal to the door sill with the screws
(Fig. 15). Tighten the screws securely.
REARVIEW MIRROR
REMOVAL
(1) Loosen the mirror base setscrew and slide the
mirror base up and off the support bracket (Fig. 16).
23 - 31
23 - 32
BODY COMPONENTS
URETHANE SET GLASS
INDEX
page
page
WINDSHIELD
WINDSHIELD REMOVAL
(1) Remove inside rear view mirror (Fig. 1).
(2) Remove cowl cover. Refer to Cowl Cover Removal paragraph in this group.
BODY COMPONENTS
23 - 33
GLASS REMOVAL
(1) Remove the latch retaining screws from the cab
rear side panel (Fig. 7)
23 - 34
BODY COMPONENTS
(2) Pull the seal away from the flange around the
perimeter
of the window opening (Fig. 8).
GLASS INSTALLATION
(1) If removed, install the latch and frame/hinge on
the glass.
(2) Position the window glass at the opening, insert the hinge studs in the B-pillar holes, and install
the retaining nuts. Tighten the nuts with 11 Nzm (95
in. lbs.) torque.
(3) Attach the latch to the rear side panel with the
screws. Tighten the screws with 11 Nzm (95 in. lbs.)
torque.
(4) Test the vent window for water leaks.
WEATHERSTRIP SEAL REMOVAL
(1) Remove the window. If necessary, refer to the
removal procedure.
REMOVAL
(1) If equipped, remove the window reveal
moulding/retainer.
(2) Separate the weatherstrip seal lip from the
window glass (or frame) at one corner with a thin
BODY COMPONENTS
23 - 35
(3) Apply a 6 mm (0.25 in) diameter bead of sealant to the window opening flange.
(4) Install the window glass (or frame) and the
weatherstrip seal in the window opening with a
length of cord (Fig. 12) according to the following instructions:
Moisten a length of 6 mm (0.25 in) diameter cord
with a soap and water solution.
Ensure that the cord is long enough to go all the
way around the perimeter of the weatherstrip seal.
Insert the cord into the window opening flange
channel in the weatherstrip seal (Fig. 12).
Position the window glass (or frame) and the
weatherstrip seal in the window opening with the
free ends of the cord inside the vehicle.
Pull on each end of the cord to pull the weatherstrip seal channel lip over the window opening flange
(Fig. 10).
(5) Test the window for water leaks.
(6) If equipped, install the window reveal moulding/retainer.
(7) Clean the vehicle, as necessary.
INSTALLATION
(1) Clean the weatherstrip seal channels and the
REMOVAL
(1) Remove quarter trim panels.
(2) Remove headliner.
(3) Remove rear closure panel trim.
(4) Bend rear window retaining tabs inward
against glass.
(5) Using a suitable pneumatic knife from inside
the vehicle, cut urethane holding rear glass frame to
opening fence.
23 - 36
BODY COMPONENTS
INSTALLATION
(1) Clean urethane adhesive from around rear
glass opening fence.
(2) Apply black-out primer to outer edge of replacement rear glass frame.
(3) Apply black-out primer to rear glass opening
frame,
(4) Apply a 10 mm (0.4 in.) bead of urethane
around perimeter of windshield along the inside of
the moldings.
(5) Place rear glass into rear glass opening.
(6) Firmly push glass against rear window glass
opening fence.
(7) Bend tabs around edges of rear window opening fence to retain glass.
(8) Clean access urethane from exterior with Mopart, Super Clean or equivalent.
(9) After urethane has cured, remove tape strips
and water test windshield to verify repair.
(10) Install interior trim.
INSTALLATION
(1) Position the sliding vent glass in the frame
track.
(2) Tighten all the retaining screws at the bottom
of the frame.
(3) Test for correct travel and the latch operation
for the sliding vent glass.
(4) Install rear window in the cab opening. If necessary, refer to the installation procedure.
(5) Inspect and ensure that the drain holes are not
restricted.
BODY COMPONENTS
23 - 37
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43
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SEATS
BENCH SEAT
REMOVAL
Bench seat support brackets are attached to the
floor panel with studs, nuts and screws. The trim
covers are attached to the brackets with screws (Fig.
1).
page
Overhead Console
Seats . . . . . . . . .
Shoulder Belts/Lap
Sunvisors . . . . . .
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Belt/Buckles
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37
39
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are in the same relative position on the lower support before any fasteners are secured. Tighten the
front nuts and screws first and then the rear nuts
and screws with 28 Nzm (250 in-lbs) torque.
(3) Install the shoulder belt buckles and lap belts.
(4) Install the seat track and support bracket covers and retaining screws. Tighten the screws with 2
Nzm (17 in-lbs) torque.
23 - 38
BODY COMPONENTS
BODY COMPONENTS
23 - 39
23 - 40
BODY COMPONENTS
BODY COMPONENTS
23 - 41
(6) At each side of the cab, remove the cover concealing the shoulder belt upper anchor bolt.
(7) At each side of the cab, use a Torx bit to remove the upper anchor bolt from the cab side panel.
(8) At each side of the cab, remove the shoulder
belt lower anchor bolt from the floor panel with a
Torx bit.
(9) At each side of the cab, remove the belt retractor support retaining bolt from the quarter panel
with a Torx bit.
(10) Remove the shoulder belts and the retractors
from the cab.
INSPECTION
Inspect the condition of the shoulder belts, lap belt
and buckles. Replace any belt or buckle that is either
cut, frayed, torn or damaged in any way. Also, replace the shoulder belt if the retractor is either damaged or inoperative.
INSTALLATION
(1) At each side of the cab, position the shoulder
belt retractor in the receptacle. Install the support
retaining bolt in the quarter panel with a Torx bit.
(2) At each side of the cab, position the other end
of the shoulder belt at the floor panel. Install the
lower anchor bolt in the floor panel with a Torx bit.
(3) At each side of the cab, position the shoulder
belt upper anchor plate on the trim panel. Install the
upper anchor bolts in the cab side panels with a Torx
bit.
(4) Tighten the upper and lower anchor bolts with
40 Nzm (350 in. lbs.) torque.
(5) Position the covers over the upper anchor bolts.
(6) Position the buckles and the lap belt on the
floor panel.
(7) Install the anchor bolts in the floor panel for
the left shoulder belt/lap belt and the right shoulder
belt/lap belt.
(8) Tighten the anchor bolts with 40 Nzm (350 in.
lbs.) torque.
(9) Install the rear seat. If necessary, refer to the
installation procedure.
(10) If applicable, adjust the seat position.
HEADLINERS
SERVICE INFORMATION
The Dakota standard equipment cab headliner is a
molded hardboard. A cloth-cover molded cab headliner is used with SLT model. The cab headliner (Fig.
10), trim mouldings/panels and overhead console are
attached to the roof panel with screws.
To remove a headliner (Fig. 10), all of the interfering trim mouldings/panels must be removed along
with (as applicable):
The sunvisors (Fig. 10).
The dome/cargo lamp.
Overhead console
The map/reading lamp.
The coat hook.
The assist handle.
Any other interfering attached component.
REMOVAL
CAUTION: A cab headliner (Fig. 10) is a one-piece,
molded hardboard. It has limited flexibility and must
not be bent during removal/installation.
(1) Remove the sunvisors and retaining clips. If
necessary, refer to the removal procedure.
(2) Remove the windshield trim mouldings, B-pillar panels or quarter panels (club cab) and rear window upper trim moulding. If necessary, refer to the
removal procedure.
(3) As applicable, remove the dome/cargo lamp, the
map/reading lamp and/or overhead console. If necessary, refer to the removal procedures.
(4) Remove the retaining screws and the assist
handle (Fig. 11).
(5) Remove the retaining screws and the coat hook
(Fig. 10).
(6) Remove all other headliner interfering components.
(7) Remove the headliner retaining screws.
(8) Carefully remove the headliner from the cab
(Fig. 10).
INSTALLATION
(1) Carefully position the headliner in the cab adjacent to the roof panel (Fig. 10).
(2) Install the headliner retaining screws. Tighten
the screws with 4 Nzm (35 in. lbs.) torque.
23 - 42
BODY COMPONENTS
(2) Remove the retaining screws from the cab rear,
inner panel.
(3) Disconnect the wire harness connectors.
(4) Remove the lamp from the headliner hole and
the rear, inner panel.
INSTALLATION
(1) Position the dome lamp adjacent to the headliner and the rear, inner panel.
(2) Connect the lamp wire harness connectors.
(3) Position the lamp in the headliner hole and install the retaining screws in the panel. Tighten the
screws with 4 Nzm (35 in. lbs.) torque.
(4) Install the lamp lens.
DOME LAMP
REMOVAL
(1) Remove the dome lamp lens by squeezing it
and forcing it downward (Fig. 12).
OVERHEAD CONSOLE
REMOVAL
(1) Open sunglasses storage bin.
(2) Remove console mounting screw (Fig. 13).
(3) Slide console forward until it detaches from
mounting bracket.
(4) Disconnect wire harness from compass.
INSTALLATION
(1) Connect compass wire harness.
(2) Place console forward of mounting bracket and
slide console rearward until it attaches to mounting
bracket.
(3) Install console mounting screw. Tighten the
screw with 2 Nzm (20 in. lbs.) torque.
SUNVISORS
REMOVAL
(1) Remove the screws that attach the sunvisor
arm support bracket to the headliner and the roof
panel (Fig. 10).
(2) Detach the sunvisor from the retaining clip.
(3) Remove the sunvisor from the headliner and
roof panel.
BODY COMPONENTS
(4) Remove the attaching screw and the retaining
clip from the headliner and the roof panel.
INSTALLATION
(1) Install the sunvisor retaining clip with the attaching screw.
(2) Position the sunvisor in the retaining clip and
align the arm support bracket holes with the headliner holes.
(3) Install the screws that attach the sunvisor arm
support bracket to the headliner and the roof panel.
Tighten the screws with 4 Nzm (35 in. lbs.) torque.
23 - 43
INSTALLATION
(1) Position the console on the floor panel and
bracket.
(2) Install the attaching screws in the panel and
bracket. Tighten the screws with 4 Nzm (35 in. lbs.)
torque.
(3) Install the front bin and close the lid.
SERVICE INFORMATION
The carpets/mats are retained around the perimeter of the floor panel by the interior trim mouldings
and trim panels.
To remove a carpet/mat, all of the retaining trim
mouldings and panels must be removed along with
all the interfering components (as applicable):
The seat(s).
The scuff plates.
The transmission and transfer case floor shift levers, bezels and boots (Fig. 16).
The floor console.
All other interfering attached components.
23 - 44
BODY COMPONENTS
REMOVAL
(1) Remove the protective floor mats (if equipped).
(2) Remove all the interfering components. If
needed refer to applicable removal procedure.
(3) Remove the carpet/mat from the floor panel.
INSTALLATION
(1) Position the carpet/mat on the floor panel.
(2) Install seat(s) and all the components that were
removed to ease carpet/mat removal. If needed refer
to applicable installation procedures.
(3) Install the trim panels, mouldings and scuff
plates.
(4) Place the protective floor mats (if equipped) on
the carpet/mat.
BODY COMPONENTS
23 - 45
PAINT
INTRODUCTION
A paint code is provided on the body code plate located on the floor behind the passenger seat. Refer to
the Introduction section at the front of this manual
for body code plate description. The color names provided in the Paint and Trim Code Description chart
are the color names used on most repair product containers. The color names in the new vehicle ordering
guides vary depending on car line but use the same
color code.
TOUCH-UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with Mopar Tar/Road Oil
Remover and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet
enough to puddle fill the defect without running. Do
not stroke brush applicator on body surface. Allow
the filler/ primer to dry hard.
(4) Cover the filler/primer with color touch-up
paint. Do not overlap touch-up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color if possible. Do not stroke
applicator brush on body surface. Allow touch-up
paint to dry hard.
(5) On vehicles without clear coat, the touch-up
color can be lightly (600 grit) wet sanded and polished with rubbing compound.
(6) On vehicles with clear coat, Apply clear top
coat to touch-up paint with the same technique as
described in step 4. Allow clear top coat to dry hard.
If desired, step 5 can be performed on clear top coat.
23 - 46
BODY COMPONENTS
AFTERMARKET PAINT AND TRIM REPAIR PRODUCTSAN-TRUCK
BODY COMPONENTS
TORQUE SPECIFICATIONS
23 - 47
24 - 1
page
REFRIGERANT SERVICE . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 26
WARNINGS, CAUTIONS AND SERVICE
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
This vehicle is equipped with a common Heater
and A/C housing. Vehicles with heater only system
have the evaporator and recirculating air door omitted from the housing (Fig. 1). Air flow is directed either through or around the heater core by adjusting
the blend-air door with the TEMP lever. Air flow can
be directed to the PANEL outlets, BI-LEVEL (panel
& floor) outlets, FLOOR outlet, or DEFROST outlets.
HEATER SYSTEM
The heater system is a blend-air type. Outside air
enters the cowl opening and passes through the
heater core. A temperature control door in the housing directs the air through or around the heater core.
The amount of heat is determined by the setting of
the temperature lever on the instrument panel. Direction of the air is controlled by the HEAT-DEFROST lever on the instrument panel.
A self-adjusting clip, on the control cables simplifies cable adjustment. The clip snaps onto the control
cable wire and slides along the wire under a specific
load to provide an automatic adjustment.
A/C COMPONENTS
ACCUMULATOR: The Accumulator is mounted in
the engine compartment on the right side of the vehicle. The inlet tube of the accumulator attaches directly to the evaporator core outlet tube. Refrigerant
enters the accumulator canister through the inlet
tube. The liquid oil-laden refrigerant falls to the bottom of the canister which acts as a separator. A desiccant bag is mounted inside the suction accumulator
canister to absorb any moisture which may be in the
refrigerant system (Fig.2).
24 - 2
Fig. 2 Accumulator
COMPRESSOR: The SD7H15 Compressor is used
on all models. The purpose of the compressor is to
compress the low-pressure refrigerant vapor into a
high pressure, high temperature vapor. The compressor is serviced as a assembly only.
CLUTCH PULLEY AND COIL: They are
mounted on the compressor and providing a way to
drive the compressor. The compressor clutch and coil
are the only serviced parts on the SD7H15 compressor. When the compressor is not in operation, the
pulley free wheels on the clutch hub bearing. When
the coil is energized the clutch plate is magnetically
engaged with the pulley and turns the compressor
shaft.
AIR CONDITIONING CYCLING SWITCH: The
switch is mounted on top of the accumulator on 3.9L
and 5.2L engines. On the 2.5L engine the switch is
mounted on the side of the accumulator. The switch
is wired in series with compressor clutch. The switch
contacts open and close turning on an off the compressor clutch. This regulates the system pressure.
Lower ambient temperatures, below approximately
-1C (30F) during cold weather will also open the
switch contacts. This is due to the pressure/temperature relationship of the refrigerant in the system.
CONDENSER: The condenser is located in front of
the engine radiator. Its function is to cool the hot
high pressure refrigerant gas. This causes it to condense into high pressure liquid refrigerant.
EVAPORATOR COIL: The coil is located in the
A/C housing. Its function is to remove heat and dehumidify the air before it enters the vehicle.
FIXED ORIFICE TUBE: The orifice tube is located in the outlet line of the condenser. The inlet
and outlet ends have a screen to filter the refrigerant. O-rings on the orifice tube body prevent the refrigerant from bypassing the orifice. The orifice tube
is used to meters the flow of liquid refrigerant into
the evaporator core.
HIGH PRESSURE RELIEF VALVE: The valve is
located on the compressor manifold. The valve is
used to prevent excessive pressure build up. This
prevents damage to the compressor and other system
components.
HIGH-PRESSURE CUT-OUT SWITCH: The
switch is located on the discharge line.The switch is
wired in series with compressor clutch. The switch
interrupts power to the compressor clutch, when excessive pressure is present.
REFRIGERANT LINES: The lines are used to
carry the refrigerant between the various system
components. The barrier hose design is used for the
air conditioning system on this vehicle. The ends of
the A/C hoses are made from light-weight aluminum
and use new braze-less fittings.
SPRING LOCK COUPLER: The coupler is used
to attach A/C lines and other components. The coupling is held together by a garter spring inside a circular cage. When the coupling is connected together,
the flared end of the female fitting slips behind the
garter spring inside the cage of the male fitting. The
garter spring and cage prevent the flared end of the
female fitting from pulling out of the cage. O-rings
are used to seal the coupling. These O-rings are compatible with R-134a refrigerant and must be replaced
with O-rings made of the same material.
SERVICE PORTS: The low and high pressure service ports are attached to the refrigerant lines. These
ports are used to attach A/C gauges. After servicing
the refrigerant system, always install service port
caps.
REFRIGERANT
This vehicle uses a new type of refrigerant called
R-134a. It is a non-toxic, non-flammable, clear colorless liquified gas.
R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small
amount of R-12 in a R-134a system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance.
24 - 3
The service port to charge the air conditioning system is located on the condenser to evaporator tube
near the front end. New service port couplers have
been used to ensure that the system is not accidentally filled with the wrong refrigerant (R-12).
R-134a refrigerant requires a special type of compressor oil (SP20 PAG). When adding oil, make sure
that it is designed to be used in the R-134a system
using the SD7H15 compressor.
REFRIGERANT EQUIPMENT
WARNING: EYE PROTECTION MUST BE USED
WHEN SERVICING AN AIR CONDITIONING REFRIGERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED
BEFORE PROCEEDING WITH THIS OPERATION.
PERSONNEL INJURY CAN RESULT.
Chrysler Corporation recommends a (R-134a) recycling device that meets SAE standard J2210 be used
when servicing the refrigerant system. Contact an
automotive service equipment supplier for refrigerant
recycling equipment that is available in your area.
Refer to the operating instructions provided with the
recycling equipment for proper operation.
CAUTIONS
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with equipment being used.
24 - 4
SERVICE PRECAUTIONS
Never open or loosen a connection before the refrigerant has been recovered from the system.
A system which has been opened or one which has
discharged through leakage must be evacuated before
charging.
DO NOT open a refrigerant system or uncap a replacement component unless it is as close as possible
to room temperature. This will prevent condensation
from forming inside of a component which is cooler
than the surrounding air.
Before disconnecting a component from the system,
clean the outside of the fittings thoroughly.
When disconnecting a fitting use a wrench on both
halves of the fitting. This will prevent twisting of the
refrigerant lines or tubes.
Immediately after disconnecting a component from
the system, seal the open fittings with a cap or plug.
DO NOT remove the sealing caps from a replacement component until ready to install.
Before connecting an open fitting always install a
new seal. Coat the fitting and seal with clean refrigerant oil before connecting.
Tighten fittings only to the specified torque. The
aluminum fittings used in the A/C system will not
tolerate over tightening.
Refrigerant oil absorbs moisture from the atmosphere. DO NOT open an oil container until ready to
use and install the cap immediately after using.
Store the oil only in a clean moisture-free container.
When installing a refrigerant line avoid sharp
bends. Position the line away from the exhaust or
any sharp edges which may chafe the line.
Keep service tools and the work area clean. Contamination of A/C system through careless work habits must be avoided.
COOLING SYSTEM
To maintain the performance level of the heating/
air conditioning system, the engine cooling system
must be properly maintained.
The use of a bug screen is not recommended. Any
obstructions in front of the radiator or condenser can
reduce the performance of the A/C and/or the engine
cooling system.
24 - 5
REFRIGERANT SERVICE
INDEX
page
page
REFRIGERANT OIL
It is important to have the correct amount of oil in
the A/C system. This will ensure proper lubrication of
24 - 6
24 - 7
24 - 8
PRESSURE DIAGNOSIS
TEMPERATURE REFERENCE
24 - 9
24 - 10
page
24 - 11
24 - 12
BLOWER MOTOR
Power to the blower motor is supplied from fuse #1.
The blower speed is controlled by the blower switch
and blower resistors. With the switch in LO, the
24 - 13
24 - 14
page
Compressor Manifold . . . . . . . . . . . . . . . . . . . . . . 15
Compressor Replacement . . . . . . . . . . . . . . . . . . . 14
Noises that develop during air conditioning operation can often be misleading.
Drive belts are speed sensitive. At different engine
speeds belts can make noises which can be mistaken
for compressor noise.
First proceed with the following steps:
(1) Select a quiet area for testing. Switch compressor on and off several times to clearly identify compressor noise.
(2) Tighten all compressor mounting bolts to correct torque. Check condition and adjustment of compressor drive belt. Verify refrigerant lines are not
contacting other components.
(3) Test vehicle; if noise persists, continue trouble
shooting system for source of noise. Refer to the
Compressor and Clutch Diagnosis Charts.
Belt slippage will reduce air conditioning performance and belt life.
Any belt which has operated for a 1/2 hour is considered a USED belt. Belt tension and condition
should be checked at regular service intervals. Refer
to Group 7 Cooling, for proper adjustment and measurement procedures.
COMPRESSOR REPLACEMENT
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THE
FOLLOWING PROCEDURE.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove drive belt (refer to Group 7, Cooling
System).
(3) Disconnect compressor clutch wire.
(4) Recover refrigerant (refer to Refrigerant Service Procedures).
(5) Remove refrigerant lines from compressor and
tape openings.
(6) Remove compressor attaching bolts and remove
compressor.
INSTALLATION
If a replacement compressor is being installed
check the oil level. Add or subtract oil as necessary and install the magnetic clutch on the
compressor.
(1) Install compressor on the mounting bracket.
Tighten compressor mounting bolts to 27 Nzm (20 ft.
lbs.) torque.
(2) Remove the tape from opened ports.
(3) Install refrigerant lines on compressor with
new seals.
(4) Install drive belt (refer to Group 7, Cooling System).
(5) Connect compressor clutch wire lead and negative battery cable.
(6) Evacuate and charge A/C system (refer to Refrigerant Service Procedures).
(7) Test system for leaks.
24 - 15
COMPRESSOR MANIFOLD
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THE
FOLLOWING PROCEDURE.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Recover refrigerant (refer to Refrigerant Service Procedures).
(3) Disconnect refrigerant lines from manifold.
(4) Remove manifold bolts and remove manifold.
INSTALLATION
(1) Install manifold on the compressor with new
seal.
(2) Install manifold bolts and tighten to 25 Nzm (19
ft. lbs.) torque.
(3) Install refrigerant lines to manifold.
24 - 16
INSTALLATION
(1) Install the field coil with the snap ring.
(2) Place coil lead wire under clip on top of compressor front housing and tighten the retaining
screw.
(3) Support the compressor on the 4 mounting ears
at the compressor rear.
CAUTION: If a vise is being used, clamp only on the
mounting ears. Never clamp on the compressor
body.
24 - 17
24 - 18
24 - 19
COMPONENT SERVICE
INDEX
page
A/C Condenser Assembly . . . . . .
Air Distribution Ducts . . . . . . . . . .
Blend-Air Door . . . . . . . . . . . . . .
Blower Motor and Wheel Assembly
Evaporator Coil . . . . . . . . . . . . . .
Heater A/C Housing . . . . . . . . . .
Heater Core . . . . . . . . . . . . . . . .
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22
21
26
23
26
23
26
REFRIGERANT LINES
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THE
FOLLOWING PROCEDURE.
REMOVAL
(1) Recover refrigerant (refer to Refrigerant Service Procedures).
(2) Fit the appropriate Spring Lock Coupling Tool
from A/C Tool Kit 6125 (Fig. 1).
page
Heater Hoses . . . . . . . . . . . . . . .
Mode Door Vacuum Actuator . . . .
Panel Air Louvers . . . . . . . . . . . .
Recirculating Air Vacuum Actuator
Refrigerant Lines . . . . . . . . . . . .
Temperature Control Cable . . . . .
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21
20
21
20
19
19
INSTALL
(1) Check to ensure that the garter spring is in the
cage of the male fitting. If the garter spring is missing, install a new spring by pushing it into the cage
opening. If the garter spring is damaged, remove it
from the cage with a small wire hook (DO NOT use a
screwdriver) and install a new spring.
(2) Clean all dirt or foreign material from both
pieces of the coupling.
(3) Install new O-rings on the male fitting.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a system. The use of any O-ring other than the specified
O-ring may allow the connection to leak intermittently during vehicle operation.
(4) Lubricate the male fitting and O-rings and the
inside of the female fitting with clean R-134a (SP20
PAG) refrigerant oil.
(5) Install the plastic indicator ring into the cage
opening if indicator ring is to be used.
(6) Fit female fitting to male fitting and push until
garter spring snaps over flared end of female fitting.
If plastic indicator ring is used, it will snap out of the
cage opening when the coupling is connected to indicate engagement.
(7) If indicator ring is not used, ensure coupling
engagement. This is done by visually checking to be
sure garter spring is over the flared end of female fitting.
24 - 20
REMOVAL
(1) Disconnect the vacuum line.
(2) Remove 2 vacuum actuator attaching nuts (Fig.
5).
(3) Disengage drive linkage from recirculating airdoor pivot.
(4) Remove the actuator from the heater A/C housing.
INSTALLATION
To install, reverse the preceding operation.
To Adjust Temperature Cable, position the TEMP
lever on the control to the cool side of its travel. Allowing the self adjusting clip to slide on the cable, rotate the blend-air door crank counterclockwise by
hand until it stops.
24 - 21
HEATER HOSES
REVIEW WARNINGS AND CAUTIONS IN
THIS GROUP BEFORE PERFORMING THE
FOLLOWING PROCEDURE.
REMOVAL
(1) Drain engine cooling system (refer to Group 7,
Cooling System).
(2) Loosen clamps at each end of hose to be removed (Figs. 8 and 9).
CAUTION: When removing hoses from heater core
inlet or outlet nipples, DO NOT use excessive force.
Heater core may become damaged and leak engine
coolant into heater A/C housing.
(3) Carefully rotate hose back and forth while tugging slightly away from connector nipples.
(4) On 3.9L and 5.2L engines:
(a) Remove the coolant return tube (Fig. 10).
(b) Discard the old O-ring.
INSTALLATION
(1) On 3.9L/5.2L engines:
(a) Install a new O-ring onto the coolant return
tube (Fig. 10). Coat the new O-ring with antifreeze
before installation.
(b) Install the coolant return tube and tighten
the coolant return tube bracket bolt.
(2) Install the hoses onto the connector nipples.
(3) Tighten the clamps at each end of hoses.
24 - 22
REMOVAL
(1) Recover refrigerant system (refer to Refrigerant
Service Procedures).
24 - 23
24 - 24
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Recover refrigerant system (refer to Refrigerant
Service Procedures).
(3) Remove lower instrument panel module (refer
to Group 8E Instrument Panel).
(4) Remove the center air distribution duct.
(5) Tape wiring harness up and out of the way
(Fig. 15).
24 - 25
DISASSEMBLE
(1) Place the heater A/C unit on a suitable work
surface (Fig. 19).
ASSEMBLE
(1) Install cover into place while guiding the panel
air mode door pivot shaft into its socket.
(2) Install cover attaching screws into the housing.
INSTALLATION
(1) Install the unit with the attaching studs facing
downward. Carefully rotate and push the housing
forward until attaching studs fit into the dash panel.
(2) Install housing support brace and tighten the
attaching screw.
(3) Install and tighten the 4 housing attaching
nuts at the rear engine compartment dash panel.
(4) Install the condensate drain tube.
(5) Remove plugs from the heater core tubes and
connect the heater hoses.
(6) Remove tape from the open ends of the refrigerant lines. Install the expansion valve and connect
refrigerant lines.
(7) Install the self adjusting clip to blend-air-door
crank. Connect the temperature control cable flag retainer to the housing.
(8) Connect vacuum harness connector from housing to the control connector. Connect the vacuum feed
line to check valve.
(9) Connect demister hoses to the adapter on top of
the housing.
(10) Connect heater blower wire.
(11) Install the antenna cable to the retaining clip
at the right end of the housing.
(12) Remove the tape holding the wiring harness
up and out of the way.
(13) Install the center air distribution duct.
(14) Install the lower instrument panel module (refer to Group 8E Instrument Panel).
(15) Connect the negative cable to the battery.
(16) Fill the engine cooling system (refer to Group
7, Cooling System).
(17) Evacuate and charge the refrigerant system
(refer to Refrigerant Service Procedures).
24 - 26
BLEND-AIR DOOR
The heater A/C housing must be removed to service
the mode, heater defroster or blend-air door.
REMOVAL
(1) Remove heater A/C unit top cover.
(2) Remove nut from bottom of the blend-air door
pivot shaft and lift from the housing (Fig. 22).
HEATER CORE
REMOVAL
(1) Remove housing top cover.
(2) Remove the attaching screw from the heater
core retaining bracket and lift the heater core from
housing.
INSTALLATION
(1) Position the heater core into housing. Install
and tighten the attaching screw to the heater core retaining bracket.
(2) Install housing top cover.
EVAPORATOR COIL
REMOVAL
(1) Remove housing top cover.
(2) Lift the evaporator coil from housing (Fig. 23).
INSTALLATION
(1) Position the evaporator coil into the housing.
(2) Install housing top cover.
TORQUE SPECIFICATIONS
HEATING AND AIR CONDITIONING
DESCRIPTION ................................................TORQUE
Compressor
Mounting Bolts ............................27 Nzm (20 ft. lbs.)
Mounting Bolts 2.5L ...................54 Nzm (40 ft. lbs.)
ft.
ft.
ft.
ft.
lbs.)
lbs.)
lbs.)
lbs.)
25 - 1
page
COMPONENT REMOVAL/INSTALLATION . . . . . . 18
EVAPORATIVE EMISSION CONTROLS . . . . . . . . 5
GENERAL INFORMATION
INDEX
page
page
All vehicles are equipped with a combined VECI label. The label is located in the engine compartment
(Fig. 1). The label contains the following:
Engine family and displacement
Evaporative family
Emission control system schematic
Certification application
Engine timing specifications (if adjustable)
Idle speeds (if adjustable)
Spark plug and plug gap
ON-BOARD DIAGNOSTICS
25 - 2
25 - 3
25 - 4
25 - 5
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8
9
5
5
page
Evap Canister Purge Solenoid . . . . . . . . . . .
Fuel Tank Filler Tube Cap . . . . . . . . . . . . . .
Positive Crankcase Ventilation (PCV) System
Pressure Relief/Rollover Valve . . . . . . . . . . .
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5
6
6
5
EVAP canister purge solenoid allows the EVAP canister to be purged at predetermined times and at certain engine operating conditions.
EVAP CANISTER
A sealed, maintenance free, EVAP canister is used
on all vehicles. The canister is mounted in the engine
compartment on the right side of the radiator closure
panel (Fig. 4). The EVAP canister is filled with granules of an activated carbon mixture. Fuel vapors entering the EVAP canister are absorbed by the
charcoal granules.
Fuel tank pressure vents into the EVAP canister.
Fuel vapors are temporarily held in the canister until
they can be drawn into the intake manifold. The
25 - 6
25 - 7
The positive crankcase ventilation (PCV) system operates by engine intake manifold vacuum (Fig. 10). Filtered air is routed into the crankcase through the air
cleaner hose and crankcase breather/filter. This forces
crankcase vapors through the PCV valve. It is then
drawn into a passage in the throttle body (2.5L engine)
or intake manifold (3.9L/5.2L engines). Here it becomes
part of the calibrated air/fuel mixture to be consumed in
the combustion chamber. The PCV system constantly
ventilates the crankcase to help prevent sludge formation and vapors from entering the atmosphere.
25 - 8
25 - 9
CRANKCASE BREATHER/FILTER3.9L/5.2L
ENGINES
The crankcase breather/filter (Fig. 18) is located on
the engine valve cover. It must be kept clean and lubricated. At the recommended interval, remove the
filter and wash it thoroughly in kerosene, or similar
solvent. Lubricate or wet the filter by inverting it
and filling with SAE 30 engine oil. Filter must then
be thoroughly drained. More frequent service may be
necessary for vehicles operated extensively on short
run, stop and go, or extended engine idle service.
The filter must be replaced at correct intervals. Refer to Lubrication and Maintenance, Group 0.
25 - 10
page
The heated air inlet system will control and maintain the temperature of air entering the throttle
body. By maintaining the inlet air temperature, the
air-fuel mixture can be calibrated much leaner. This
is done to reduce hydrocarbon emissions, improve engine warm-up characteristics and minimize icing.
This system is used only on the 2.5L 4-cylinder engine.
The system consists of:
A diaphragm that operates the blend door in the
air cleaner. It will open to either heated air or ambient air.
A thermal vacuum valve (TVV).
An air duct hose connected to a heat stove on the
exhaust manifold (Fig. 1).
The air cleaner blend door opens to ambient (outside) air, or preheated air from the heat stove, or to a
position in between them.
25 - 11
dilute the incoming fuel/air mixture. This dilution reduces peak flame temperature during combustion.
A malfunctioning EGR system can cause engine
spark knock, sags or hesitation, rough idle, engine
stalling and poor driveability.
25 - 12
25 - 13
25 - 14
25 - 15
25 - 16
25 - 17
25 - 18
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18
18
20
19
19
18
20
18
page
EVAP Canister . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister Purge Solenoid2.5L Engine
Fuel Tank Filler Tube Cap . . . . . . . . . . . . . .
Oxygen (O2S) Sensor . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) . . . . . . . .
Pressure Relief/Rollover Valve . . . . . . . . . . .
Thermal Vacuum Valve (TVV)2.5L Engine
Vacuum Diaphragm2.5L Engine . . . . . . . .
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20
21
21
22
22
22
22
21
EGR VALVE
The EGR valve, EGR valve control and attaching
hoses are serviced as one unit on the 2.5L engine.
REMOVAL2.5L ENGINE
(1) Disconnect vacuum source line to EGR valve
control. Inspect for damage.
(2) Remove 2 EGR valve mounting bolts from intake manifold (Fig. 1).
(3) Remove EGR valve from intake manifold.
(4) Clean gasket mating surfaces and discard old
gasket. Inspect for any signs of leakage or cracked
surfaces.
INSTALLATION2.5L ENGINE
(1) Assemble EGR valve with new gasket onto the
intake manifold.
REMOVAL3.9L/5.2L ENGINES
The EGR valve, EGR valve control and attaching
hoses are serviced as one unit on the 3.9L/5.2L engine.
(1) Disconnect vacuum hoses to EGR valve control
and EGR valve. Note position of hoses for easier installation.
(2) Remove EGR mounting bolts (Fig. 2).
(3) Remove EGR valve and gasket. Discard old
gasket. Clean intake manifold mating surface and
check for cracks.
25 - 19
INSTALLATION
(1) Loosely assemble the EGR tube, with new gaskets in place, to the intake and exhaust manifolds.
Install mounting bolts.
(2) Tighten attaching bolts to 22 Nzm (200 in. lbs.)
torque.
25 - 20
INSTALLATION
(1) Clean the EGR tube and exhaust manifold (at
EGR tube mounting point) of any old gasket material.
(2) Install a new gasket to exhaust manifold end of
EGR tube.
(3) Install EGR tube to both manifolds. Tighten
mounting nut at intake manifold. Tighten 2 mounting bolts at exhaust manifold to 23 Nzm (204 in. lbs.)
torque.
(4) Coat the threads of the oil pressure sending
unit with thread sealant. Do not allow any of the
thread sealant to get into the sending unit opening,
or the opening at the engine. Install sending unit to
engine and tighten to 14 Nzm (130 in. lbs.) torque. Install electrical connector to sending unit.
(5) Clean the intake manifold and EGR valve of
any old gasket material.
(6) Install a new EGR valve gasket to intake manifold.
(7) Install EGR valve to intake manifold. Tighten 2
mounting bolts to 23 Nzm (200 in. lbs.) torque.
(8) Install vacuum lines to EGR valve.
(9) Install spark plug cable loom and plug cables to
valve cover mounting stud.
EVAP CANISTER
The EVAP canister is located in the engine compartment on the right inner fender.
REMOVAL
(1) Remove fuel tubes/lines at EVAP canister. Note
location of tubes/lines before removal for easier installation.
(2) Remove canister bracket-to-body bolts (Fig. 6).
One of the bracket bolts must be removed from over
the top of right front tire.
(3) Remove canister and bracket from body.
INSTALLATION
(1) Position canister to mounting bracket.
(2) Install canister-to-bracket bolt and tighten to
10 Nzm (95 in. lbs.) torque.
(3) Position canister and bracket to body and install bolts.
(4) Tighten bolts to 10 Nzm (95 in. lbs.) torque.
25 - 21
INSTALLATION
(1) Install EVAP canister purge solenoid and its
mounting bracket to intake manifold.
(2) Connect vacuum harness and wiring connector.
(3) Install air cleaner housing.
25 - 22
door to snorkel side walls for interference or obstructions. Inspect the hinge pin for binding and repair as
necessary.
INSTALLATION
(1) Insert operating rod into heat control door. Position diaphragm tang into opening and rivet the tab
in place.
(2) Apply 4 inches of vacuum to diaphragm nipple.
The heat control door should operate freely. Do not
operate the heat control door by hand. Hand
operation could cock the operating rod or diaphragm, restricting proper operation of the system.
(3) Assemble air cleaner.
(4) Install air cleaner assembly on vehicle and test
operation.
INSTALLATION
(1) Install TVV into position in air cleaner.
(2) Support TVV outer edges and securely install
retainer clip. Be sure gasket forms a tight air seal.
Do not attempt to adjust TVV.
(3) Install venturi tube into air cleaner.
(4) Connect vacuum hose to temperature TVV.
(5) Install air cleaner.
INDEX
Description
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Description
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Description
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INDEX
Description
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Description
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Description
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INDEX
Description
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Description
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BREATHER/FILTER3.9L/5.2L ENGINES,
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . 25-9
BULB APPLICATION . . . . . . . . . . . . . . . . . . . 8L-13
BULB REPLACEMENT, AERO HEADLAMP . . . 8L-7
BULB REPLACEMENT, UNDERHOOD
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-12
BULBS REMOVE/INSTALL, CLUSTER . . . . . 8E-17
BUMPER, FRONT . . . . . . . . . . . . . . . . . . . . . . 13-1
BUMPER, REAR . . . . . . . . . . . . . . . . . . . . . . . 13-1
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
BURNED FLUID, CAUSES OF . . . . . . . . . . . . 21-92
BUSHING, DISTRIBUTOR . . . . . . . . . . . . . . . 9-64
BUSHING REPLACEMENT, LEAF SPRING
EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
BUSHINGS, CLUTCH AND BRAKE PEDAL . . . 0-20
BUZZER MODULE . . . . . . . . . . . . . . . . . 8U-1,8U-2
BUZZER MODULE SCHEMATIC . . . . . . . . . . . 8U-3
BYPASS HOSE3.9L/5.2L ENGINE,
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . 7-17
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-17
CAB AND CARGO BOX STRIPES . . . . . . . . . 23-13
CAB INTERIOR COMPONENTS . . . . . . . . . . 23-37
CAB, QUARTER VENT WINDOWCLUB . . . 23-33
CAB, REAR WINDOWCLUB . . . . . . . . . . . 23-34
CAB, REAR WINDOWCONVENTIONAL . . . 23-35
CABLE, ACCELERATOR PEDAL AND
THROTTLE . . . . . . . . . . . . . . . . 14-18,14-43,14-83
CABLE ADJUSTMENT, TRANSMISSION
THROTTLE VALVE . . . . . . . . . . . . . . . . . . . 21-128
CABLE AND LINKAGE ADJUSTMENT,
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-93
CABLE, HOOD INSIDE RELEASE . . . . . . . . . . 23-5
CABLE INSTALLATION, FRONT . . . . . . . . . . . 5-63
CABLE INSTALLATION, INTERMEDIATE . . . . . 5-66
CABLE INSTALLATION, REAR . . . . . . . . . . . . 5-66
CABLE REMOVAL, FRONT . . . . . . . . . . . . . . . 5-63
CABLE REMOVAL, INTERMEDIATE . . . . . . . . 5-66
CABLE REMOVAL, REAR . . . . . . . . . . . . . . . . 5-66
CABLE REMOVE/INSTALL, SERVO . . . . . . . . 8H-9
CABLE RESISTANCE, SPARK PLUG . 8D-16,8D-29
CABLE, SERVO . . . . . . . . . . . . . . . . . . . . . . . 8H-1
CABLE, SPEEDOMETER . . . . . . . . . . . . . . . . . 0-29
CABLE, TEMPERATURE CONTROL . . . . . . . 24-19
CABLE TENSIONER ADJUSTMENT,
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . 5-67
CABLE, THROTTLE . . . . . . . . . . . . . . . . . . . 14-19
CABLES, DISTRIBUTOR CAP AND
ROTOR, IGNITION . . . . . . . . . . . . . . . . . . . . . 0-18
CABLES, SPARK PLUG SECONDARY . . . . . 8D-15,
8D-25
CALIBRATION, COMPASS . . . . . . . . . . . . . . . 8C-5
CALIPER ASSEMBLY . . . . . . . . . . . . . . . 5-32,5-38
CALIPER CLEANING AND INSPECTION . 5-31,5-37
CALIPER DISASSEMBLY . . . . . . . . . . . . 5-30,5-37
CALIPER INSPECTION, BRAKESHOE . . . . . . . 5-35
CALIPER INSTALLATION . . . . . . . . . . . . 5-32,5-40
CALIPER REMOVAL . . . . . . . . . . . . . . . . 5-30,5-37
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . 9-63,9-95
CAMSHAFT, CRANKSHAFT AND
INTERMEDIATE SHAFTS TIMING
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
CAMSHAFT POSITION SENSOR; FUEL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-84
CAMSHAFT POSITION SENSOR;
FUEL/IGNITION3.9L AND 5.2L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8
CAMSHAFT POSITION SENSOR;
IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . 8D-18
CAMSHAFT POSITION SENSOR TEST . . . . . . 8D-6
CAMSHAFT POSITION SENSOR TESTING . . 14-70
CAMSHAFT POSITION SENSOR3.9L/
5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 8D-2
CAMSHAFT POSITION SENSORPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-57
CANISTER, EVAP . . . . . . . . . . . . . . . . . 25-20,25-5
CANISTER PURGE SOLENOID, EVAP;
EMISSION CONTROL SYSTEMS . . . . . . . . . . 25-5
CANISTER PURGE SOLENOID, EVAP;
FUEL SYSTEM . . . . . . . . . . . . . . . . . . 14-44,14-85
CANISTER PURGE SOLENOID2.5L
ENGINE, EVAP . . . . . . . . . . . . . . . . . . . . . . . 25-21
CANISTER PURGE SOLENOIDPCM
OUTPUT, EVAP . . . . . . . . . . . . . . . . . 14-27,14-62
CAP AND ROTOR, IGNITION CABLES,
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . 0-18
CAP, DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . 8D-7
CAP, FUEL TANK FILLER TUBE;
EMISSION CONTROL SYSTEMS . . . . . 25-21,25-6
Description
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INDEX
Description
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Description
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Description
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. . . . 8D-22,
8D-4,8D-8
COIL RESISTANCE, IGNITION . . . . . . . 8D-29,8D-9
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . 2-10
COILPCM OUTPUT, IGNITION . . . . 14-28,14-62
COLUMN ASSEMBLY REPLACEMENT . . . . . 19-39
COLUMN, STEERING . . . . . . . . . . . . . 19-36,19-42
COMBINATION VALVE INSTALLATION . . 5-47,5-57
COMBINATION VALVE OPERATION . . . . 5-46,5-55
COMBINATION VALVE REMOVAL . . . . . 5-47,5-57
COMBINATION VALVE TESTING . . . . . . . 5-10,5-6
COMBUSTION PRESSURE LEAKAGE
TEST, CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 9-6
COMPARTMENT DOOR REMOVE/
INSTALL, GARAGE DOOR OPENER
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-8
COMPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-1
COMPASS CALIBRATION . . . . . . . . . . . . . . . . 8C-5
COMPASS DEMAGNETIZING . . . . . . . . . . . . . 8C-5
COMPASS VARIATION ADJUSTMENT . . . . . . 8C-5
COMPASS/DISPLAY SELF-DIAGNOSTIC
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2
COMPASS/THERMOMETER DIAGNOSIS . . . . 8C-3
COMPASS/THERMOMETER MODULE
REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . . 8C-6
COMPLAINT, HISS NOISE . . . . . . . . . . . . . . . 19-3
COMPLETE DOOR . . . . . . . . . . . . . . . . . . . . 23-25
COMPONENTS2WD, FRONT
SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
COMPONENTS4WD, FRONT
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
COMPONENTSIN-VEHICLE SERVICE,
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . 9-21
COMPRESSION PRESSURE TEST,
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
COMPRESSOR, AIR-CONDITIONER . . . . . . . . 0-19
COMPRESSOR AND CLUTCH DIAGNOSIS . . 24-14
COMPRESSOR BRACKET SERVICE,
SOLID MOUNT . . . . . . . . . . . . . . . . . . . . . . . . 9-15
COMPRESSOR CLUTCH COIL ASSEMBLY . . 24-15
COMPRESSOR CLUTCH TEST . . . . . . . . . . . 24-13
COMPRESSOR DRIVE BELT . . . . . . . . . . . . 24-14
COMPRESSOR MANIFOLD . . . . . . . . . . . . . 24-15
COMPRESSOR NOISE, A/C . . . . . . . . . . . . . 24-14
COMPRESSOR REPLACEMENT . . . . . . . . . . 24-14
COMPRESSOR SERVICE . . . . . . . . . . . . . . . 24-14
CONDENSER ASSEMBLY, A/C . . . . . . . . . . . 24-22
CONDITION CAUSES, ABS/RWAL FAULT . . . . 5-10
CONDITION, CHECKING FLUID LEVEL . . . . . 21-91
CONDITIONS, ABS SYSTEM NORMAL
AND FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
CONNECTING ROD ASSEMBLY, PISTON / . 9-103,
9-71
CONNECTING ROD ASSEMBLY SERVICE,
CYLINDER BLOCK, PISTON . . . . . . . . . . . . . . 9-34
CONNECTIONS, INTERMITTENT AND
POOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-4
CONNECTIONS, STARTER RELAY . . . . . . . . 8A-15
CONNECTOR, ABS DATA LINK . . . . . . . . 8W-32-2
CONNECTOR, AIRBAG DATA LINK . . . . . 8W-43-1
CONNECTOR AND TERMINAL
REPLACEMENT . . . . . . . . . . . . . . . . . . . . 8W-01-7
CONNECTOR, DATA LINK; ANTI-LOCK
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-32-4
CONNECTOR, DATA LINK;
FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-5
CONNECTOR, DATA LINK; FUEL/
IGNITION3.9L AND 5.2L ENGINES . . 8W-30-11
CONNECTOR LOCATION, ABS
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CONNECTOR LOCATION, RWAL
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CONNECTOR LOCATIONS; CONNECTOR
LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 8W-90-1
CONNECTOR LOCATIONS; CONNECTOR
PIN OUTS . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-1
CONNECTOR LOCATIONS; WIRING
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
CONNECTOR, POWERTRAIN CONTROL
MODULE (PCM) 60-WAY . . . . . . . . . . . . . . . 14-70
CONNECTOR REPLACEMENT . . . . . . . . . 8W-01-7
CONNECTORPCM INPUT AND
OUTPUT, DATA LINK . . . . . . . . . . . . . . . . . . 14-57
CONNECTORS . . . . . . . . . . . . . . . . . . . . . 8W-01-2
CONNECTORS, RADIO AND SPEAKER . . . . . . 8F-4
CONNECTORS, TERMINAL/CONNECTOR
REPAIRMOLEX . . . . . . . . . . . . . . . . . . 8W-01-6
INDEX
Description
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Description
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Description
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INDEX
Description
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Description
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Description
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INDEX
Description
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Description
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Description
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INDEX
Description
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Description
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INDEX
Description
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Description
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10
INDEX
Description
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Description
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Description
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INDEX
Description
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IDENTIFICATION/SYSTEM OPERATION,
COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . . 8D-1
IDLE AIR CONTROL (IAC) MOTOR; FUEL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14-46,14-88
IDLE AIR CONTROL (IAC) MOTOR;
FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-3
IDLE AIR CONTROL (IAC) MOTOR;
FUEL/IGNITION3.9L AND 5.2L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8
IDLE AIR CONTROL (IAC) MOTOR TEST . . . 14-72
IDLE AIR CONTROL (IAC) MOTORPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . 14-27,14-61
IDLER ARM . . . . . . . . . . . . . . . . . . . . . . . . . 19-17
IGNITION CABLES, DISTRIBUTOR CAP
AND ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . 0-18
IGNITION CIRCUIT SENSEPCM INPUT . . 14-58
IGNITION COIL; FUEL SYSTEM . . . . . 14-47,14-88
IGNITION COIL; FUEL/IGNITION . . . . . . . 8W-30-2
IGNITION COIL; FUEL/IGNITION3.9L
AND 5.2L ENGINES . . . . . . . . . . . . . . . . . 8W-30-7
IGNITION COIL; IGNITION SYSTEMS . . . . . 8D-22,
8D-4,8D-8
IGNITION COIL RESISTANCE . . . . . . . 8D-29,8D-9
IGNITION COILPCM OUTPUT . . . . 14-28,14-62
IGNITION KEY-IN SWITCH . . . . . . . . . . 8U-1,8U-2
IGNITION SECONDARY CIRCUIT
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-9
IGNITION SWITCH; FUEL/IGNITION . . . . 8W-30-1
IGNITION SWITCH; FUEL/IGNITION3.9L
AND 5.2L ENGINES . . . . . . . . . . . . . . . . . 8W-30-6
IGNITION SWITCH; IGNITION SYSTEMS . . . . 8D-27
IGNITION SWITCH AND KEY CYLINDER
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-27
IGNITION SWITCH LAMP, COURTESY
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . 8D-11
IGNITION TIMING PROCEDURE . . . . . . . . . . 14-36
IGNITION-OFF DRAW . . . . . . . . . . . . . . . . . . 8A-10
IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . 8F-1
ILLUMINATION LAMPS, CLUSTER . . . 8E-14,8E-4
ILLUMINATION, RADIO . . . . . . . . . . . . . . 8W-47-1
ILLUMINATION, SERVICE BRAKE
WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . 5-3
IMPACT SENSOR . . . . . . . . . . . . . . . . . . . . . 8M-2
IMPACT SENSOR REMOVE/INSTALL . . . . . . 8M-4
IMPACT SENSORS, AIRBAG . . . . . . . . . . 8W-43-1
IMPORTANCE OF CLEAN BRAKE FLUID . . . . 5-12
IMPROPER CLUTCH RELEASE . . . . . . . . . . . . 6-7
IMPROPER CLUTCH RELEASE OR
ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
INCORRECT FLUID LEVEL, EFFECTS OF . . . 21-92
INDEX, DIAGRAM; AIR CONDITIONING/
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
INDEX, DIAGRAM; AIRBAG SYSTEM . . . 8W-43-1
INDEX, DIAGRAM; ANTI-LOCK BRAKES . 8W-32-3,
8W-32-4
INDEX, DIAGRAM; FRONT LIGHTING . . . 8W-50-2
INDEX, DIAGRAM; FUEL/IGNITION . . . . . 8W-30-5
INDEX, DIAGRAM; FUEL/IGNITION3.9L
AND 5.2L ENGINES . . . . . . . . . . . . . . . . 8W-30-11
INDEX, DIAGRAM; FUSE BLOCK . . . . . . . 8W-10-1
INDEX, DIAGRAM; GROUND
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-15-1
INDEX, DIAGRAM; HORN/CIGAR
LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-1
INDEX, DIAGRAM; INSTRUMENT
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
INDEX, DIAGRAM; INTERIOR LIGHTING . 8W-44-2
INDEX, DIAGRAM; OVERHEAD CONSOLE . 8W-49-1
INDEX, DIAGRAM; POWER
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-11-1
INDEX, DIAGRAM; POWER DOOR
LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-1
INDEX, DIAGRAM; POWER MIRRORS . . 8W-62-1
INDEX, DIAGRAM; POWER WINDOWS . . 8W-60-1
INDEX, DIAGRAM; REAR LIGHTING . . . . 8W-51-2
INDEX, DIAGRAM; TRAILER TOW . . . . . . 8W-54-1
INDEX, DIAGRAM; TRANSMISSION
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . 8W-31-1
INDEX, DIAGRAM; TURN SIGNALS . . . . . 8W-52-1
INDEX, DIAGRAM; VEHICLE SPEED
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-1
INDEX, DIAGRAM; WIPERS . . . . . . . . . . 8W-53-2
INDEX, SPLICE . . . . . . . . . . . . . . . . . . . . 8W-70-1
INDEX2.5L, DIAGRAM; CHARGING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-1
INDEX2.5L, DIAGRAM; STARTING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Description
Group-Page
INDEX3.9L/5.2L, DIAGRAM;
CHARGING SYSTEM . . . . . . . . . . . . . . . . 8W-20-1
INDEX3.9L/5.2L, DIAGRAM; STARTING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
INDICATOR ADJUSTMENT, GEAR
SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . 21-127
INDICATOR LAMP SWITCH, FOURWHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . 8W-31-1
INDICATOR LAMPPCM OUTPUT,
MALFUNCTION . . . . . . . . . . . . . . . . . 14-28,14-62
INDICATOR LAMPS . . . . . . . . . . . . . . . 8E-10,8E-3
INDICATOR REMOVE/INSTALL, GEAR
SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-20
INDICATORPCM OUTPUT, SHIFT . . . . . . . 14-63
INDICATORS, TREAD WEAR . . . . . . . . . . . . . 22-3
INFLATION PRESSURES, TIRE . . . . . . . . . . . 22-2
INITIAL OPERATION, POWER STEERING
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-16
INJECTION (MFI)COMPONENT
DESCRIPTION/SYSTEM OPERATION
3.9L/5.2L ENGINE, MULTI-PORT FUEL . . . . 14-52
INJECTION (MFI)COMPONENT
REMOVAL/INSTALLATION3.9L/5.2L
ENGINE, MULTI-PORT FUEL . . . . . . . . . . . . 14-83
INJECTIONCOMPONENT
DESCRIPTION/SYSTEM OPERATION
2.5L ENGINE, SINGLE-PORT FUEL . . . . . . . 14-21
INJECTIONCOMPONENT REMOVAL/
INSTALLATION2.5L ENGINE,
SINGLE-PORT FUEL . . . . . . . . . . . . . . . . . . . 14-43
INJECTIONGENERAL DIAGNOSIS
2.5L ENGINE, SINGLE-PORT FUEL . . . . . . . 14-32
INJECTIONGENERAL DIAGNOSIS
3.9L/5.2L ENGINE, MULTI-PORT FUEL
. . . . . . 14-67
INJECTOR DIAGNOSISVEHICLE RUNS
ROUGH AND/OR HAS A MISS . . . . . . . . . . . 14-77
INJECTOR, FUEL; FUEL SYSTEM . . . . . . . . . 14-44
INJECTOR, FUEL; FUEL/IGNITION . . . . . . 8W-30-2
INJECTOR TEST, FUEL . . . . . . . . . . . . . . . . . 14-76
INJECTORPCM OUTPUT, FUEL . . . . . . . . 14-27
INJECTOR(S), FUEL . . . . . . . . . . . . . . . . . . . 14-85
INJECTORS, FUEL . . . . . . . . . . . . . . . . . . 8W-30-7
INJECTORSPCM OUTPUT, FUEL . . . . . . . 14-62
INLET AIR SYSTEM2.5L ENGINE,
HEATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-10
INLET FILTER, PCV/CRANKCASE AIR . . . . . . 0-17
INNER CV JOINT . . . . . . . . . . . . . . . . . . . . . . 2-24
INPUT, AIR CONDITIONING (A/C)
CONTROLSPCM . . . . . . . . . . . . . . . 14-23,14-56
INPUT AND OUTPUT, DATA LINK
CONNECTORPCM . . . . . . . . . . . . . . . . . . . 14-57
INPUT, AUTOMATIC SHUTDOWN (ASD)
SENSEPCM . . . . . . . . . . . . . . . . . . . . . . . 14-57
INPUT, BATTERY VOLTAGEPCM . . . 14-23,14-57
INPUT, BRAKE SWITCHPCM . . . . . 14-23,14-57
INPUT, CAMSHAFT POSITION SENSOR
PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-57
INPUT, CRANKSHAFT POSITION
SENSORPCM . . . . . . . . . . . . . . . . . . . . . . 14-58
INPUT, ENGINE COOLANT
TEMPERATURE SENSORPCM . . . . 14-23,14-58
INPUT, ENGINE SPEEDPCM . . . . . . . . . . . 14-23
INPUT, IGNITION CIRCUIT SENSEPCM . . 14-58
INPUT, INTAKE MANIFOLD AIR
TEMPERATURE SENSORPCM . . . . . . . . . 14-58
INPUT, MANIFOLD ABSOLUTE
PRESSURE (MAP) SENSORPCM . . 14-24,14-59
INPUT, OXYGEN (O2S) SENSORPCM . . . 14-24,
14-59
INPUT, PARK BRAKE SWITCH . . . . . . . . 8W-32-4
INPUT, PARK/NEUTRAL SWITCHPCM . . . 14-60
INPUT, SCI RECEIVEPCM . . . . . . . . . . . . 14-60
INPUT, SENSOR RETURNPCM . . . . . . . . . 14-60
INPUT, SPEED CONTROLPCM . . . . . . . . . 14-60
INPUT, THROTTLE BODY TEMPERATURE
SENSORPCM . . . . . . . . . . . . . . . . . . . . . . 14-25
INPUT, THROTTLE POSITION SENSOR
(TPS)PCM . . . . . . . . . . . . . . . . . . . 14-25,14-60
INPUT, VEHICLE SPEED SENSORPCM . . 14-25,
14-60
INSIDE DOOR HANDLE . . . . . . . . . . . . . . . . 23-29
INSIDE RELEASE CABLE, HOOD . . . . . . . . . . 23-5
INSPECTION AND DIAGNOSIS CHARTS . . . . . 6-4
INSPECTION AND OVERHAUL,
OVERRUNNING CLUTCHLOWREVERSE DRUMOVERDRIVE PISTON
RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . 21-154
INSPECTION, BRAKESHOE AND CALIPER . . . 5-35
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. . . 8D-23,
8D-4
PIECE, REARTWO . . . . . . . . . . . . . . . . . . . 16-9
PILOT BEARING REPLACEMENT . . . . . . . . . . 6-12
PINION DEPTH MEASUREMENT AND
ADJUSTMENT WITH GAUGE SET . . . . . . . . . 3-22
PINION GEAR DEPTH VARIANCE; FRONT
SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-42
PINION GEAR DEPTH VARIANCE; REAR
SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-24
PINION GEAR SHAFT REMOVAL . . . . . . . . . . 2-38
PINION MEASUREMENT WITH GAUGE
SET C-3715-B, DIFFERENTIAL . . . . . . . . . . . . 2-40
PINION SEAL REPLACEMENT . . . . . . . . . . . . 3-17
PINION SHAFT SEAL REPLACEMENT . . . . . . 2-34
PINION STEERING GEAR, RACK . . . . . . . . . 19-33
PIPE, EXHAUST . . . . . . . . . . . . . . . . . . . . . . . 11-3
PIPE, EXTENSION . . . . . . . . . . . . . . . . . . . . . 11-4
PISTON / CONNECTING ROD ASSEMBLY . . 9-103,
9-71
PISTON AND CONNECTING ROD
ASSEMBLY SERVICE, CYLINDER
BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
PISTON AND RETAINER SERVICE,
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-201
PISTON AND WORM SHAFT
REPLACEMENT, RACK . . . . . . . . . . . . . . . . . 19-28
PISTON RETAINER INSPECTION AND
OVERHAUL, OVERRUNNING
CLUTCHLOW-REVERSE DRUM
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-154
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . 19-17
PITMAN SHAFT AND SIDE COVER
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 19-24
PITMAN SHAFT SEALS AND BEARING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 19-30
PITMAN SHAFT SEALS IN CAR
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 19-19
PIVOT BRACKET, SNOW PLOW . . . . . . . . . . 13-16
PIVOTS REMOVE/INSTALL, WIPER . . . . . . . . 8K-8
PLANETARY GEAR TRAIN AND
INTERMEDIATE SHAFT OVERHAUL . . . . . . 21-164
PLANETARY GEARTRAIN OVERHAUL . . . . 21-211
PLASTIC HOSES/TUBING, RUBBER . . . . . . . . 0-24
PLASTIGAGE, MEASURING WITH . . . . . . . . . . 9-3
PLATE, BODY CODE . . . . . . . . . . . . . . . . . Intro.-2
PLATE DECODING, BODY CODE . . . . . . . . Intro.-3
PLATE, EQUIPMENT IDENTIFICATION . . . . Intro.-3
PLATE INSTALLATION, BRAKE SUPPORT . . . 5-23
PLATE LAMPS, LICENSE . . . . . . . . . . . . . . . 8L-11
PLATE LAMPS, TAIL LAMPS AND REAR
LICENSE . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-1
PLATE REMOVAL, BRAKE SUPPORT . . . . . . . 5-23
PLATE, VEHICLE IDENTIFICATION
NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . Intro.-1
PLATE-RING GEAR SERVICE,
CONVERTER-DRIVE . . . . . . . . . . . . . . . . . . 21-140
PLATES, SKID . . . . . . . . . . . . . . . . . . . . . . . 13-34
PLATE/SNAP RING SPECIFICATIONS,
42RH/46RH SPACER/THRUST . . . . . . . . . . 21-288
PLOW CONTROL MODULE, SNOW . . . . . . . 13-17
PLOW DIAGNOSIS, SNOW . . . . . . . . . . . . . . 13-9
PLOW FRAME, SNOW . . . . . . . . . . . . . . . . . 13-16
PLOW MALFUNCTION DIAGNOSIS AND
TESTS, SNOW . . . . . . . . . . . . . . . . . . . . . . . . 13-4
PLOW PIVOT BRACKET, SNOW . . . . . . . . . . 13-16
PLOW, SNOW . . . . . . . . . . . . . . . . . . . . . . . . 13-3
PLOW SPECIFICATIONS, SNOW . . . . . . . . . 13-19
PLOW WIRING DIAGRAMS, SNOW . . . . . . . . 13-4
PLUG ASSEMBLY REPLACEMENT,
ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . 19-25
PLUG CABLE RESISTANCE, SPARK . 8D-16,8D-29
PLUG, HOUSING END . . . . . . . . . . . . . . . . . 19-24
PLUG LOCATIONS, DRAIN AND FILL . . . . . 21-40
PLUG LOCATIONS, SWITCH . . . . . . . . . . . . . 21-2
PLUG SECONDARY CABLES, SPARK . . . . . 8D-15,
8D-25
PLUGS, ENGINE CORE . . . . . . . . . . . . . . . . . 9-38
PLUGS, SPARK; IGNITION SYSTEMS . . . . 8D-12,
8D-24,8D-30
PLUGS, SPARK; LUBRICATION AND
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 0-18
POLISHING, WET SANDING,BUFFING . . . . . 23-45
POOR CONNECTIONS, INTERMITTENT . . 8W-01-4
POSITION SENSOR, CAMSHAFT; FUEL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-84
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REQUIRING NO LUBRICATION,
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
RESERVE/OVERFLOW SYSTEM,
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
RESERVOIR, FUEL . . . . . . . . . . . . . . . . . . . . 14-16
RESERVOIR REMOVE/INSTALL, VACUUM . . 8H-9
RESERVOIR REPLACEMENT . . . . . . . . . . . . 19-15
RESERVOIR REPLACEMENT, MASTER
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
RESERVOIR, VACUUM . . . . . . . . . . . . . . . . . 8H-1
RESISTANCE, IGNITION COIL . . . . . . . 8D-29,8D-9
RESISTANCE (OHMS)COOLANT
TEMPERATURE SENSOR/INTAKE
MANIFOLD AIR TEMPERATURE
SENSOR, SENSOR . . . . . . . . . . . . . . . . . . . . 14-70
RESISTANCE, SPARK PLUG CABLE . 8D-16,8D-29
RETAINER INSPECTION AND OVERHAUL,
OVERRUNNING CLUTCHLOWREVERSE DRUMOVERDRIVE PISTON . . 21-154
RETAINER SERVICE, OVERDRIVE PISTON . 21-201
RETURN HOSE REPLACEMENT,
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 19-12
RETURNPCM INPUT, SENSOR . . . . . . . . . 14-60
REVERSE FLUSHING, TRANSMISSION
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135
REVERSE, HYDRAULIC FLOW IN . . . . . . . 21-117
RIGHT INSTRUMENT PANEL BEZEL
REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . 8E-21
RING CHART, AX 15 SELECTIVE SNAP . . . 21-286
RING SPECIFICATIONS, 42RH/46RH
SPACER/THRUST PLATE/SNAP . . . . . . . . . 21-288
RIVET REMOVAL, BLIND . . . . . . . . . . . . . . . 23-23
ROAD LAMP DIAGNOSIS, FOG/OFF . . . . . . . . 8L-3
ROAD LAMP SWITCH REPLACEMENT,
OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-10
ROAD LAMPS, OFF . . . . . . . . . . . . . . . . . . . . 8L-9
ROAD TEST, ANALYZING THE . . . . . . . . . . . 21-93
ROAD TESTING; BRAKES . . . . . . . . . . . . . . . . 5-3
ROAD TESTING; NV3500 MANUAL
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-93
ROCKER ARMS AND PUSH RODS . . . . 9-54,9-87
ROD ASSEMBLY, PISTON / CONNECTING . 9-103,
9-71
ROD ASSEMBLY SERVICE, CYLINDER
BLOCK, PISTON AND CONNECTING . . . . . . . 9-34
ROD, TIE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-17
RODS, ROCKER ARMS AND PUSH . . . . 9-54,9-87
ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-3
ROTOR, DISTRIBUTOR . . . . . . . . . . . . . . . . . 8D-7
ROTOR, IGNITION CABLES,
DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . . . . 0-18
ROTOR INSTALLATION . . . . . . . . . . . . . . . . . 5-41
ROTOR MINIMUM THICKNESS . . . . . . . . . . . 5-42
ROTOR REFINISHING . . . . . . . . . . . . . . . . . . 5-42
ROTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . 5-41
ROTOR RUNOUT . . . . . . . . . . . . . . . . . . . . . . 5-42
ROTOR SERVICE, DISC BRAKE . . . . . . . . . . . 5-41
ROTOR THICKNESS VARIATION AND
TAPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
ROTOR TYPES . . . . . . . . . . . . . . . . . . . . . . . . 5-41
ROUGH AND/OR HAS A MISS, INJECTOR
DIAGNOSISVEHICLE RUNS . . . . . . . . . . . 14-77
ROUTING SCHEMATICS, VACUUM HOSE . . . 25-1
ROUTING, SYSTEM COOLANT . . . . . . . . . . . . . 7-2
RUBBER AND PLASTIC HOSES/TUBING . . . . 0-24
RUBBER BOOTS . . . . . . . . . . . . . . . . . . . . . . 2-29
RUBBER/PLASTIC COMPONENTS . . . . . . . . . 0-19
RUNNING LAMP (DRL) MODULE,
DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2
RUNNING LIGHT MODULE (DRLM),
DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-12
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4
RUNOUT, BRAKE DRUM . . . . . . . . . . . . . . . . 5-23
RUNOUT, CLUTCH COVER AND DISC . . . . . . . 6-4
RUNOUT, ROTOR . . . . . . . . . . . . . . . . . . . . . . 5-42
RUNOUT SPECIFICATIONS . . . . . . . . . . . . . . 16-4
RUNOUT, TIRE AND WHEEL . . . . . . . . . . . . . 22-8
RUNS ROUGH AND/OR HAS A MISS,
INJECTOR DIAGNOSISVEHICLE . . . . . . . . 14-77
RWAL BRAKE OPERATION AND SERVICE . . . 5-44
RWAL DIAGNOSTIC CONNECTOR
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
RWAL DIAGNOSTIC FAULT FLASH
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
RWAL FAULT CODE CAPACITY . . . . . . . . . . . 5-10
RWAL FAULT CODE IDENTIFICATION . . . . . . 5-10
RWAL FAULT CODES, CLEARING . . . . . . . . . 5-10
RWAL FLASH CODES, GENERATING . . . . . . . 5-10
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SUSPENSION COMPONENTS4WD,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
SUSPENSION, FRONT . . . . . . . . . . . . . . . . . . . 2-1
SUSPENSION2WD AND 4WD
VEHICLES, REAR . . . . . . . . . . . . . . . . . . . . . . . 3-4
SUSPENSION2WD VEHICLES, FRONT . . . . . 2-8
SUSPENSION4WD VEHICLES, FRONT . . . . 2-14
SWITCH ADJUSTMENT, STOPLAMP . . . . . . . 5-18
SWITCH, AIR CONDITIONING CYCLING . . . 24-13
SWITCH AND KEY CYLINDER SERVICE,
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-27
SWITCH AND PLUG LOCATIONS . . . . . . . . . . 21-2
SWITCH, BACKUP LAMP . . . . . . . . . . . . . . . 8L-11
SWITCH, BRAKE . . . . . . . . . . . . . . . . 14-43,14-84
SWITCH, BRAKE WARNING LAMP . . . . . 8W-32-4
SWITCH, CLUTCH PEDAL POSITION . . . . . . . . 6-2
SWITCH, DRIVERS DOOR JAMB . . . . . 8U-1,8U-2
SWITCH, DRIVERS SEAT BELT . . . . . . . . . . 8U-1
SWITCH, DRIVER9S SEAT BELT . . . . . . . . . . 8U-3
SWITCH, FOUR-WHEEL DRIVE
INDICATOR LAMP . . . . . . . . . . . . . . . . . . 8W-31-1
SWITCH, HEADLAMP; CHIME/BUZZER
WARNING SYSTEMS . . . . . . . . . . . . . . 8U-1,8U-3
SWITCH, HEADLAMP; LAMPS . . . . . . . . . . . 8L-10
SWITCH, HIGH-PRESSURE CUT-OFF . . . . . . 24-13
SWITCH, HORN . . . . . . . . . . . . . . . . . . 8G-1,8G-2
SWITCH, IGNITION; FUEL/IGNITION . . . . 8W-30-1
SWITCH, IGNITION; FUEL/IGNITION
3.9L AND 5.2L ENGINES . . . . . . . . . . . . . 8W-30-6
SWITCH, IGNITION; IGNITION SYSTEMS . . 8D-27
SWITCH, IGNITION KEY-IN . . . . . . . . . . 8U-1,8U-2
SWITCH INPUT, PARK BRAKE . . . . . . . . 8W-32-4
SWITCH LAMP, COURTESY LAMP AND
IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1
SWITCH, MULTI-FUNCTION . . . . . . . . . . . . . . 8J-3
SWITCH, OVERDRIVE . . . . . . . . . . . . . . . 8W-31-1
SWITCH, OVERDRIVE SELECTOR . . . . . . . . 21-88
SWITCH, OVERDRIVE/OVERRIDE . . . . . . . . 14-59
SWITCH, PARK/NEUTRAL . . . . . . . . . 14-47,14-89
SWITCH, PARK/NEUTRAL POSITION;
FUEL/IGNITION3.9L AND 5.2L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-10
SWITCH, PARK/NEUTRAL POSITION;
NV3500 MANUAL TRANSMISSION . . . . . . 21-130
SWITCH, POWER BRAKE BOOSTER
BRAKE PEDALSTOPLAMP . . . . . . . . . . . . . 5-17
SWITCH, POWER LOCK . . . . . . . . . . . . . . . . 8P-1
SWITCH, POWER MIRROR . . . . . . . . . . . . . . 8T-1
SWITCH, POWER WINDOW . . . . . . . . . . . . . 8S-1
SWITCH REMOVE/INSTALL, GLOVE BOX
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21
SWITCH REMOVE/INSTALL, HEADLAMP,
POWER MIRROR, OVERDRIVE
LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-19
SWITCH REMOVE/INSTALL, HORN . . . . . . . . 8G-3
SWITCH REMOVE/INSTALL, MULTIFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-4
SWITCH REMOVE/INSTALL, POWER
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2
SWITCH REMOVE/INSTALL, POWER
MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-3
SWITCH REMOVE/INSTALL, POWER
WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-3
SWITCH REMOVE/INSTALL, SPEED
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-8
SWITCH REMOVE/INSTALL, WIPER/
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8K-8
SWITCH REPLACEMENT, FOG LAMP . . . . . . 8L-10
SWITCH REPLACEMENT, OFF ROAD
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-10
SWITCH SENSE, FOUR-WHEEL DRIVE . 8W-32-2,
8W-32-4
SWITCH SENSE, STOP LAMP . . . . . . . . . 8W-32-2
SWITCH SERVICE PROCEDURES,
MULTI-FUNCTION . . . . . . . . . . . . . . . . . . . . 8L-10
SWITCH, SPEED CONTROL . . . . . . . . . 8H-1,8H-3
SWITCH, STOP LAMP . . . . . . . . . . . . . 8H-1,8H-6
SWITCH TEST, VACUUM . . . . . . . . . . . . . . . 24-10
SWITCH TESTING PROCEDURES,
MULTI-FUNCTION . . . . . . . . . . . . . . . . . . . . . 8L-4
SWITCH, WIPER/WASHER . . . . . . . . . . . . . . 8K-6
SWITCHPCM INPUT, BRAKE . . . . . 14-23,14-57
SWITCHPCM INPUT, PARK/NEUTRAL . . . 14-60
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-2
SYMBOLS, INTERNATIONAL . . . . . . . . . . . . . . 0-1
SYMBOLS, INTERNATIONAL CONTROL
AND DISPLAY . . . . . . . . . . . . . . . . . . . . . . Intro.-7
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TEMPERATURE SENSOR3.9L/5.2L
ENGINE, INTAKE MANIFOLD AIR . . . . . . . . . 8D-5
TEMPERATURE SENSORPCM INPUT,
ENGINE COOLANT . . . . . . . . . . . . . . . 14-23,14-58
TEMPERATURE SENSORPCM INPUT,
INTAKE MANIFOLD AIR . . . . . . . . . . . . . . . . 14-58
TEMPERATURE SENSORPCM INPUT,
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . 14-25
TENSION, ACCESSORY DRIVE BELT . . . . . . . 7-48
TENSION, BELT . . . . . . . . . . . . . . . . . . . . . . . 7-43
TENSIONER ADJUSTMENT, PARKING
BRAKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . 5-67
TENSIONER3.9L/5.2L ENGINE,
AUTOMATIC BELT . . . . . . . . . . . . . . . . . . . . . 7-45
TERMINAL REPLACEMENT . . . . . . . . . . . 8W-01-8
TERMINAL REPLACEMENT, CONNECTOR . 8W-01-7
TERMINAL/CONNECTOR REPAIR
MOLEX CONNECTORS . . . . . . . . . . . . . . 8W-01-6
TEST, AIR CONDITIONING AND HEATER
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 24-7
TEST, AIR CONDITIONING
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 24-7
TEST ANALYSIS, STALL . . . . . . . . . . . . . . . 21-96
TEST, ANALYZING THE ROAD . . . . . . . . . . . 21-93
TEST, AUTOMATIC SHUTDOWN (ASD)
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-6
TEST, CAMSHAFT POSITION SENSOR . . . . . 8D-6
TEST CHART, MIRROR . . . . . . . . . . . . . . . . . 8T-2
TEST, COMPASS/DISPLAY SELFDIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2
TEST, COMPRESSOR CLUTCH . . . . . . . . . . . . 24-13
TEST, CONVERTER STALL . . . . . . . . . . . . . . 21-96
TEST, CRANKSHAFT POSITION SENSOR;
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 14-72
TEST, CRANKSHAFT POSITION SENSOR;
IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . 8D-7
TEST, CYLINDER COMBUSTION
PRESSURE LEAKAGE . . . . . . . . . . . . . . . . . . . 9-6
TEST, CYLINDER COMPRESSION
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TEST, ENGINE COOLANT TEMPERATURE
SENSOR; FUEL SYSTEM . . . . . . . . . . . . . . . 14-70
TEST, ENGINE COOLANT TEMPERATURE
SENSOR; IGNITION SYSTEMS . . . . . . . . . . . 8D-8
TEST, FUEL INJECTOR . . . . . . . . . . . . . . . . . 14-76
TEST, FUEL PUMP PRESSURE . . . . . . . . . . 14-76
TEST, HEATER OUTPUT . . . . . . . . . . . . . . . . . 24-8
TEST, HYDRAULIC PRESSURE . . . . . . . . . . 21-94
TEST, IDLE AIR CONTROL (IAC) MOTOR . . 14-72
TEST, INTAKE MANIFOLD AIR
TEMPERATURE SENSOR; FUEL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-70
TEST, INTAKE MANIFOLD AIR
TEMPERATURE SENSOR; IGNITION
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-12
TEST, MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR; FUEL SYSTEM . . . . . . . . . 14-71
TEST, MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR; IGNITION SYSTEMS . . . . . 8D-12
TEST, MASTER CYLINDER/POWER
BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
TEST, OXYGEN (O2S) SENSOR HEATING
ELEMENT . . . . . . . . . . . . . . . . . . . . . . 14-35,14-72
TEST, POWER BOOSTER CHECK VALVE . . . . . 5-7
TEST, POWER BOOSTER VACUUM . . . . . . . . . 5-7
TEST, POWER STEERING PUMP FLOW
RATE AND PRESSURE . . . . . . . . . . . . . . . . . . 19-3
TEST PROCEDURES, HEATING AND AIR
CONDITIONING . . . . . . . . . . . . . . . . . . . . . . 24-10
TEST SPECIFICATIONS, 42RH/46RH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . 21-289
TEST, STARTER MOTOR RELAY . . . . . . . . . 14-76
TEST, THROTTLE POSITION SENSOR . . . . . 8D-16
TEST, THROTTLE POSITION SENSOR
(TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-72
TEST, VACUUM SUPPLY . . . . . . . . . . . . . . . . 8H-6
TEST, VACUUM SWITCH . . . . . . . . . . . . . . . 24-10
TEST, VEHICLE SPEED SENSOR . . . . 14-35,14-74
TESTING, AUTOMATIC TRANSMISSION
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 21-91
TESTING, CAMSHAFT POSITION SENSOR . 14-70
TESTING, COMBINATION VALVE . . . . . . . 5-10,5-6
TESTING COOLING SYSTEM FOR LEAKS . . . 7-25
TESTING, POWERTRAIN CONTROL
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-76
TESTING PROCEDURES, MULTIFUNCTION SWITCH . . . . . . . . . . . . . . . . . . . . 8L-4
TESTING RADIATOR CAPS, PRESSURE . . . . 7-28
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TRANSMISSION/TRANSFER CASE
IDENTIFICATION, ENGINE . . . . . . . . . . . . . Intro.-3
TRANSMITPCM OUTPUT, SCI . . . . . . . . . 14-63
TRAY, BATTERY . . . . . . . . . . . . . . . . . . . . . . . 23-8
TREAD WEAR INDICATORS . . . . . . . . . . . . . . 22-3
TRIM PANELS, INTERIOR . . . . . . . . . . . . . . 23-38
TRIM PANEL/WATERDAM/NOISE
INSULATOR, DOOR . . . . . . . . . . . . . . . . . . . 23-24
TRIM REPAIR PRODUCTS
AFTERMARKET PAINT . . . . . . . . . . . . . . . . . 23-46
TROUBLE CODE (DTC), DIAGNOSTIC . . . . . 14-39,
14-79
TROUBLE CODE, GENERATOR
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . 8A-21
TROUBLE CODE, SPEED CONTROL
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . 8H-6
TROUBLESHOOTING TESTS . . . . . . . . . . 8W-01-4
TROUBLESHOOTING TOOLS . . . . . . . . . . 8W-01-4
TROUBLESHOOTING WIRING PROBLEMS . 8W-01-5
TUBE CAP, FUEL TANK FILLER;
EMISSION CONTROL SYSTEMS . . . . . 25-21,25-6
TUBE CAP, FUEL TANK FILLER; FUEL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
TUBE, NO-LEAD FUEL TANK FILLER . . . . . . 14-14
TUBE2.5L ENGINE, EGR . . . . . . . . . . . . . 25-19
TUBE3.9L/5.2L ENGINE, EGR . . . . . . . . . 25-19
TUBES/LINES/HOSES AND CLAMPS,
FUEL . . . . . . . . . . . . . . . . . . . . 14-10,14-46,14-87
TURN SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . 8J-2
TURN SIGNAL LAMPS, PARK . . . . . . . . . . . . . . 8L-9
TURN SIGNAL LAMPS, TAIL, STOP AND . . 8L-11
TURN SIGNAL SYSTEM . . . . . . . . . . . . . . . . . 8J-1
TURN SIGNALS . . . . . . . . . . . . . . . . . . . . 8W-52-1
(TVV)2.5L ENGINE, THERMAL
VACUUM VALVE . . . . . . . . . . . . . . . . . . . . . . 25-22
TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . 0-11
TYPICAL VEHICLE EMISSION CONTROL
INFORMATION LABEL . . . . . . . . . . . . . . . . . . 25-2
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . 16-3
UNDERHOOD LAMP; INTERIOR
LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1
UNDERHOOD LAMP; LAMPS . . . . . . . . . . . . 8L-11
UNDERHOOD LAMP BULB
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 8L-12
UNDERHOOD LAMP REPLACEMENT . . . . . . 8L-12
UNDERSIZE ENGINE COMPONENT
MARKINGS, OVERSIZE . . . . . . . . . . . . 9-112,9-80
UNIT DISASSEMBLY, OVERDRIVE . . . . . . . 21-238
UNIT, FUEL GAUGE SENDING . . . . . . . . . . . 14-16
UNIT INSTALLATION2-WHEEL DRIVE,
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-144
UNIT INSTALLATION4-WHEEL DRIVE,
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-145
UNIT OVERHAUL, 42RH/46RH
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-238
UNIT, POWER . . . . . . . . . . . . . . . . . . . . . . . 13-13
UNIT REMOVAL2-WHEEL DRIVE,
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-143
UNIT REMOVAL4-WHEEL DRIVE,
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-145
UNIT REMOVE/INSTALL, OIL PRESSURE
SENDING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16
UNITS, WHEEL BRAKE . . . . . . . . . . . . . . . . . . 5-1
UNIVERSAL JOINT ANGLE
MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . 16-4
UNIVERSAL JOINT, PROPELLER SHAFT . . . 16-15
UNIVERSAL JOINT REPLACEMENT . . . . . . . 16-10
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . 16-2
UPPER BALL STUD . . . . . . . . . . . . . . . . 2-12,2-17
UPPER SUSPENSION ARM . . . . . . . . . . 2-12,2-16
UPSHIFT LAMP . . . . . . . . . . . . . . . . . . . 8W-30-10
URETHANE SET GLASS . . . . . . . . . . . . . . . . 23-32
USAGE STATEMENT, FUEL . . . . . . . . . . . . . . . 14-1
USE THIS GROUP, HOW TO . . . . . . . . . . . . . 8W-1
USING ALIGNMENT SCREEN,
HEADLAMP/FOG LAMP ADJUSTMENT . . . . . 8L-6
USING ON-BOARD DIAGNOSTIC
SYSTEM; BATTERY/STARTING/
CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-21
USING ON-BOARD DIAGNOSTIC
SYSTEM; VEHICLE SPEED CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3
V-6 AND 5.2L V-8 ENGINES, ENGINE
VACUUM SCHEMATIC3.9L . . . . . . . . . . . . . 25-4
V-6 AND V-8, PUMP REPLACEMENT . . . 19-13
V-6 ENGINE, ENGINE FIRING ORDER
3.9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29
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