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Chrysler Voyager Service Manual GS 1999-1996 PDF
Chrysler Voyager Service Manual GS 1999-1996 PDF
INTERNATIONAL
SERVICE MANUAL
1998
CHRYSLER VOYAGER
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
Chrysler International reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
GROUP TAB LOCATOR
Introduction
2 Suspension
5 Brakes
6 Clutch
7 Cooling System
8A Battery
8B Starting System
8L Lamps
8W Wiring Diagrams
9 Engine
19 Steering
23 Body
INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 1) is located
on the rear shut face of the driver’s door. This label
indicates date of manufacture (month and year),
Gross Vehicle Weight Rating (GVWR), Gross Axle
Weight Rating (GAWR) front, Gross Axle Weight Rat-
ing (GAWR) rear and the Vehicle Identification Num-
ber (VIN). The Month, Day and Hour of manufacture
is also included.
When it is necessary to contact the manufacturer
regarding service or warranty, the information on the
Vehicle Safety Certification Label would be required.
DIGIT 19
Open Space
DIGITS 1, 2, AND 3
Transaxle Codes
Fig. 3 Body Code Plate • DGB = 31TH 3-Speed Automatic Transaxle
• DGL = 41TE 4-speed Electronic Automatic Tran-
DIGIT 21
saxle
Price Class • DGM = 31TH 3-Speed Automatic Transaxle
• H = Highline
• L = Lowline DIGIT 4
• P = Premium Open Space
• S = Luxury
DIGIT 5
DIGITS 22 AND 23
Market Code
Body Type • C = Canada
• 52 = Short Wheel Base • B = International
• 53 = Long Wheel Base • M = Mexico
• U = United States
BODY CODE PLATE LINE 2
DIGIT 6
DIGITS 1, 2 AND 3
Open Space
Paint procedure
DIGITS 7 THROUGH 23
DIGIT 4
Vehicle Identification Number
Open Space
• Refer to Vehicle Identification Number (VIN)
DIGITS 5 THROUGH 8 paragraph for proper breakdown of VIN code.
Primary paint IF TWO BODY CODE PLATES ARE REQUIRED
See Group 23, Body for color codes. The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
DIGIT 9
last code space on the first plate will indicate (CTD)
Open Space When a second plate is required, the first four
spaces of each line will not be used due to overlap of
DIGITS 10 THROUGH 13
the plates.
Secondary Paint
DIGIT 14
Open Space
4 INTRODUCTION NS
GENERAL INFORMATION (Continued)
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
Fig. 4
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS INTERNATIONAL VEHICLE CONTROL
AND DISPLAY SYMBOLS
The graphic symbols illustrated in the following
chart (Fig. 4) are used to identify various instrument
controls. The symbols correspond to the controls and
displays that are located on the instrument panel.
FASTENER IDENTIFICATION
FASTENER IDENTIFICATION Fig. 5 Thread Notation—SAE and Metric
bolt strength grade corresponds to the number of line
THREAD IDENTIFICATION marks plus 2. The most commonly used metric bolt
SAE and metric bolt/nut threads are not the same. strength classes are 9.8 and 12.9. The metric strength
The difference is described in the Thread Notation class identification number is imprinted on the head of
chart (Fig. 5). the bolt. The higher the class number, the greater the
bolt strength. Some metric nuts are imprinted with a
GRADE/CLASS IDENTIFICATION single-digit strength class on the nut face. Refer to the
The SAE bolt strength grades range from grade 2 Fastener Identification and Fastener Strength Charts.
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
NS INTRODUCTION 5
GENERAL INFORMATION (Continued)
FASTENER IDENTIFICATION
6 INTRODUCTION NS
GENERAL INFORMATION (Continued)
FASTENER STRENGTH
NS INTRODUCTION 7
GENERAL INFORMATION (Continued)
METRIC SYSTEM
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
TORQUE REFERENCES
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-
cations Chart for torque references not listed in the
individual torque charts.
8 INTRODUCTION NS
GENERAL INFORMATION (Continued)
METRIC CONVERSION
NS INTRODUCTION 9
GENERAL INFORMATION (Continued)
TORQUE SPECIFICATIONS
NS/GS INTRODUCTION 1
INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
E-MARK LABEL
An E-mark Label (Fig. 1) is located on the rear
shut face of the driver’s door. The label contains the
following information:
• Date of Manufacture
• Month-Day-Hour (MDH)
• Vehicle Identification Number (VIN)
• Country Codes
• Regulation Number
• Regulation Amendment Number
• Approval Number
DIGIT 5
Market Code
• B = International
• M = Mexico
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number (VIN)
Refer to Vehicle Identification Number (VIN) para-
graph for proper breakdown of VIN code.
Fig. 3 Body Code Plate IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
DIGITS 5 THROUGH 8 lowed by END. When two plates are required, the
Primary Paint last code space on the first plate will indicate contin-
See Group 23, Body for color codes. ued (CTD).
When a second plate is required, the first four
DIGIT 9 spaces of each line will not be used due to overlap of
Open Space the plates.
DIGITS 1, 2, AND 3
Transaxle Codes
• DGL = 41TE 4-speed Electronic Automatic Tran- Fig. 4 Manufacturer Plate
saxle
• DD3 = A-598 5–speed Manual Transaxle
NS LUBRICATION AND MAINTENANCE 0-1
page page
GENERAL INFORMATION
INDEX
page page
MAINTENANCE SCHEDULES
INDEX
page page
97,500 Miles (156 000 km) or at 78 months 12,000 Miles (19 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter.
100,000 Miles (160,000 km)
• Replace spark plugs on 3.3L and 3.8L 15,000 Miles (24 000 km)
engines. • Change engine oil.
• Replace ignition cables on 3.3L and 3.8L • Inspect air cleaner element. Replace as
engines. necessary.
NS LUBRICATION AND MAINTENANCE 0-5
GENERAL INFORMATION (Continued)
• Drain and refill automatic transmission fluid • Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See and replace filter. Adjust bands, if so equipped. (See
note) note)
• Change AWD powertransfer fluid unit. • Inspect brake linings.
• Change AWD power transfer unit fluid.
18,000 Miles (29 000 km)
• Change engine oil. 48,000 Miles (77 000 km)
• Replace engine oil filter. • Change engine oil.
• Inspect brake linings. • Replace engine oil filter.
21,000 Miles (34 000 km) 51,000 Miles (82 000 km)
• Change engine oil. • Change engine oil.
• Check AWD overrunning clutch and rear carrier • Flush and replace engine coolant.
fluid.
54,000 Miles (86 000 km)
24,000 Miles (38 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Inspect brake linings.
27,000 Miles (43 000 km) 57,000 Miles (91 000 km)
• Change engine oil. • Change engine oil.
• Inspect brake linings.
60,000 Miles (96 000 km)
30,000 Miles (48 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Replace air cleaner element.
• Replace air cleaner element. • Inspect PCV valve, replace if necessary. *
• Inspect PCV valve. Replace as necessary. * • Inspect serpentine drive belt, replace if neces-
• Drain and refill automatic transmission fluid sary.
and replace filter. Adjust bands, if so equipped. (See • Drain and refill automatic transmission fluid
note) and replace filter. Adjust bands, if so equipped. (See
• Change AWD power transfer unit fluid. note)
• Inspect tie rod ends and boot seals. • Change AWD power transfer unit fluid.
• Inspect tie rod ends and boot seals.
33,000 Miles (53 000 km)
• Change engine oil. 63,000 Miles (101 000 km)
• Change engine oil.
36,000 Miles (58 000 km) • Change AWD overrunning clutch and rear car-
• Change engine oil. rier fluid.
• Replace engine oil filter. • Inspect brake linings.
• Inspect brake linings.
66,000 Miles (106 000 km)
39,000 Miles (62 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
42,000 Miles (67 000 km) 69,000 Miles (110 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter.
• Change AWD overrunning clutch and rear car- 72,000 Miles (115 000 km)
rier fluid. • Change engine oil.
• Replace engine oil filter.
45,000 Miles (72 000 km) • Inspect brake linings.
• Change engine oil.
• Inspect air cleaner element. Replace as 75,000 Miles (120 000 km)
necessary. • Change engine oil.
• Inspect air cleaner element. Replace as
necessary.
0-6 LUBRICATION AND MAINTENANCE NS
GENERAL INFORMATION (Continued)
• Replace spark plugs. 105,000 Miles (168 000 km)
• Replace ignition cables. • Change engine oil.
• Inspect serpentine drive belt, replace if neces- • Inspect air cleaner element. Replace as
sary. This maintenance is not required if belt was necessary.
previously replaced. • Inspect serpentine drive belt, replace if neces-
• Drain and refill automatic transaxle fluid and sary. This maintenance is not required if belt was
replace filter. Adjust band, if so equipped. (See note) previously replaced.
• Change AWD power transfer unit fluid. • Drain and refill automatic transmission fluid
and filter. Adjust bands, if so equipped. (See note)
78,000 Miles (125 000 km) • Change AWD power transfer unit fluid.
• Change engine oil. • Change AWD overrunning clutch and rear car-
• Replace engine oil filter. rier fluid.
81,000 Miles (130 000 km) 108,000 Miles (173 000 km)
• Change engine oil. • Change engine oil.
• Inspect brake linings. • Replace engine oil filter.
• Flush and replace engine coolant. • Inspect brake linings.
84,000 Miles (134 000 km) 111,000 Miles (178 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Flush and replace engine coolant.
• Change AWD overrunning clutch and rear car-
rier fluid. 114,000 Miles (182 000 km)
• Change engine oil.
87,000 Miles (139 000 km) • Replace engine oil filter.
• Change engine oil.
117,000 Miles (187 000 km)
90,000 Miles (144 000 km) • Change engine oil.
• Change engine oil. • Inspect brake linings.
• Replace engine oil filter.
• Replace air cleaner element. 120,000 Miles (192 000 km)
• Check PCV valve and replace if necessary. • Change engine oil.
Not required if previously changed. * • Replace engine oil filter.
• Inspect serpentine drive belt, replace if neces- • Replace air cleaner element.
sary. This maintenance is not required if belt was • Inspect PCV valve. Replace as necessary. *
previously replaced. • Inspect serpentine drive belt. Not required if
• Drain and refill automatic transmission fluid replaced at 75,000, 90,000 or 105,000 miles.
and replace filter. Adjust bands, if so equipped. (See • Drain and refill automatic transmission fluid
note) and replace filter. Adjust bands, if so equipped.
• Change AWD power transfer unit fluid. • Change AWD power transfer unit fluid.
• Inspect tie rod ends and boot seals. • Inspect tie rod ends and boot seals.
• Inspect brake linings. * This maintenance is recommended by Chrysler to
the owner but is not required to maintain the war-
93,000 Miles (149 000 km) ranty on the PCV valve.
• Change engine oil. ** If California vehicle, this maintenance is recom-
mended by Chrysler to the owner but is not required
96,000 Miles (154 000 km) to maintain the warranty of the timing belt.
• Change engine oil.
• Replace engine oil filter. NOTE: Operating vehicle more than 50% in heavy
traffic during hot weather, above 90°F (32°C), using
99,000 Miles (158 000 km) vehicle for police, taxi, limousine type operation or
• Change engine oil. trailer towing require the more frequent transaxle
• Inspect brake linings. service noted in Schedule – B. Perform these ser-
vices if vehicle is usually operated under these con-
102,000 Miles (163 000 km) ditions.
• Change engine oil. Inspection and service should also be performed
• Replace engine oil filter. anytime a malfunction is observed or suspected.
NS LUBRICATION AND MAINTENANCE 0-7
INDEX
page page
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS Fig. 2 Recommended Towing Devices
HOISTING RECOMMENDATIONS
Refer to Owner’s Manual provided with vehicle for
proper emergency jacking procedures.
page page
GENERAL INFORMATION
INDEX
page page
MAINTENANCE SCHEDULES
INDEX
page page
INDEX
page
SERVICE PROCEDURES
TOWING RECOMMENDATIONS . . . . . . . . . . . . . 5
SERVICE PROCEDURES
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
CAUTION: Do not use steering column lock to A tow-hook bolt, located in the rear interior trim
secure steering wheel during towing operation. storage compartment (with jack), is provided with
your vehicle. The tow hook is used for towing the
• On AWD vehicles, all four wheels must be free to vehicle with all four wheels on the ground only. It
rotate. Use towing dollies at unlifted end of vehicle. can be attached to the vehicle through an opening in
• Unlock steering column and secure steering the lower front fascia. The tow hook must be fully
wheel in straight ahead position with a clamp device seated to the attach bracket through the lower front
designed for towing. fascia as shown. If the tow hook is not fully seated to
• 4-speed electronic automatic transaxle vehicles the attach bracket the vehicle should not be towed.
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The NOTE: The tow hook bolt protective plug must be
steering column must be unlocked and gear selector removed from the tow hook bracket prior to bolt
in neutral. attachment. The tow hook is used ONLY for towing
the vehicle with all four wheels on the ground.
NS SUSPENSION 2-1
SUSPENSION
CONTENTS
page page
WHEEL ALIGNMENT
INDEX
page page
Camber adjustment is allowed in the event that a Camber is the number of degrees the top of the
vehicle is involved in an accident and after repairs wheel and tire assembly is tilted inboard or outboard
are made meeting manufacturers tolerance specifica- from a true vertical line. Inboard tilt is negative cam-
tions, the camber setting will not meet manufactur- ber. Outboard tilt is positive camber (Fig. 1).
ers specifications. If camber adjustment is required, Excessive camber is a tire wear factor: negative
refer to the following Service Camber Adjustment camber causes wear on the inside of the tires tread
Procedure for the required steps to be followed. surface, while positive camber causes wear to the
outside of the tires tread surface. See Front Wheel
CAUTION: Do not attempt to modify any suspen- Drive Specifications for Camber. settings.
sion or steering components to meet vehicle align- Toe is measured in degrees or inches and is the
ment specifications, by heating and or bending. distance the front edges of the tires are closer (or far-
ther apart) than the rear edges. See Front Wheel
Alignment checks and adjustments should be made Drive Specifications for Toe. settings.
in the following sequence.
(1) Camber
(2) Toe
NS SUSPENSION 2-3
PRE-WHEEL ALIGNMENT INSPECTION (5) Check vehicle ride height to verify it is within
Before any attempt is made to change or correct specifications.
the wheel alignment factors. The following part (6) Alignment MUST only be checked after the
inspection and the necessary corrections should be vehicle has the following areas inspected and or
made to those parts which influence the steering of adjusted. Recommended tire pressures, full tank of
the vehicle. fuel, no passenger or luggage compartment load and
(1) Check and inflate all tires to recommended is on a level floor or a properly calibrated alignment
pressure. All tires should be the same size and in rack.
good condition and have approximately the same
wear. Note the type of tread wear which will aid in
SERVICE PROCEDURES
diagnosing, see Wheels and Tires, Group 22.
(2) Check front wheel and tire assembly for radial
WHEEL ALIGNMENT CHECK AND ADJUSTMENT
runout.
(3) Inspect lower ball joints and all steering link- PROCEDURE
age for looseness.
CASTER AND CAMBER
(4) Check for broken or sagged front and rear
Front suspension Caster and Camber settings on
springs.
this vehicle are determined at the time the vehicle is
designed. This is done by determining the precise
NS SUSPENSION 2-5
SERVICE PROCEDURES (Continued)
mounting location of the vehicle’s suspension compo- CAMBER ADJUSTMENT CAM BOLT PACKAGE INSTALLATION
nents throughout the design and assembly processes PROCEDURE
of the vehicle. This is called a Net Build vehicle and (1) If the front camber readings obtained are not
results in no normal requirement to adjustment the within the vehicle’s specifications, use the following
Caster and Camber after a vehicle is built or when procedure and the Mopar Clevis Bolt Service Kit to
servicing the suspension components. Thus Caster provide camber adjustment. The kit contains 2 flange
and Camber are not normally considered an adjust- bolts, 2 cam bolts, and 2 dog bone washers. These
able specification when performing an alignment on components of the service kit are necessary to assem-
this vehicle. Though Caster and Camber are not ble the strut to the steering knuckle, after modifica-
adjustable they should be checked during the align- tion of the strut clevis bracket.
ment procedure to ensure they meet the manufactur- (2) Verify that the strut and steering knuckle are
ers specifications. not bent or otherwise damaged. If either component
If front camber does not meet the vehicle align- is bent or show other signs of damage, replace
ment specifications, it can be adjusted using a Mopar required component(s) and check the camber setting
Service Kit developed to allow for camber adjust- again. Refer to Strut Damper Assembly Service in
ment. If a vehicle’s front camber does not meet this group of the service manual for the required
required specifications, the vehicles suspension com- strut replacement procedure.
ponents should be inspected for any signs of damage (3) If no component is bent or damaged, use the
or bending and the vehicle ride height should be following procedure for modifying the strut clevis
checked to verify it is within required specification. bracket and adjusting the camber setting.
This inspection must be done before using the (4) Raise front of vehicle until tires are not sup-
Mopar Service Kit for setting camber to the porting the weight of the vehicle. Then remove wheel
vehicle specification. and tire assembly from the location on the vehicle
requiring the strut to be modified.
CAUTION: Do not attempt to adjust the vehicles
Caster or Camber by heating, bending or by per- CAUTION: When removing the steering knuckle
forming any other modification to the vehicle’s front from the strut clevis bracket, do not put a strain on
suspension components. the brake flex hose. Also, do not let the weight of
the steering knuckle assembly be supported by the
(1) Correctly position the vehicle on the alignment brake flex hose when removed from the strut
rack. Then install all required alignment equipment assembly. If necessary use a wire hanger to sup-
on the vehicle, per the alignment equipment manu- port the steering knuckle assembly or if required
facturers specifications. remove the brake flex hose from the caliper assem-
bly.
NOTE: Prior to reading each alignment specifica-
tion, front and rear of vehicle should be jounced an
equal number of times. Induce jounce (rear first CAUTION: The steering knuckle strut assembly
then front) by grasping center of bumper and jounc- attaching bolts are serrated and must not be turned
ing each end of vehicle an equal number of times. during removal. Remove nuts while holding bolts
Bumper should always be released when vehicle is stationary in the steering knuckles.
at the bottom of the jounce cycle.
(5) Remove the top and bottom, strut clevis
(2) Correctly jounce vehicle and then read the bracket to steering knuckle attaching bolts (Fig. 2)
vehicle’s current front and rear alignment settings. and discard. Separate the steering knuckle from the
Compare the vehicle’s current alignment settings to strut clevis bracket and position steering knuckle so
the vehicle specifications for camber, caster and Toe- it is out of the way of the strut.
in. See Alignment Specifications in this group of the
service manual for the required specifications. If CAUTION: When slotting the bottom mounting
front and rear camber readings are within hole on the strut clevis bracket, do not enlarge the
required specifications proceed to step Step 3 hole beyond the indentations (Fig. 3) on the sides
for the Toe-in adjustment procedure if of the strut clevis bracket.
required. If Camber readings are not within
specifications refer to step Step 1 in the front
camber adjustment cam bolt adjustment proce-
dure.
2-6 SUSPENSION NS
SERVICE PROCEDURES (Continued)
Fig. 2 Clevis Bracket To Steering Knuckle Attaching Fig. 4 Mopar Service Kit Bolts Correctly Installed
Bolts bolts. Then install the nuts from the original attach-
(6) Using an appropriate grinder and grinding ing bolts onto the replacement bolts from the service
wheel slot the bottom hole (Fig. 3) in both sides of kit. Tighten the bolts just enough to hold the steering
the strut clevis bracket. When grinding slot do not knuckle in position when adjusting camber, while
go beyond the indentation area on the sides of still allowing the steering knuckle to move in clevis
the clevis bracket (Fig. 3). bracket.
Fig. 3 Strut Clevis Bracket Bolt Hole Grinding Area Fig. 5 Dog Bone Washer And Nuts Installed On
CAUTION: After slotting the strut clevis bracket Attaching Bolts
hole, do not install the original attaching bolts when (9) Lower vehicle until the full weight of the vehi-
assembling the steering knuckle to the strut assem- cle is supported by the vehicles’ suspension. Then
bly. Only the flange bolts, cam bolts, and dog bone correctly jounce the front and rear of vehicle an equal
washers from the Mopar Clevis Bolt Service Kit, can amount of times.
be used to attach the steering knuckle to the strut (10) Adjust the front camber to the preferred set-
after the mounting hole is slotted. ting by rotating the lower eccentric cam bolt (Fig. 6)
against the cam stop areas on the strut clevis
(7) Install the flanged bolt (Fig. 4) from the Mopar bracket. When camber is correctly set, tighten the
Clevis Bolt Service Kit, into the top clevis bracket to upper strut clevis bracket bolt and lower cam bolt.
steering knuckle mounting hole. Install the cam bolt Again jounce front and rear of vehicle an equal
(Fig. 4) into the bottom clevis bracket to steering amount of times and verify front camber setting. See
knuckle mounting hole. Alignment Specifications in this group of the service
(8) Install the dog bone washer (Fig. 5) on the manual for required specifications.
steering knuckle to strut clevis bracket attaching
NS SUSPENSION 2-7
SERVICE PROCEDURES (Continued)
(3) Loosen front inner to outer tie rod end jam
nuts (Fig. 7). Grasp inner tie rods at serrations and
rotate inner tie rods of steering gear (Fig. 7) to set
front Toe to the preferred Toe specification. See
Alignment Specifications in this group of the service
manual for preferred specification.
* Camber is adjustable using the Mopar Camber Adjustment Service Kit. Refer to the Mopar
Parts Catalog for the required service kit part number.
** Caster is not adjustable. If found to be out of specification check for proper ride heights and
damaged/worn out suspension components and replace as necessary.
*** Toe-In is positive.
**** Toe, Camber and thrust angle are not adjustable. If found to be out of specification check for
proper ride heights and damaged/worn out suspension components and replace as necessary.
***** When Measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the vehicle at the
bumper several times and release at the bottom of the stroke. 3) Measure from the ground to the outboard, lower,
center section of the fender wheel well opening. Ride heights are not adjustable. If found to be out of specification
check for damaged and/or worn out suspension components and replace as necessary.
NS SUSPENSION 2-9
FRONT SUSPENSION
INDEX
page page
DESCRIPTION AND OPERATION attaching points for the lower control arms, stabilizer
bar and steering gear. The cradle also has the power
FRONT SUSPENSION DESCRIPTION steering hoses and the chassis brake tubes attached
An independent Mc Pherson Strut type front sus- to it.
pension is used on these vehicles. Vertical shock The cradle is mounted to the front frame rails at
absorbing Mc Pherson Struts attach to the top of the four points, two on each side of the vehicle. The cra-
steering knuckle and to the front strut tower. This dle is isolated from the body of the vehicle using four
interconnection between the steering knuckle and the isolators, one located at each mounting bolt location.
body of the vehicle, provides for the correct steering
knuckle position. This steering knuckle position pro- WARNING: If a threaded hole in the suspension
vides for the correct front Caster and Camber set- cradle needs to be repaired, only use the type of
tings for the vehicle, at the time the vehicle is thread insert and installation procedure specified
designed. for this application.
Lower control arms are attached inboard to the
The threaded holes in the cradle that are
cast aluminum front suspension cradle and outboard
used for attachment of the lower control arm
to the bottom of the steering knuckle. Attachment of
rear bushing retainer, power steering hose and
the lower control arm to the steering knuckle is done
chassis brake tubes can be repaired. The repair
through a ball joint in the lower control arm.
is done by the installation of a Heli-Coilt
During steering maneuvers, the strut and the
thread insert which has been specifically devel-
steering knuckle (through the ball joint and a pivot
oped for this application. Refer to the Mopar
bearing in the strut’s upper retainer) turn as an
Parts Catalog for the specified Heli-Coil thread
assembly.
insert to be used for this application. The pro-
cedure for installing the Heli-Coilt thread
SUSPENSION CRADLE (CROSSMEMBER)
insert is detailed in the Service Procedures sec-
This vehicle uses a one piece cast aluminum cradle
tion in this group of the service manual.
for the front suspension. The cradle is used as the
2 - 10 SUSPENSION NS
DESCRIPTION AND OPERATION (Continued)
Mc PHERSON STRUT ASSEMBLY using a pivot bolt through the center of the front
The front suspension of the vehicle is supported by pivot bushing, and a retainer which traps the rear
coil springs positioned around the strut assembly. bushing in the crossmember.
The springs are contained between an upper seat, The ball joint is pressed into the control arm and
located just below the top strut mount assembly and has a non-tapered stud with a notch for clamp bolt
a lower spring seat on the strut fluid reservoir. clearance. The stud is clamped and locked into the
The top of each strut assembly is bolted to the steering knuckle leg with a clamp bolt.
upper fender reinforcement (strut tower) through a The ball joint is lubricated for the life of the vehi-
rubber isolated mount. cle and does not require any periodic lubrication.
The bottom of the strut assembly attaches to the
steering knuckle with two through bolts. Caster is a STABILIZER BAR
fixed setting on all vehicles and is not adjustable The stabilizer bar interconnects both Mc Pherson
when an alignment is performed. In the event the strut assemblies of the vehicle and is attached
camber setting on a vehicle requires adjustment, a through rubber isolator bushings to the front suspen-
service strut is available which will provide a method sion cradle
by which the camber can be adjusted. Jounce and rebound movements affecting one
The strut assemblies on this vehicle are inter-con- wheel are partially transmitted to the opposite wheel
nected by the front stabilizer bar through 2 link to stabilize body roll.
assemblies attaching the struts to the stabilizer bar. Attachment of the stabilizer bar to the front sus-
pension cradle is through 2 rubber-isolator bushings
STEERING KNUCKLE and bushing retainers. The stabilizer bar to Mc Pher-
The steering knuckle (Fig. 1) is a single casting son strut assembly attachment is done utilizing a
with legs machined for attachment of the strut sway bar attaching link. All parts of the stabilizer
damper, steering linkage, disc brake caliper, and bar are serviceable, and the stabilizer bar to cross-
lower control arm ball joint. The steering knuckle member bushings are split for easy removal and
also has the front hub/bearing assembly mounted to installation. The split in the stabilizer bar to cross-
it. The hub is positioned through the bearing and member bushing should be positioned toward the
knuckle, with the constant velocity stub shaft splined rear of the vehicle, with the square corner down
through the hub. toward the ground, when the stabilizer bar is
installed in the vehicle.
BALL JOINT
The ball joint (Fig. 2) is pressed into the lower con-
trol arm. The ball joint has a non-tapered stud with
a notch (Fig. 2) to provide clearance for the steering
knuckle clamp bolt and to provide retention of the
ball stud in the steering knuckle. The ball joint stud
is clamped and locked into the steering knuckle leg
using a pinch bolt. The ball joint used on this vehicle
is replaceable and if found defective can be serviced
as a separate component of the lower control arm
assembly.
Fig. 11 Hub/Bearing To Stub Axle Retaining Nut Fig. 13 Front Disc Brake Caliper Attaching Bolts
Fig. 43 Correctly Installed Lower Ball Joint Fig. 45 Installing Ball Joint Seal Boot
CAUTION: When installing the ball joint seal on the prior to top of seal boot being pushed down below
ball joint/lower control arm, the shield (Fig. 44) on notch in ball joint stud (Fig. 41). Air must vent out
the ball joint seal must be positioned as shown. of the seal boot at notch when grease is pumped
into ball joint, failure to do so will balloon and dam-
(4) Install a NEW seal boot by hand as far as pos- age seal boot. Do not over grease the ball joint, this
sible on the ball joint. Installation of the seal boot is will prevent the seal boot from pushing down on
to be with the shield positioned as shown (Fig. 44). the stud of the ball joint.
STABILIZER BAR
REMOVE
(1) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
Fig. 44 Ball Joint Seal Boot Installed Position
NOTE: The attaching bolts for the cradle plate are
CAUTION: Do not use an arbor press to install the
of two different thread sizes. Nine of the bolts are a
sealing boot on the ball joint. Damage to the seal-
M-14 thread and one of the bolts is a M-12 thread.
ing boot will occur if excessive pressure is applied
Refer to (Fig. 46) for the cradle plate attaching bolt
to the sealing boot when it is being installed.
locations.
(5) Place Installer, Special Tool 6758 over seal boot
(2) Remove the 10 bolts (Fig. 46) attaching the cra-
and squarely align it with bottom edge of seal boot
dle plate to the front suspension cradle. Then remove
(Fig. 45). Apply hand pressure to Special Tool 6758
the cradle plate from the cradle.
until seal boot is pressed squarely against top surface
of lower control arm. NOTE: When removing nut from stud of stabilizer
bar attaching link, do not allow the stud to rotate.
CAUTION: A replacement ball joint is not prelubri-
Hold stud from rotating by inserting a Torx Plus 40
cated. Properly lubricate the replacement ball joint
IP bit in the end of the stud (Fig. 47).
using Mopar Multi–Mile grease or an equivalent.
Lubricate ball joint after seal boot is installed but
2 - 24 SUSPENSION NS
REMOVAL AND INSTALLATION (Continued)
Fig. 46 Cradle Plate And Mounting Bolts Fig. 48 Front Stabilizer Bar Bushing Retainers
(3) Remove the nuts (Fig. 47) attaching the stabi- when the stabilizer bar is installed on the vehi-
lizer bar attaching links to the stabilizer bar. Then cle (Fig. 49).
remove the attaching links from the stabilizer bar.
Fig. 58 Hub/Bearing Assembly Mounting Bolts Fig. 60 Hub And Bearing Assembly Mounting
Surfaces
steering knuckle. Then tighten the 4 hub and bearing
assembly mounting bolts to a torque of 65 N·m (45
ft.lbs.)
(3) Install the hub/bearing assembly to stub shaft
washer and retaining nut (Fig. 61).Tighten, but do
not torque the hub nut at this time.
Fig. 67 Installing Wheel Stud Into Hub And Bearing Fig. 68 Strut Assembly Correctly Installed In Vise
(3) Install the rear brake drum on the hub and COIL SPRING MUST BE CAPTURED BY THE JAWS
bearing assembly. OF THE COIL SPRING COMPRESSOR (Fig. 69).
(4) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper (3) Compress strut coil spring, using Pentastar
sequence until all nuts are torqued to half specifica- Service Equipment Spring Compressor, 7522A (Fig.
tion. Then repeat the tightening sequence to the full 69). Be sure the top and bottom attachment shoe
specified torque of 129 N·m (95 ft. lbs.). selected, (Fig. 69) properly fit the coil spring.
(5) Lower vehicle to the ground.
ASSEMBLY
(1) Clamp strut in vise, with strut in vertical posi-
tion. Do not clamp strut in vise by body of strut,
only by the clevis bracket (Fig. 68).
(2) Install the spring isolator on the strut lower
spring seat (Fig. 74). When installing the spring iso-
lator, be sure the 2 retaining tabs on the spring iso-
lator (Fig. 74) are installed in the 2 holes in the
spring seat. When properly installed, the oversize
holes in the spring seat should line up with the holes
in the spring isolator. Fig. 76 Installing Dust Boot
(3) Install the jounce bumper (Fig. 75) on the strut
shaft. Jounce bumper is to be installed with the
small end of the jounce bumper pointing down (Fig.
75).
WARNING: WHEN COMPRESSING THE COIL WARNING: THE FOLLOWING 2 STEPS MUST BE
SPRING, THE COIL SPRING UPPER SEAT AND THE COMPLETELY DONE BEFORE SPRING COMPRES-
BOTTOM COIL OF THE SPRING MUST BE CAP- SOR IS RELEASED FROM THE COIL SPRING.
NS SUSPENSION 2 - 33
DISASSEMBLY AND ASSEMBLY (Continued)
INSTALL
SPECIAL TOOLS
FRONT SUSPENSION
REAR SUSPENSION
INDEX
page page
GENERAL INFORMATION The rear axle used on front wheel drive applica-
tions of this vehicle is mounted to the rear leaf
REAR SUSPENSION springs using isolator bushings at the axle mounting
The rear suspension design on this vehicle uses brackets.
leaf springs and a tube and casting axle (Fig. 1) and The rear axle used on all wheel drive applications
(Fig. 2). It is designed to handle the various load of this vehicle is also mounted to the rear leaf
requirements of the vehicle. The leaf springs used on springs but does not use isolator bushings between
the rear suspension of this vehicle are of either a the rear axle and the leaf springs.
mono-leaf or multi-leaf design.
INSTALLATION
(1) Assemble front spring mount to front of spring
eye and install pivot bolt and nut. Do not tighten.
INSTALL
(1) Install the front of the rear leaf spring into the
spring mount (Fig. 18). Install the pivot bolt and nut.
Do not tighten the pivot bolt at this time.
(2) Position the front spring mount for the rear
leaf spring against the floor pan of the vehicle.
Install the 4 mounting bolts for the spring mount.
Tighten the 4 mounting bolts to a torque of 61 N·m
(45 ft. lbs.).
(3) Install the rear of the leaf spring onto the outer
half of the rear hanger. Install the inner half of the
rear hanger. Install the nut and bolts on the rear
Fig. 17 Leaf Spring Remove/Install hanger but do not tighten at this time.
(12) Loosen and remove the pivot bolt from the (4) Raise axle assembly into correct position with
front mount of the rear leaf spring. (Fig. 18). axle centered under spring locator post.
(5) Install axle plate bolts. Tighten bolts to 108
N·m (80 ft. lbs.) torque.
(6) Install shock absorber bolts. Do not tighten.
(7) Lower vehicle to floor and with full weight of
vehicle on wheels. Tighten component fasteners as
follows:
INSPECTION
Inspect for broken or distorted clamps, retainers,
and bushings. If bushing replacement is required, the
stabilizer bar to axle bushings can be removed from
the stabilizer bar by opening the split.
Fig. 23 Jounce Bumper-Standard
INSTALLATION
(1) Install the link arms onto the frame rail brack- INSTALLATION-STANDARD
ets. DO NOT TIGHTEN. (1) For installation, reverse the removal procedure.
(2) Position the axle to stabilizer bar bushings on Tighten the jounce bumper mounting bolt to a torque
the stabilizer bar with the slit in the bushings facing of 33 N·m (290 in. lbs.).
up.
NS SUSPENSION 2 - 47
REMOVAL AND INSTALLATION (Continued)
REMOVAL-HEAVY DUTY jackstand support the weight of the axle and leaf
The jounce bumpers are serviced as an assembly. spring.
The jounce bumpers screw into a weld nut located in (3) Remove the lower mounting bolt from the
the frame rail (Fig. 24). shock absorber.
(1) Using slip-joint pliers grasp the base of the (4) Remove the bolts attaching the leaf spring
jounce bumper. Turn the base counterclockwise (Fig. front mount (Fig. 26) to the body of the vehicle.
25). (5) Lower the leaf spring and remove the front
(2) Remove the jounce bumper from the frame rail. mount from the spring.
SPECIFICATIONS
Fig. 28 Leaf Spring Shackle Nuts/Bolts (AWD) REAR SUSPENSION FASTENER TORQUES
(2) Install a jackstand under the side of the axle
having the leaf spring mount removed. Using the DESCRIPTION TORQUE
jackstand, support the weight of the axle and leaf SHOCK ABSORBER MOUNTING BOLTS:
spring. Standard Shock Absorber . . . . . .101 N·m (75 ft. lbs.)
(3) Remove the lower mounting bolt from the Self Load Leveling Shock
shock absorber. Absorber . . . . . . . . . . . . . . . . .101 N·m (75 ft. lbs.)
(4) Remove the bolts attaching the leaf spring rear JOUNCE BUMPER:
mount to the body of the vehicle (Fig. 29). To Frame Rail . . . . . . . . . . . . . .33 N·m (290 in. lbs.)
TRACK BAR:
To Axle And Mounting
Bracket Pivot Bolt . . . . . . . . . .95 N·m (70 ft. lbs.)
Bracket To Body Attaching . . . . . .61 N·m (45 ft. lbs.)
LEAF SPRING:
Spring Plate To Axle
Attaching Bolts . . . . . . . . . . . .108 N·m (80 ft. lbs.)
Rear Mount To Body Bolts . . . . . .61 N·m (45 ft. lbs.)
Front Mount To Body Bolts. . . . . .61 N·m (45 ft. lbs.)
To Front Hanger
Mounting Nut . . . . . . . . . . . .156 N·m (115 ft. lbs.)
Shackle Plate Nuts . . . . . . . . . . . .61 N·m (45 ft. lbs.)
STABILIZER BAR:
Bushing Retainer To Axle
Attaching Bolts . . . . . . . . . . . . .61 N·m (45 ft. lbs.)
Attaching Link Nuts . . . . . . . . . . .61 N·m (45 ft. lbs.)
Fig. 29 Rear Spring Mount Frame Rail Bracket
(5) Lower the jackstand and the rear of the leaf Mounting Bolts . . . . . . . . . . . . .61 N·m (45 ft. lbs.)
spring. Remove the shackle from the leaf spring Link Arm To Frame
bushing. Rail Bracket . . . . . . . . . . . . . . .61 N·m (45 ft. lbs.)
HUB AND BEARING:
INSTALL To Axle Mounting Bolts. . . . . . . .129 N·m (95 ft. lbs.)
Stub Axle Nut . . . . . . . . . . . . . .224 N·m (180 ft. lbs.)
CAUTION: The following sequence must be fol- Wheel Mounting
lowed when tightening the pin nuts on the rear Lug Nut . . . . . . . . . . .110-135 N·m (85-115 ft. lbs.)
NS/GS SUSPENSION 2-1
SUSPENSION
CONTENTS
page
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . 1
ALTERNATIVE
ALIGNMENT ANGLE TIRE SIZES TIRE SIZES
FUELS
P205/75/R14 P205/75/R15 C.N.G.
P215/65/R15 P215/65/R16 ELECTRIC
* FRONT INDIVIDUAL CAMBER IN +0.15° +or- 0.40° +0.05° +or- 0.40° +0.15° +or- 0.40°
DEGREES............................................
Front Side To Side Camber Difference Not 0.00° - 0.50° MAX 0.00° - 0.50° MAX 0.00° - 0.50° MAX
To Exceed...................
** FRONT INDIVIDUAL CASTER IN +1.40° + or - 1.00° +1.40° + or - 1.00° +1.40° +or- 1.00°
DEGREES............................................
Front Side To Side Caster Difference Not To 0.00° - 1.00° MAX 0.00° - 1.00° MAX 0.00° - 1.00° MAX
Exceed.....................................
*** FRONT INDIVIDUAL TOE RIGHT/ +0.05°+or- 0.10° +0.05° +or- 0.10° +0.05° +or- 0.10°
LEFT.........................................
FRONT TOTAL +0.10° +or- 0.20° +0.10° +or- 0.20° +0.10° +or- 0.20°
TOE....................................................
Specified In Degrees
FRONT SIDE TO SIDE TOE 0.00° - 0.06° MAX 0.00° - 0.06° MAX 0.00° - 0.06° MAX
DIFFERENTIAL.....................................
****REAR INDIVIDUAL CAMBER IN +0.00° +or- 0.25° +0.00° +or- 0.25° -0.10° +or- 0.25
DEGREES............................................
REAR INDIVIDUAL TOE RIGHT/ 0.00° +or- 0.40° 0.00° +or- 0.40° 0.00° +or- 0.40°
LEFT........................................
**** REAR TOTAL TOE..................... 0.00° +or- 0.40° 0.00° +or- 0.40° 0.00° +or- 0.40°
Specified In Degrees
TOE OUT: When Backed On Alignment Rack
Is TOE In When Driving
****REAR THRUST ANGLE................ 0.00° +or- 0.30° 0.00° +or- 0.30° 0.00° +or- 0.30°
STEERING WHEEL ANGLE................ 0.00° +or- 2.50° 0.00° +or- 2.50° 0.00° +or- 2.50°
FRONT RIDE HEIGHT (MEASURED AT 747.5 mm 753.5 mm 783.5 mm
TOP OF FENDER WHEEL +or-10.0mm +or-10.0mm +or-10.0mm
OPENING)............................................
FRONT RIDE HEIGHT SIDE TO SIDE 0.0 mm 12.5 mm 0.0 mm 12.5 mm 0.0 mm 12.5 mm
DIFFERENTIAL..................................... MAX MAX MAX
*****REAR RIDE HEIGHT (MEASURED AT 766.0 mm 772.0 mm 802.5 mm
TOP OF FENDER WHEEL +or-10.0mm +or-10.0mm +or-10.0mm
OPENING)............................................
*****REAR RIDE HEIGHT SIDE TO SIDE 0.0 mm 12.5 mm 0.0 mm 12.5 mm 0.0 mm 12.5 mm
DIFFERENTIAL..................................... MAX MAX MAX
NS BRAKES 5-1
BRAKES
CONTENTS
page page
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
GENERAL VEHICLE SERVICE CAUTIONS
CAUTION: At no time when servicing a vehicle, can a
sheet metal screw, bolt or other metal fastener be
installed in the shock tower to take the place of an
original plastic clip. Also, NO holes can be drilled into
the front shock tower in the area shown in (Fig. 1), for
the installation of any metal fasteners into the shock
tower. Because of the minimum clearance in this area
(Fig. 1), installation of metal fasteners could damage
the coil spring coating and lead to a corrosion failure
of the spring. If a plastic clip is missing, or is lost or
broken during servicing a vehicle, replace only with
the equivalent part listed in the Mopar parts catalog.
CAUTION: Only the recommended jacking or hoisting Fig. 1 Shock Tower To Spring Minimum Clearance
positions for this vehicle are to be used whenever it is Area
necessary to lift a vehicle. Failure to raise a vehicle
• Rear automatic adjusting drum brakes.
from the recommended locations could result in lifting
• Master cylinder with brake fluid level sensor.
a vehicle by the hydraulic control unit mounting
• Vacuum booster.
bracket. Lifting a vehicle by the hydraulic control unit
• Height sensing proportioning valve (non-antilock
mounting bracket will result in damage to the mount-
brake applications)
ing bracket and the hydraulic control unit.
• Non-height sensing proportioning valve (antilock
brake applications)
BASE BRAKE SYSTEM COMPONENT DESCRIPTION The brakes hydraulic system on both non-antilock
The standard brake system on this vehicle consists and antilock brake systems is diagonally split (Fig. 2)
of the following components: (Fig. 3). A diagonally split brake system means the
• Double pin floating caliper disc front brakes. left front and right rear brakes on one hydraulic sys-
• Double pin floating caliper rear disc brakes on tem and the right front and left rear on the other.
all wheel drive applications.
5-2 BRAKES NS
GENERAL INFORMATION (Continued)
Fig. 2 Non-Antilock Brakes Hydraulic Brake Tube Routing And Fitting Locations
Fig. 3 Antilock Brakes/Traction Control Hydraulic Brake Tube Routing And Fitting Locations
NS BRAKES 5-3
INDEX
page page
DESCRIPTION AND OPERATION sleeves, and 2 caliper guide pin bolts which thread
directly into the steering knuckle (Fig. 3).
FRONT DISC BRAKE SYSTEM
The single piston, floating caliper disc brake
assembly (Fig. 1) and (Fig. 2) consists of:
• The driving hub.
• Braking disc (rotor).
• Caliper assembly.
• Shoes and linings.
CAUTION: The use of after-market load leveling or Fig. 8 Height Sensing Proportioning Valve
load capacity increasing devices on this vehicle are HEIGHT SENSING PROPORTIONING VALVE OPERATION
prohibited. Using air shock absorbers or helper The height sensing proportioning valve regulates
springs on this vehicle will cause the height sens- the hydraulic pressure to the rear brakes. The pro-
ing proportioning valve to inappropriately reduce portioning valve regulates the pressure by sensing
the hydraulic pressure to the rear brakes. This inap- the load condition of the vehicle through the move-
propriate reduction in hydraulic pressure potentially ment of the proportioning valve actuator assembly
NS BRAKES 5-7
DESCRIPTION AND OPERATION (Continued)
(Fig. 8). The actuator assembly is mounted between an anodized aluminum casting. It has a machined
the height sensing proportioning valve and the actua- bore to accept the master cylinder piston and
tor bracket on the left rear leaf spring (Fig. 8). As the threaded ports with seats for the hydraulic brake
rear height of the vehicle changes depending on the line connections. The brake fluid reservoir of the
load the vehicle is carrying the height change is master cylinder assembly is made of a see through
transferred to the height sensing proportioning valve. polypropylene type plastic. A low fluid switch is also
This change in vehicle height is transferred through part of the reservoir assembly.
the movement of the left rear leaf spring. As the posi-
tion of the left rear leaf spring changes this move-
ment is transferred through the actuator bracket
(Fig. 8) to the actuator assembly (Fig. 8) and then to
the proportioning valve.
Thus, the height sensing proportioning valve
allows the brake system to maintain the optimal
front to rear brake balance regardless of the vehicle
load condition. Under a light load condition, hydrau-
lic pressure to the rear brakes is minimized. As the
load condition of the vehicle increases, so does the
hydraulic pressure to the rear brakes.
The proportioning valve section of the valve oper-
ates by transmitting full input hydraulic pressure to
the rear brakes up to a certain point, called the split
point. Beyond the split point the proportioning valve
reduces the amount of hydraulic pressure to the rear Fig. 9 Master Cylinder Assembly
brakes according to a certain ratio. Thus, on light
brake applications, approximately equal hydraulic This vehicle uses 3 different master cylinders.
pressure will be transmitted to the front and rear Master cylinder usage depends on what type of brake
brakes. At heavier brake applications, the hydraulic system the vehicle is equipped with. If a vehicle is
pressure transmitted to the rear brakes will be lower not equipped with antilock brakes, or is equipped
then the front brakes. This will prevent premature with antilock brakes without traction control, a con-
rear wheel lock-up and skid. ventional compensating port master cylinder is used.
The height sensing section of the valve thus If a vehicle is equipped with antilock brakes with
changes the split point of the proportioning valve, traction control, a dual center port master cylinder is
based on the rear suspension height of the vehicle. used.
When the height of the rear suspension is low, the The third master cylinder used on this vehicle is
proportioning valve interprets this as extra load and unique to vehicles equipped with four wheel disc
the split point of the proportioning valve is raised to brakes. The master cylinder used for this brake
allow more rear braking. When the height of the rear application has a different bore diameter and stroke
suspension is high, the proportioning valve interprets then the master cylinder used for the other available
this as a lightly loaded vehicle and the split point of brake applications.
the proportioning valve is lowered and rear braking The master cylinders used on front wheel drive
is reduced. applications (non four wheel disc brake vehicles)
have a master cylinder piston bore diameter of 23.8
CHASSIS TUBES AND HOSES mm. The master cylinder used on the all wheel drive
The purpose of the chassis brake tubes and flex applications (four wheel disc brake vehicles) have a
hoses is to transfer the pressurized brake fluid devel- master cylinder piston bore diameter of 25.4 mm.
oped by the master cylinder to the wheel brakes of When replacing a master cylinder, be sure to
the vehicle. The chassis tubes are steel with a corro- use the correct master cylinder for the type of
sion resistant coating applied to the external surfaces brake system the vehicle is equipped with.
and the flex hoses are made of reinforced rubber. The The master cylinder is not a repairable component
rubber flex hoses allow for the movement of the vehi- and must be replaced if diagnosed to be functioning
cles suspension. improperly
Fig. 10 Power Brake Booster Identification RED BRAKE WARNING LAMP OPERATION
The power brake booster reduces the amount of The red Brake warning lamp is located in the
force required by the driver to obtain the necessary instrument panel cluster and is used to indicate a
hydraulic pressure to stop vehicle. low brake fluid condition or that the parking brake is
The power brake booster is vacuum operated. The applied. In addition, the brake warning lamp is
vacuum is supplied from the intake manifold on the turned on as a bulb check by the ignition switch
engine through the power brake booster check valve every time the ignition switch is turned to the crank
(Fig. 10) and (Fig. 11). position.
As the brake pedal is depressed, the power brake The warning lamp bulb is supplied a 12 volt igni-
boosters input rod moves forward (Fig. 11). This tion feed anytime the ignition switch is on. The bulb
opens and closes valves in the power booster, allow- is then illuminated by completing the ground circuit
ing atmospheric pressure to enter on one side of a either through the park brake switch, the fluid level
diaphragm. Engine vacuum is always present on the sensor in the master cylinder reservoir, or the igni-
other side. This difference in pressure forces the out- tion switch when it is turned to the crank position.
put rod of the power booster (Fig. 11) out against the The Brake Fluid Level sensor is located in the
primary piston of the master cylinder. As the pistons brake fluid reservoir of the master cylinder assembly.
in the master cylinder move forward this creates the The purpose of the sensor is to provide the driver
hydraulic pressure in the brake system. with an early warning that brake fluid level in the
master cylinder fluid reservoir has dropped to below
NS BRAKES 5-9
DESCRIPTION AND OPERATION (Continued)
normal. This may indicate: (1) Abnormal loss of with speed control, the stop lamp switch will deacti-
brake fluid in the master cylinder fluid reservoir vate speed control when the brake pedal is
resulting from a leak in the hydraulic system. (2) depressed.
Brake shoe linings which have worn to a point The stop lamp switch controls operation of the
requiring replacement. right and left tail, stop and turn signal lamp and
As the brake fluid drops below the minimum level, CHMSL lamp, by supplying battery current to these
the brake fluid level sensor closes to ground the lamps.
brake warning light circuit. This will turn on the red The stop lamp switch controls the lamp operation
brake warning light. At this time, master cylinder by opening and closing the electrical circuit to the
fluid reservoir should be checked and filled to the full stop lamps.
mark with DOT 3 brake fluid. If brake fluid level
has dropped below the add line in the master HUB/BEARING REAR WHEEL
cylinder fluid reservoir, the entire brake The rear hub and bearing assembly used on this
hydraulic system should be checked for evi- vehicle is serviceable only as a complete assembly. No
dence of a leak. attempt should be made to disassemble a rear hub
and bearing assembly in an effort to repair it.
STOP LAMP SWITCH The rear hub and bearing assembly is attached to
The stop lamp switch controls operation of the the rear axle using 4 mounting bolts that are remov-
vehicles stop lamps. Also, if the vehicle is equipped able from the back of the rear hub/bearing.
PROPORTIONING VALVES
FIXED PROPORTIONING VALVE TEST
PROCEDURE
On a vehicle equipped with ABS, premature or
excessive rear wheel ABS cycling may be an indica-
tion that the brake fluid pressure to the rear brakes
is above the desired output.
Prior to testing a proportioning valve for function,
check that all tire pressures are correct. Also, ensure
the front and rear brake linings are in satisfactory
condition. It is also necessary to verify that the
brakes shoe assemblies on a vehicle being
tested, are either original equipment manufac-
turers (OEM), or original replacement brake
shoe assemblies meeting the OEM lining mate-
rial specification. The vehicles brake system is
not balanced for after market brake shoe
assembly lining material.
If brake shoe assembly lining material is of satis-
Fig. 17 Minimum Rotor Thickness Markings
factory condition, and of the correct material specifi-
micrometer at a radius approximately 25.4 mm (1 cation, check for proper proportioning valve function
inch) from outer edge of rotor (Fig. 18). If thickness using the following procedure.
measurements vary by more than 0.013 mm (0.0005 (1) Road test vehicle to be sure the vehicle is truly
inch), rotor should be removed and resurfaced, or a exhibiting a condition of excessive rear wheel ABS
new rotor installed. If cracks or burned spots are evi- cycling. Since ABS cycles both rear brakes together
dent, rotor must be replaced. both proportioning valves of the assembly (Fig.
19) must be tested. Use the following procedure to
test the proportioning valve.
OUTLET
WHEEL DRIVE BRAKE SYS- INLET PRES-
SALES CODE SPLIT POINT SLOPE PRESSURE
BASE TRAIN TEM SURE PSI
PSI
SWB FWD BRA+BGF 149 DISC/DRUM VAR. .30 1000 PSI 250-350 PSI
W/O ANTILOCK
BRA+BGF 149,159,159HD 660-780
SWB FWD BRB+BGF DISC/DRUM 25 BAR .59 1000 PSI PSI
BRV+BGF WITH ANTILOCK
LWB FWD BRA+BGF 149 DISC/DRUM VAR. .30 1000 PSI 250-350 PSI
W/O ANTILOCK
BRA+BGF 149,159,159HD
LWB FWD BRB+BGF DISC/DRUM 25 BAR .59 1000 PSI 660-780 PSI
BRV+BGF WITH ANTILOCK
SWB AWD BRE+BGF 159 DISC/DISC 25 BAR .36 1000 PSI 525-640 PSI
WITH ANTILOCK
LWB AWD BRE+BGF 159 DISC/DISC 41 BAR .36 1000 PSI 690-800 PSI
WITH ANTILOCK
5 - 20 BRAKES NS
MASTER CYLINDER FLUID LEVEL CHECK CAUTION: Before removing the master cylinder
Check master cylinder reservoir fluid level a mini- cover, throughly clean the cover and master cylin-
mum of twice annually. der fluid reservoir to prevent dirt and other foreign
Master cylinder reservoirs are marked with the matter from dropping into the master cylinder fluid
words FULL and ADD to indicate proper brake fluid reservoir.
fill level of the master cylinder (Fig. 26).
If necessary, add brake fluid to bring the level to CAUTION: Use bleeder tank Special Tool C-3496-B
the bottom of the FULL mark on the side of the mas- with adapter Special Tool 6921 to pressurize the
ter cylinder fluid reservoir. When filling master hydraulic system for bleeding.
cylinder fluid reservoir do not fill the filler
neck of the fluid reservoir (Fig. 26) with brake
fluid. CAUTION: When pressure bleeding the brakes
hydraulic system the fluid reservoir filler neck must
be removed from the master cylinder fluid reservoir.
Failure to remove the filler neck from the fluid res-
ervoir, may result in the filler neck separating from
the fluid reservoir when the hydraulic system is
pressurized.
Fig. 28 Pressure Bleeding Cap Installed On Master NOTE: Correct manual bleeding of the brakes
Cylinder hydraulic system will require the aid of a helper.
Rotor Thick- Minimum Rotor Rotor Thick- Rotor Run Rotor Micro
Braking Rotor
ness Thickness ness Variation Out* Finish
Front Rotor 23.87-24.13 mm 22.4 mm .013 mm .08 mm 15-80 RMS
.939 -.949 in. .881 in. .0005 in. .003 in.
Rear Rotor 12.75-12.25 mm 11.25 mm .013 mm .08 mm 15-80 RMS
.502 -.482 in. .443 in. .0005 in. .003 in.
* TIR Total Indicator Reading (Measured On Vehicle)
Fig. 40 Inverted Double Wall Flare And ISO Flare Fig. 41 Brake Tubing ISO Flaring Process
Tubing Connections out the automatic adjuster when servicing the park
obtain the correct form of a (metric) ISO tubing brake pedal mechanism and cables.
flare. Use the following procedure to release the tension
(2) Open jaws of the Flaring Tool. Align the mating from the park brake cables and the auto adjuster in
size jaws of the flaring tool around the size of the the park brake pedal mechanism.
tubing to be flared. Close the jaws of the Flaring Tool (1) Grasp the exposed section of the front park
around the tubing to keep it from sliding out of the brake cable and pull rearward on it. While holding
flaring tool, but do not lock the tubing in place. See the park brake in this position, install a pair of lock-
(Fig. 41) ing pliers on the front park brake cable just rearward
(3) Position the tubing in the jaws of the Flaring of the second body outrigger bracket (Fig. 42).
Tool so that it is flush with the top surface of the
flaring tool bar assembly. (Fig. 41) )
(4) Install the correct size adaptor for the brake
tubing being flared, on the feed screw of the yoke
assembly. Center the yoke and adapter over the end
of the tubing. Apply lubricant to the adapter area
that contacts brake tubing. Making sure the adapter
pilot is fully inserted in the end of the brake tubing.
Screw in the feed screw of the yoke assembly until
the adaptor has seated squarely on the surface of the
bar assembly (Fig. 41). This process has created the
(metric) ISO tubing flare.
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove rear wheel and tire assemblies from
vehicle.
(3) Remove the caliper to adapter guide pin bolts
(Fig. 55).
(4) Remove rear caliper from adapter using the fol-
lowing procedure. First rotate rear of caliper up from
the adapter. Then pull the front of the caliper and
the outboard brake shoe anti-rattle clip out from
Fig. 54 Installing Outboard Brake Shoe Assembly under the front abutment on the adapter (Fig. 56).
REAR DISC BRAKE SHOES (5) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
WARNING: ALTHOUGH FACTORY INSTALLED 57).
BRAKELININGS ARE MADE FROM ASBESTOS
5 - 32 BRAKES NS
REMOVAL AND INSTALLATION (Continued)
retaining clip over raised area on caliper and sliding
the brake shoe off the caliper.
(8) Remove inboard brake shoe from caliper.
Inboard brake shoe is removed by pulling it out of
the caliper piston, until the retaining clip is free of
the piston (Fig. 58).
INSTALL
CAUTION: Use care when installing the caliper Fig. 60 Park Brake Cable Equlizer
assembly onto the adapter, so the caliper guide pin (2) Remove the rear brake shoe adjusting hole
bushings do not get damaged by the mounting cover plug.
bosses. (3) Insert a thin screwdriver into brake adjusting
hole and hold adjusting lever away from notches of
(6) Carefully lower caliper and brake shoes over
adjusting screw star wheel.
rotor and onto adapter, reversing the removal proce-
(4) Insert Tool C-3784 into brake adjusting hole
dure (Fig. 56)
and engage notches of brake adjusting screw star
CAUTION: When installing the caliper guide pin wheel. Release brake adjustment by prying down
bolts extreme caution should be taken not to with adjusting tool.
crossthread the guide pin bolts. (5) Remove rear brake drum from rear hub/bear-
ing assembly.
(7) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 22 N·m (192 in. lbs.). INSTALL
(8) Install the wheel and tire assembly. (1) Adjust brake shoes assemblies so as not to
(9) Tighten the wheel mounting stud nuts in interfere with brake drum installation.
proper sequence until all nuts are torqued to half (2) Install the rear brake drums on the hubs.
specification. Then repeat the tightening sequence to (3) Adjust rear brake shoes per Adjusting Rear
the full specified torque of 129 N·m (95 ft. lbs.). Brakes procedure in the service adjustments section
(10) Remove jackstands or lower hoist. of the service manual.
(4) Install the removed park brake cable back on
CAUTION: Before moving vehicle, pump the brake the park brake cable equalizer (Fig. 60)
pedal several times to insure the vehicle has a firm (5) Install wheel and tire.
brake pedal to adequately stop the vehicle. (6) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
(11) Road test the vehicle and make several stops specification. Then repeat the tightening sequence to
to wear off any foreign material on the brakes and to the full specified torque of 130 N·m (95 ft. lbs.).
seat the brake shoe linings.
INSTALL
(1) Apply Mopart Gasket In-A-Tube or equivalent
sealant around wheel cylinder mounting surface in
brake support plate.
(2) Install wheel cylinder onto brake support, and
tighten the wheel cylinder to brake support plate
attaching bolts (Fig. 81) to 8 N·m (75 in. lbs.).
(3) Attach hydraulic brake tube to wheel cylinder,
(Fig. 81) and tighten tube to wheel cylinder fitting to
16 N·m (142 in. lbs.).
(4) Install brake shoes on support plate.
(5) Install rear brake drum onto rear hub. Install
rear wheel and tire assembly, tighten wheel stud Fig. 82 Rear Wheel Speed Sensor
nuts to 129 N·m (95 ft. lbs.).
(6) Adjust the rear brakes, (See Adjusting Service
Brakes) in Service Adjustments section in this group
of the service manual.
(7) Bleed the entire brake system. See (Bleeding
Brake System) in Service Adjustments section in this
group of the service manual.
HUB/BEARING
FRONT WHEEL DRIVE
REMOVE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual for required lifting procedure. Fig. 83 Rear Hub/Bearing Mounting Bolts
(2) Remove wheel and tire.
it by hand, do not pound on the hub/bearing to
(3) Remove brake drum from hub/bearing.
remove it from the axle. Pounding on the hub/bear-
(4) Remove rear wheel speed sensor from rear hub/
ing to remove it from the axle will damage the hub/
bearing (Fig. 82). This will prevent damage to the
bearing. This damage will result in noise or failure
speed sensor during removal and installation of the
of the bearing.
hub/bearing. The rear wheel speed sensor bolts
to the hub/bearing. It can not be removed (6) If hub/bearing cannot be removed from the axle
unless the speed sensor is removed first. by hand, use Remover Special Tool 8214 (Fig. 84) and
following procedure to press the hub/bearing out of
CAUTION: When working in the area of the rear
the axle.
hub/bearing and when removing it from the rear
(a) Place Special Tool 8214-1 over tone wheel
axle, care must be used so the teeth on the tone
and against cast flange of hub/bearing (Fig. 84)
wheel are not damaged. Damage to the teeth on the
(b) Put a dab of grease in the bolt pilot hole on
tone wheel will result in false ABS cycling and cor-
the back of Special Tool 8214-1.
rosion of the tone wheel.
(c) Insert Special Tool 8214-2 into the hole in the
(5) Remove the 4 bolts (Fig. 83) attaching the hub/ bottom of the end casting on the axle (Fig. 84).
bearing to the rear axle. Special Tool 8214-2 should be against and sup-
ported by the axle plate (Fig. 84) when pressing
CAUTION: Corrosion may occur between the hub/ the wheel bearing out of the axle. If Special Tool
bearing and the axle. If this occurs the hub/bearing 8214-2 will not fit into the hole in the end
will be difficult to remove from the axle. If the hub/ casting, file or grind the flashing from the
bearing will not come out of the axle by pulling on hole until tool fits properly.
NS BRAKES 5 - 41
REMOVAL AND INSTALLATION (Continued)
(5) Install the rear wheel speed sensor on the rear
hub/bearing flange (Fig. 82). Install the speed sensor
attaching bolt and tighten to a torque of 12 N·m (105
in. lbs.).
(6) Install brake drum on hub/bearing.
(7) Install wheel and tire.
(8) Tighten the wheel stud nuts in the proper
sequence to a torque of 129 N·m (95 ft. lbs.).
(9) Adjust the rear brakes, (See Adjusting Service
Brakes) in Service Adjustments section in this group
of the service manual.
REMOVE
(1) Set the parking brake. The parking brake is
Fig. 84 Special Tool 8214 Installed set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut.
(d) Align bolt in Special Tool 8214-2 with pilot (2) Raise vehicle. Vehicle is to be raised and sup-
hole in Special Tool 8214-1. Tighten bolt against ported on jackstands or on a frame contact type
Special Tool 8214-1. hoist. See Hoisting in the Lubrication And Mainte-
(e) Press hub/bearing out of axle by continuing nance section of this service manual.
to tighten bolt in Special Tool 8214-2 against Spe- (3) Remove the wheel/tire.
cial Tool 8214-1. (4) Remove the cotter pin and nut retainer (Fig.
(7) Remove the hub/bearing from the rear axle and 86) from the stub shaft of the outer C/V joint.
brake support plate (Fig. 85).
Fig. 88 Hub Nut And Washer Fig. 91 Caliper Guide Pin Bolts
(1) With engine not running, pump brake pedal Fig. 105 Battery Tray Mounting Locations
until a firm pedal is achieved (4-5 strokes).
(2) Remove both battery cables from battery.
(3) Remove the battery thermal guard and the bat-
tery from the battery tray.
(4) Remove the air inlet resonator and hoses as an
assembly from the throttle body and air cleaner
housing (Fig. 104)
(5) If vehicle is equipped with speed control,
unplug wiring harness connector from the speed con-
trol servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery
tray.
(6) Remove bolt attaching the speed control servo
bracket to the battery tray. Slide the bracket forward
to unhook it from the battery tray and remove.
(7) Remove the 2 bolts and the nut (Fig. 105)
attaching the battery tray to the body.
Fig. 106 Fluid Level Sensor Electrical Connection
(8) Remove wiring harness connector from brake
fluid level sensor in master cylinder fluid reservoir only a solvent such as Mopar Brake Parts Cleaner or
(Fig. 106). an equivalent.
(9) Clean the area where the master cylinder (10) Remove clip attaching drain hose for wiper
assembly attaches to the power brake booster. Use module to brake tube at master cylinder. Remove
5 - 48 BRAKES NS
REMOVAL AND INSTALLATION (Continued)
drain hose (Fig. 107) from wiper module. Remove the (14) Rotate screwdriver enough to allow retaining
2 nuts attaching the master cylinder to the vacuum clip center tang to pass over end of brake pedal pin.
booster (Fig. 107). Then pull retaining clip off brake pedal pin. Discard
retaining clip. It is not to be reused. Replace
only with a new retaining clip when assembled.
(15) Remove the 4 nuts attaching the vacuum
booster to the dash panel. Nuts are accessible from
under dash panel in area of the steering column and
pedal bracket assembly.
(16) From outside the vehicle, slide vacuum
booster forward until its mounting studs clear dash
panel. Then tilt the booster up and toward the center
of vehicle to remove.
INSTALL
Fig. 107 Master Cylinder Attachment To Vacuum
Booster CAUTION: When installing the vacuum booster in
the vehicle be sure the heater hoses do not become
NOTE: It is not necessary to remove the brake
trapped between the booster and the dash panel of
tubes from the master cylinder when removing the
the vehicle.
master cylinder from the vacuum booster.
(1) Position vacuum booster onto dash panel using
(11) Remove the master cylinder and brake tubes
the reverse procedure for its removal.
as an assembly from the vacuum booster. When mas-
(2) Install the 4 mounting nuts for the vacuum
ter cylinder is removed, lay it out of the way on top
booster. Tighten the 4 mounting nuts to a torque of
of the left motor mount
29 N·m (250 in. lbs.).
(12) Disconnect vacuum hose from check valve
(3) Using lubriplate, or an equivalent, coat the sur-
located on vacuum booster. DO NOT REMOVE
face of the brake pedal pin where it contacts the vac-
CHECK VALVE FROM POWER BRAKE
uum booster input rod.
BOOSTER.
(13) Locate the vacuum booster input rod to brake CAUTION: When installing the brake pedal pin on
pedal attachment under instrument panel. Position a the vacuum booster input rod, do not re-use the old
small screwdriver between the center tang on the retaining clip.
vacuum booster input rod to brake pedal pin retain-
ing clip (Fig. 108). (4) Connect the vacuum booster input rod on the
brake pedal pin and install a NEW retaining clip
(Fig. 109).
(5) Connect the vacuum hose on the check valve in
the vacuum booster.
Fig. 115 Booster Input Rod Retaining Pin Fig. 116 Retaining Pin Installed On Brake Pedal Pin
clear dash panel. Then tilt the booster up and toward CAUTION: When removing the vacuum seal from
the center of vehicle to remove. the master cylinder do not use a sharp tool.
CAUTION: Do not attempt to disassemble the (6) Using a soft tool such as a trim stick, remove
power brake vacuum booster it is to be serviced the vacuum seal from the master cylinder mounting
ONLY as a complete assembly. flange.
(7) Install a NEW vacuum seal on mounting flange
of master cylinder assembly (Fig. 117).
INSTALL
Fig. 120 Electrical Connector At EGR Transducer Fig. 122 Throttle Body Attachment To Intake
Manifold
INSTALL
JUNCTION BLOCK
REMOVE
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
Fig. 128 Vacuum Seal Installed On Master Cylinder out of the master cylinder when the brake tubes are
removed from the junction block.
(9) Position master cylinder on studs of vacuum
(2) Raise vehicle on jackstands or centered on a
booster, aligning push rod on vacuum booster with
hoist. See Hoisting in the Lubrication And Mainte-
master cylinder piston.
nance Group of this service manual.
(10) Install the 2 nuts mounting the master cylin-
der to the vacuum booster (Fig. 124). Tighten both CAUTION: Before removing the brake tubes from
mounting nuts to a torque of 25 N·m (225 in. lbs.). the junction block, the junction block and the brake
(11) Install the wiper module drain hose (Fig. 124) tubes must be thoroughly cleaned. This is required
on the wiper module. Install the tie strap attaching to prevent contamination from entering the brake
the wiper module drain hose to brake tube at the hudraulic system.
master cylinder. Tie strap should be loosely tight-
ened so as not to collapse the wiper module (3) Remove the 6 chassis brake tubes (Fig. 129)
drain hose. from the junction block.
(12) Install the wiring harness connector on the (4) Remove the bolt (Fig. 130) attaching the junc-
brake fluid level sensor in the master cylinder fluid tion block mounting braket to the front suspension
reservoir (Fig. 123). cradle.
(13) Install the throttle body and throttle cable
bracket on the intake manifold. Install the 2 bolts INSTALL
(Fig. 122) attaching the throttle body to the intake (1) Install the junction block and mounting bracket
manifold and tighten to a torque of 25 N·m (225 in. (Fig. 130) on the front suspension cradle. Install the
lbs.) Install clip (Fig. 122) attaching the wiring har- attaching bolt and tighten to a torque of 28 N·m (250
ness to the throttle cable bracket. in. lbs.).
(14) Install the wiring harness connectors on the (2) Install the 6 chassis brake tubes (Fig. 131) into
throttle position sensor and the AIS motor on throttle the inlet and outlet ports of the junction block.
body (Fig. 121).
5 - 56 BRAKES NS
REMOVAL AND INSTALLATION (Continued)
tem. See Bleeding Brake System in the Service
Adjustments section in this group of the service man-
ual for the proper bleeding procedure.
(4) Lower the vehicle.
(5) Road test the vehicle to verify proper operation
of the vehicles brake system.
REMOVE
(1) Using a brake pedal depressor, move and lock
Fig. 129 Junction Block Brake Tubes the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the proportioning valve.
(2) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication And Mainte-
nance Group of this service manual.
REMOVE
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining Fig. 135 Proportioning Valve Mounting
out of the master cylinder when the brake tubes are (5) Remove the hooked end of the proportioning
removed from the proportioning valve. valve actuator (Fig. 136) from the isolator bushing on
the lever of the height proportioning valve (Fig. 136).
5 - 58 BRAKES NS
REMOVAL AND INSTALLATION (Continued)
attach components to the front suspension cradle
have an anti—corrosion coating due to the suspen-
sion cradle being made of aluminum. Only Mopar
replacement fasteners with the required anti-corro-
sion coating are to be used if a replacement fas-
tener is required when installing a brake chassis
line or flex hose.
Fig. 137 Locking Out Automatic Adjuster Fig. 138 Park Brake Pedal Mounting
(8) Remove tension from front park brake cable. (4) Install cable strand button into the clevis on
Tension is removed by releasing the locking pliers the park brake pedal mechanism.
from the front park brake cable. (5) Install wiring harness connector on red brake
(9) Remove the 3 bolts mounting the wiring junc- warning lamp ground switch.
tion block to the instrument panel. (6) Install the park brake release cable on the
release mechanism of the park brake pedal.
NOTE: When removing the lower mounting bolt, (7) Position the park brake pedal mechanism into
push the park brake pedal down 5 clicks to access its installed position on the body of the vehicle.
the lower mounting bolt. (8) Remove the lock-out pin from the park brake
pedal release mechanism.
(10) Remove the lower bolt mounting the park (9) Loosely install the top bolt (Fig. 138) mounting
brake pedal to the body. the park brake pedal mechanism to the body.
(11) Remove the forward bolt mounting the park (10) Loosely install the forward bolt (Fig. 138)
brake pedal to the body. mounting the park brake pedal mechanism to the
(12) Remove the upper bolt mounting the park body.
brake pedal to the body. (11) Loosely install the lower bolt (Fig. 138)
(13) Disconnect the electrical connector for the mounting the park brake pedal mechanism to the
brake light switch (Fig. 138). body.
(14) Pull downward on front park brake cable (12) Tighten pedal mechanism attaching bolts to
while rotating park brake pedal mechanism out from 28 N·m (250 in. lbs.).
behind junction block. (13) Verify that the park brake pedal is in the fully
(15) Remove park brake pedal release cable (Fig. released (full up) position.
138) from park brake mechanism. (14) Raise vehicle.
(16) Remove the ground switch for the red brake (15) Install the front park brake cable on the park
warning lamp from the park brake pedal mechanism. brake cable equalizer.
(17) Remove front park brake cable button from (16) Lower vehicle.
park brake pedal mechanism. Tap end housing of (17) Remove the lock-out pin (Fig. 138) from the
front park brake cable out of park brake pedal mech- automatic cable adjuster on the park brake pedal
anism (Fig. 138). mechanism.
(18) Install the electrical junction block on the
INSTALL
instrument panel.
(1) Install the ground switch for the red brake
(19) Install the reinforcement on the lower instru-
warning lamp on the park brake pedal mechanism
ment panel.
(2) Install park brake cable end housing (Fig. 138)
(20) Install the steering column cover on the lower
into park brake pedal mechanism.
instrument panel.
(3) Install cable retainer (Fig. 138) onto the park
(21) Install the left side kick panel.
brake cable strand and then install retainer into
(22) Install the sill scuff plate on the lower sill of
pedal bracket.
the left door.
5 - 60 BRAKES NS
REMOVAL AND INSTALLATION (Continued)
(23) Install the negative (ground) cable on the bat-
tery.
(24) Cycle the park brake pedal one time. This will
seat the park brake cables and will allow the auto-
matic self adjuster to properly tension the park brake
cables.
REMOVE
(1) Set the parking brake. The parking brake is
set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut.
(2) Raise vehicle. Vehicle is to be raised and sup- Fig. 140 Spring Washer
ported on jackstands or on a frame contact type
hoist. See Hoisting in the Lubrication And Mainte-
nance section of this service manual.
(3) Remove the wheel/tire.
(4) Remove the cotter pin and nut retainer (Fig.
139) from the stub shaft of the outer C/V joint.
Fig. 148 Speed Sensor Attaching Bolt Fig. 151 Adapter Mounted In Vise
Fig. 149 Hub/Bearing Mounting Bolts Fig. 152 Lower Return Spring
Fig. 150 Hub/Bearing Removal And Installation Fig. 153 Leading Brake Shoe Hold Down Pin And
(21) Remove the lower return spring (Fig. 152) Spring
from the leading and trailing park brake shoes.
(22) Remove the hold down spring and pin (Fig.
153) from the leading park brake shoe.
NS BRAKES 5 - 63
REMOVAL AND INSTALLATION (Continued)
(23) Remove the adjuster (Fig. 154) from the lead-
ing and trailing park brake shoe.
Fig. 159 Park Brake Cable Attachment To Equalizer Fig. 161 Front Park Brake Cable At Floor Pan
(4) Remove the front park cable housing retainer INSTALL
from body outrigger bracket (Fig. 160). Cable is (1) Pass park brake cable assembly through hole
removable by sliding a 14 mm box wrench over cable in floor pan from the inside of the vehicle.
retainer and compressing the three retaining fingers. (2) Pass cable strand button through the hole in
Alternate method is to use an aircraft type hose the pedal assembly bracket.
clamp and screwdriver. (3) Install cable retainer onto the park brake cable
(5) Lower vehicle. and then install cable retainer into pedal assembly
(6) Remove the left front door sill molding. bracket.
(7) Remove the left front kick panel for access to (4) Install the end of the park brake cable into the
the park brake cable and park brake pedal assembly. retainer previously installed into the park brake
(8) Lift floor mat for access to park brake cable pedal bracket.
and floor pan. Pull the seal and the park brake cable (5) Install cable strand button into the clevis on
(Fig. 161) out of the floor pan of vehicle. the park brake pedal mechanism.
(9) Pull park brake cable strand end forward and (6) Install the front park brake cable floor pan seal
disconnect button from clevis. Tap cable housing end into hole in floor pan. Seal is to be installed so the
fitting out of pedal assembly bracket. flange on the seal is flush with the floor pan (Fig.
(10) Remove cable retainer from the park brake 161). Fold carpeting back down on floor.
pedal assembly bracket. (7) Raise vehicle.
(11) Pull park brake cable assembly out of vehicle (8) Insert brake cable and housing into body out-
through hole in floor pan. rigger bracket making certain that housing retainer
fingers lock the housing firmly into place (Fig. 160).
5 - 66 BRAKES NS
REMOVAL AND INSTALLATION (Continued)
(9) Assemble the park brake cables onto the park
brake cable equalizer (Fig. 159).
(10) Release the automatic adjuster mechanism on
the park brake pedal assembly. Refer to Parking
Brake Automatic Adjuster in the Service Procedures
Section in this group of the service manual for the
required procedure.
(11) Lower vehicle and apply the park brake pedal
1 time, this will seat the park brake cables.
REMOVE
(1) Check brake fluid level in master cylinder fluid
reservoir to be sure brake fluid is not in the filler
neck. If brake fluid is in filler neck, lower fluid level
before removing filler neck from fluid reservoir
(2) Grasp filler neck at cap end (Fig. 177) and
push straight down. This will cause the filler neck to
pop out of the fluid reservoir.
Fig. 178 Fluid Level Sensor Electrical Connection
CALIPER ASSEMBLY
CALIPER INSPECTION
Check for brake fluid leaks in and around boot
area and inboard lining, and for any ruptures, brit-
tleness or damage to the piston dust boot. If the boot Fig. 194 Brake Adjustment Hole Rubber Plug
is damaged, or a fluid leak is visible, disassemble cal- (3) Insert a thin screwdriver into brake adjusting
iper assembly and install a new seal and boot, and hole to hold the adjusting lever away from the
piston if scored. Refer to Rear Disc Brake Caliper in notches on the adjusting screw star wheel.
the Disassembly And Assembly Section in this group (4) Insert Tool C-3784 into brake adjusting hole
of the service manual. and engage notches of brake adjusting screw star
Check the guide pin dust boots to determine if they wheel. Release brake by prying down with adjusting
are in good condition. Replace if they are damaged, tool.
dry, or found to be brittle. Refer to Rear Disc Brake (5) Remove the rear brake drum from the rear
Caliper in the Disassembly And Assembly Section in hub/bearing assembly.
this group of the service manual. (6) Inspect brake lining for wear, shoe alignment,
and or contamination from grease or brake fluid.
5 - 78 BRAKES NS
CLEANING AND INSPECTION (Continued)
REAR DRUM BRAKE WHEEL CYLINDER ADJUSTMENTS
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu- STOP LAMP SWITCH
ally check the boots for cuts, tears, or heat cracks. If (1) Remove stop lamp switch from its bracket by
any of these conditions exist, the wheel cylinders rotating it approximately 30° in a counter-clockwise
should be completely cleaned, inspected and new direction.
parts installed. (2) Disconnect wiring harness connector from stop
If a wheel cylinder is leaking and the brake lining lamp switch.
material is saturated with brake fluid, the brake (3) Hold stop lamp switch firmly in one hand.
shoes must be replaced. Then using other hand, pull outward on the plunger
of the stop lamp switch until it has ratcheted out to
BRAKE HOSE AND BRAKE LINES INSPECTION its fully extended position.
Flexible rubber hose is used at both front brakes (4) Install the stop lamp switch into the bracket
and at the rear axle. Inspection of brake hoses using the following procedure. Depress the brake
should be performed whenever the brake system is pedal as far down as possible. Then while keeping
serviced and every 7,500 miles or 12 months, which- the brake pedal depressed, install the stop lamp
ever comes first (every engine oil change). Inspect switch into the bracket by aligning index key on
hydraulic brake hoses for surface cracking, scuffing, switch with slot at top of square hole in mounting
or worn spots. If the fabric casing of the rubber hose bracket. When switch is fully installed in the square
becomes exposed due to cracks or abrasions in the hole of the bracket, rotate switch clockwise approxi-
rubber hose cover, the hose should be replaced imme- mately 30° to lock the switch into the bracket.
diately. Eventual deterioration of the hose can take
place with possible burst failure. Faulty installation CAUTION: Do not use excessive force when pulling
can cause twisting, resulting in wheel, tire, or chassis back on brake pedal to adjust the stop lamp switch.
interference. If too much force is used, damage to the vacuum
The steel brake tubing should be inspected period- booster, stop lamp switch or striker (Fig. 195) can
ically for evidence of physical damage or contact with result.
moving or hot components.
The flexible brake tube sections used on this vehi- (5) Connect the wiring harness connector to the
cle in the primary and secondary tubes from the stop lamp switch.
master cylinder to the ABS hydraulic control unit (6) Gently pull back on brake pedal until the pedal
connections and the chassis brake tubes between the stops moving. This will cause the switch plunger
hydraulic control unit and the proportioning valve (Fig. 195) to ratchet backward to the correct position.
must also be inspected. This flexible tubing must be
inspected for kinks, fraying and its contact with
other components of the vehicle or contact with the
body of the vehicle.
SPECIAL TOOLS
SPECIAL TOOLS—BASE BRAKES
INDEX
page page
HCU PUMP/MOTOR
The HCU (Fig. 4) contains 2 pump assemblies, one
for the primary and one for the secondary hydraulic
circuit of the brake system. Both pumps are driven
by a common electric motor (Fig. 4) which is part of
the HCU. The pumps draw brake fluid from the fluid
accumulators to supply build pressure to the brakes Fig. 5 Fuse Locations In Power Distribution Center
during an ABS stop. The pump motor runs during
the drive-off cycle as a check and during an ABS stop ABS RELAYS
and is controlled by the CAB. The Pump/Motor On the Teves Mark 20 Antilock Brake System both
Assembly is not a serviceable item. If the pump/mo- the pump motor relay and the system relay are
tor requires replacement the complete HCU (Fig. 4) located in the CAB. If either of the relays is diag-
(minus the CAB) must be replaced. nosed as not functioning properly the CAB will need
to be replaced. Refer to Controller Antilock Brakes in
the Removal And Installation Section in this group of
the service manual for the procedure.
PROPORTIONING VALVES
One assembly containing two proportioning valves
are used in the system, one for each rear brake
hydraulic circuit. The proportioning valve is located
on the frame rail next to the fuel tank, forward of the
right rear shock absorber (Fig. 6). Be sure replace-
ment proportioning valve assemblies have the same
split point and slope as the proportioning valve being
replaced.
Fig. 6 Proportioning Valve Mounting Location Fig. 9 Rear Wheel Speed Sensor (AWD)
mounted through the rear axle, rear brake support
plate and directly to the rear bearing (Fig. 8) (Fig. 9).
The rear tone wheel on a front wheel drive vehicle is
an integral part of the rear wheel hub/bearing
assembly. If damaged though, the rear tone wheel on
a front wheel drive vehicle can be replaced as a indi-
vidual component of the rear hub/bearing assembly.
Refer to Rear Tone Wheel in the Remove And Install
Section in this group of the service manual for the
required procedure. The wheel speed sensor air gap
is NOT adjustable.
The rear tone wheel on a all wheel drive vehicle, is
part of the outboard constant velocity joint on the
rear driveshaft (Fig. 9).
The four wheel speed sensors are all serviced indi-
vidually, but the front tone wheel on all vehicles and
Fig. 7 Front Wheel Speed Sensor the rear tone wheel on all wheel drive vehicles are
serviced as part of the front or rear driveshaft out-
board constant velocity joint (Fig. 7) and (Fig. 9).
Correct ABS system operation is dependent on
accurate wheel speed signals. The vehicle’s wheels
and tires must all be the same size and type to gen-
erate accurate signals. Variations in wheel and tire
size can produce inaccurate wheel speed signals,
which can cause false ABS cycles to occur.
NORMAL BRAKING HYDRAULIC CIRCUIT AND TEVES MARK 20 SECONDARY ABS CIRCUIT
SOLENOID VALVE FUNCTION AND SOLENOID VALVE FUNCTION
This condition is the normal operation of the vehi- This hydraulic circuit diagram (Fig. 13) shows the
cles base brake hydraulic system. The hydraulic sys- vehicle in the ABS braking mode. This hydraulic cir-
tem circuit diagram (Fig. 11) shows a situation where cuit (Fig. 13) shows a situation where one wheel is
no wheel spin or slip is occurring relative to the slipping because the driver is attempting to stop the
speed of the vehicle. The driver is applying the brake vehicle at a faster rate than the surface the vehicle’s
pedal to build pressure in the brake hydraulic system tires are on will allow. The normally open and nor-
to apply the brakes and stop the vehicle. mally closed valves modulate the brake hydraulic
pressure as required. The pump/motor is switched on
so that the brake fluid from the low pressure accu-
INSTALL
(1) Install wheel speed sensor head. Note, the plas- REMOVE
tic anti rotation pin must be fully seated prior to (1) Raise vehicle on jack stands or centered on a
installing the attaching bolt. frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
CAUTION: Prior to installing the speed sensor the required lifting procedure to be used for this
head attaching bolt, the plastic anti-rotation pin vehicle.
must be fully seated into the bearing flange. (2) Remove the tire and wheel assembly from the
vehicle.
(2) Install the wheel speed sensor head to bearing
flange attaching bolt (Fig. 42). Tighten the attaching CAUTION: When unplugging speed sensor cable
bolt to a torque 12 N·m (105 in. lbs.) from vehicle wiring harness be careful not to dam-
(3) Check the air gap between the face of the age pins on the electrical connectors. Also inspect
wheel speed sensor and the top surface of the tone- connectors for any signs of previous damage.
wheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (.047 in.). (3) Remove grommet from floor pan of vehicle and
(4) Install the 2 routing brackets attaching the unplug speed sensor cable connector from vehicle
speed sensor cable and brake tube to the rear axle wiring harness (Fig. 43).
(Fig. 41). The rear wheel speed sensor cable
CAUTION: When removing rear wheel speed sen-
should be routed under the rear brake tube
sor cable from routing clips on rear brake flex hose,
(Fig. 41).
be sure not to damage the routing clips. Routing
CAUTION: When installing rear wheel speed sen- clips are molded onto the hose and will require
sor cable in the routing clips on rear brake flex replacement of the brake flex hose if damaged dur-
hose, be sure not to damage the routing clips. ing removal of the speed sensor cable.
Routing clips are molded onto the hose and will
require replacement of the brake flex hose if dam-
aged during installation of the wheel speed sensor
cable.
NS BRAKES 5 - 109
REMOVAL AND INSTALLATION (Continued)
Fig. 43 Speed Sensor Cable Connection To Vehicle Fig. 45 Rear Speed Sensor Routing Brackets And
Wiring Harness Clips
(4) Carefully remove the speed sensor cable from
the rear brake flex hose routing clips (Fig. 44).
BRAKES
CONTENTS
page page
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT DESCRIPTION
The standard brake system on this vehicle contains
the same components as brake systems described in
group 5 of the service manual, with the exception of
the brake pedal system and master cylinder. These
differences are mainly related to service procedures.
The major differences are as follows:
• Use of a torque shaft assembly to transfer brake
pedal travel to the power brake booster and master
cylinder on the left side of the vehicle
• A unique power brake booster and master cylin-
der.
Refer to the Base Brake System Component
Description in the General Information section of
group 5 for more information on components used in Fig. 1 Master Cylinder Assembly
the base brake system. DIAGNOSIS AND TESTING
INSTALL
(1) Install torque shaft. Reconnect pedal arm, link
and pedal bracket assembly to torque shaft as neces-
sary.
(2) Tighten the retaining nut (1) for the Brake
Booster Bracket in the engine compartment. Tighten
the four (4) Brake Booster retaining nuts from inside
Fig. 6 Torque Shaft and Brake Pedal Assembly the passenger compartment.
(3) Install new retaining clip on torque shaft.
(4) Access the brake booster bracket inside the
(4) Install steering column intermediate shaft.
passenger compartment. Remove the retaining clip
Install 72 and 36 way connector brackets.
from brake pedal torque shaft. Discard retaining
(5) Tighten the six (6) retaining nuts for the Brake
clip. It is not to be re-used. Replace only with a
Pedal Bracket assembly.
new clip when reassembled. (Fig. 7)
(6) Connect the Brake Pedal Switch connector.
NS/GS CLUTCH 6-1
CLUTCH
CONTENTS
page page
CLUTCH REPLACEMENT
The transaxle must be removed to service the
clutch assembly, fork, or bearing.
DESCRIPTION AND OPERATION Slave cylinder force causes the release lever to
move the release bearing into contact with the dia-
CLUTCH RELEASE SYSTEM phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward
CLUTCH CABLE — LHD on the fulcrums. This action moves the pressure
The manual transaxle clutch release system has a plate rearward relieving clamp force on the disc. The
unique self-adjusting mechanism to compensate for clutch disc is disengaged and not driven at this point.
clutch disc wear (Fig. 7). This adjuster mechanism is The process of clutch engagement is simply the
located within the clutch cable assembly. The preload reverse of what occurs during disengagement. Releas-
spring maintains tension on the cable. This tension ing pedal pressure removes clutch linkage pressure.
keeps the clutch release bearing continuously loaded The release bearing moves away from the diaphragm
against the fingers of the clutch cover assembly. spring which allows the pressure plate to exert
clamping force on the clutch disc.
DRIVE PLATE MISALIGNMENT Clean the crankshaft flange before mounting the
Common causes of misalignment are: drive plate. Dirt and grease on the flange surface
• Heat warping may misalign the flywheel, causing excessive runout.
• Mounting drive plate on a dirty crankshaft Use new bolts when mounting drive plate to crank-
flange shaft. Tighten drive plate bolts to specified torque
• Incorrect bolt tightening only. Over-tightening can distort the drive plate hub
• Improper seating on the crankshaft shoulder causing excessive runout.
• Loose crankshaft bolts
6-8 CLUTCH NS/GS
DIAGNOSIS AND TESTING (Continued)
CLUTCH COVER AND DISC RUNOUT (4) Check to see if the clutch disc hub splines are
Check condition of the clutch cover before installa- damaged, and replace with new clutch assembly if
tion. A warped cover or diaphragm spring will cause required.
grab and/or incomplete release or engagement. Use (5) Check the input shaft for damaged splines.
care when handling the clutch assembly. Impact can Replace as necessary.
distort the cover, diaphragm spring, and release fin- (6) Check for broken clutch cover diaphragm
gers. spring fingers.
(7) Install clutch assembly and transaxle.
CLUTCH CHATTER COMPLAINTS
For all clutch chatter complaints, do the following:
REMOVAL AND INSTALLATION
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
CLUTCH CABLE SYSTEM — LHD
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further. If REMOVAL
chatter persists: (1) Hoist vehicle
(2) Check to see if clutch cable routing is correct (2) Using a pair of pliers, grasp end of clutch cable
and operates smoothly (LHD applications). and pull downward.
(3) Check for loose connections in drivetrain. Cor- (3) Remove clutch cable retaining clip from clutch
rect any problems and determine if clutch chatter release lever (Fig. 9).
complaints have been satisfied. If not:
(4) Remove transaxle. See Group 21, Manual Tran-
saxle for procedure.
(5) Check to see if the release bearing is sticky or
binding. Replace bearing, if needed.
(6) Check linkage for excessive wear on the pivot
shaft, fork, and bushings. Replace all worn parts.
(7) Check clutch assembly for contamination (dirt,
oil). Replace clutch assembly, if required.
(8) Check to see if the clutch disc hub splines are
damaged. Replace with new clutch assembly, if nec-
essary.
(9) Check input shaft splines for damage. Replace,
if necessary.
(10) Check for uneven wear on clutch fingers.
(11) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly, if
necessary. Fig. 9 Clutch Cable Retaining Clip — LHD
(4) Guide cable through slot in transaxle and dis-
CLASH–INTO–REVERSE COMPLAINTS connect (Fig. 10).
(1) Depress clutch pedal to floor and hold. After (5) Unsnap cable from the cable guide located at
three seconds, shift to reverse. If clash is present, the left shock tower (Fig. 10).
clutch has excessive spin time. (6) Inside the vehicle, remove the driver side lower
dash cover and steel support plate. This provides
NOTE: Verify that nothing is obstructing pedal access to the top of the clutch pedal.
travel. Floormats or other articles located under- (7) Disconnect clutch cable upstop/spacer with
neath the clutch pedal could prevent the clutch cable strand from clutch pedal (Fig. 11) (Fig. 12).
from disengaging fully.
Fig. 10 Clutch Cable Routing — LHD Fig. 11 Clutch Cable Retaining (Upstop) Clip — LHD
NOTE: Depressing the clutch pedal to the floor pro-
vides access to the clutch cable strand. Disconnect
the cable upstop/spacer from the pedal pivot pin by
removing the retaining clip at the top of the clutch
pedal. Wedge a flat blade pry tool in the clip slot to
remove the clip. Remove the clutch pedal upstop/
spacer from the pedal by wedging a flat blade pry
tool between the spacer and pedal. It may be nec-
essary to push the steel support bracket supporting
the electrical junction block slightly to the left for
clearance to remove the upstop/spacer from the
pedal. Push the cable end fitting out of upstop/
spacer.
NOTE: If the adjuster mechanism does not function Fig. 13 Clutch Pedal Position Switch and
properly, the most likely cause is that the cable is Components (LHD Shown)
not properly seated in the bracket.
REMOVAL
(1) Disconnect electrical harness to switch connec-
ADJUSTER MECHANISM FUNCTION CHECK — LHD tor.
(1) With slight pressure, pull the clutch release (2) Depress wing tabs on switch and push switch
lever end of the cable to draw the cable taut. Push out of mounting bracket. Then slide wires through
the clutch cable housing toward the dash panel (With slot in bracket.
less than 20 lbs. of effort, the cable housing should
move 30-50mm.). This indicates proper adjuster INSTALLATION
mechanism function. If the cable does not adjust, (1) Slide switch wires through slot in switch
determine if the mechanism is properly seated on the bracket.
bracket. (2) Line up switch tab with slot in switch bracket
(2) If the adjust mechanism functions properly, and push switch into position. Do not pull on the
route cable to the transaxle. Install battery and cable switch wires to seat switch into bracket, switch dam-
guide. age may occur.
(3) Snap cable into cable guide located at the left (3) Attach switch wiring harness to vehicle wiring
shock tower. harness. Attach switch panel to the dash panel
(4) Insert cable into transaxle and through clutch bracket (Fig. 13).
release lever. Ensure the cable is routed through the (4) After installation, the switch must be checked
smaller hole in the transaxle deck (Fig. 10). for proper operation. Refer to Diagnosis and Testing
(5) Pull down on cable and insert cable retaining section for proper testing procedures.
clip onto clutch cable end.
(6) Check clutch pedal position switch operation.
NS/GS CLUTCH 6 - 11
REMOVAL AND INSTALLATION (Continued)
REMOVAL
1. Disconnect the quick connect coupling to facili-
tate the removal of the master cylinder assembly and
slave cylinder assembly separately (Fig. 14). Refer to
the removal and installation procedure in this section
for detailed instructions on disconnecting and con- Fig. 15 Self-Retaining Snap-on Bushing — RHD
necting the quick connect coupling.
INSTALLATION
2. Remove the master cylinder assembly (Fig. 15).
1. For installation of the hydraulic clutch linkage
Refer to the master cylinder removal and installation
system, reverse the above procedure.
procedure in this section for detailed instructions on
removal of the master cylinder assembly.
6 - 12 CLUTCH NS/GS
REMOVAL AND INSTALLATION (Continued)
MASTER CYLINDER SYSTEM — RHD
REMOVAL
(1) Disconnect the quick connect coupling. Refer to
the “Quick Connect Coupling” removal and installa-
tion procedure in this section.
(2) Remove the master cylinder pushrod from the
clutch pedal pin by prying between the self-retaining
snap-on bushing, located in the master cylinder
pushrod, and the clutch pedal pin (Fig. 15).
(3) Disconnect the hydraulic line from the weld
stud clips (Fig. 14).
(4) Remove the rubber grommet at the master cyl-
inder pass through in the dash panel (Fig. 16).
(5) Remove the master cylinder assembly from the
engine compartment by rotating it clockwise from the
12 o’clock lock position to the 2 o’clock unlock posi-
tion and pulling the master cylinder out tilted 20
degrees down. NOTE: A “Twist and Lock” type
mechanism is used to secure the master cylin-
der to the clutch pedal bracket which is
attached to the dash panel.
Fig. 16 Clutch Master Cylinder — RHD
INSTALLATION
QUICK CONNECT COUPLING — RHD (1) Position the master cylinder assembly to the
clutch pedal bracket by tilting it 20 degrees upward
CAUTION: Do not actuate the master cylinder or and at the 2 o’clock unlocked position.
step on the clutch pedal before the quick connect (2) Rotate the master cylinder counterclockwise to
coupling is joined, or an over pressure condition the 12 o’clock locked position.
could result in damage to the master cylinder, the (3) Install the rubber grommet into the dash panel
quick connect coupling, or the dash panel. at the master cylinder pass through (Fig. 16).
(4) Connect the hydraulic line to the weld stud
REMOVAL clips in the engine compartment (Fig. 14).
1. Disconnect the quick connect coupling by lightly (5) Connect the quick connect coupling. Refer to
pushing down on the black release collar on the male the “Quick Connect Coupling” removal and installa-
side of the quick connect coupling while separating it tion procedure in this section.
from the female side of the quick connect coupling (6) Install the self-retaining snap-on bushing into
(Fig. 14). the master cylinder pushrod, if necessary.
(7) Install the master cylinder pushrod with self-
INSTALLATION retaining snap-on bushing onto the clutch pedal pin
1. Connect the male side of the quick connect cou- by pressing it onto the clutch pedal pin until seats in
pling (part of the master cylinder assembly) by hold- the groove of the clutch pedal pin.
ing the clutch tube at the rear and inserting it into
the female side of the quick connect coupling (part of SLAVE CYLINDER ASSEMBLY — RHD
the slave cylinder assembly) until an audible click is
heard (Fig. 14). Do not push on the black release REMOVAL
collar on the male side of the quick connect 1. Disconnect the quick connect coupling. Refer to
coupling while inserting it into the female side the “Quick Connect Coupling” removal and installa-
of the quick connect coupling. tion procedure in this section.
2. Confirm the connection by pulling firmly on the 2. Remove the nut and washer assemblies (2)
clutch tube. retaining the slave cylinder and mounting bracket
assembly to the transaxle (Fig. 14).
3. Remove the slave cylinder assembly from the
transaxle.
NS/GS CLUTCH 6 - 13
REMOVAL AND INSTALLATION (Continued)
INSTALLATION To service the flywheel, refer to Group 9, Engine.
1. Position the slave cylinder assembly to the tran-
saxle deck and secure with the nut and washer
assemblies (2) and tighten to specifications (Fig. 14).
2. Make sure the slave cylinder pushrod is prop-
erly seated in the cup end of the clutch release lever.
3. Connect the quick connect coupling. Refer to the
“Quick Connect Coupling” removal and installation
procedure in this section.
Fig. 17 Modular Clutch Assembly — 2.0L and 2.4L CAUTION: Do not flat-machine the flywheel face.
The surface profile is slightly tapered and has a
CLUTCH ASSEMBLY (2.5L DIESEL) 0.30 mm step.
The transaxle must be removed to service the
clutch disc assembly and components. The disc assembly should be handled without
touching the facings. Replace disc if the facings show
REMOVAL evidence of grease or oil soakage, or wear to within
(1) Remove the transaxle, refer to Group 21, Tran- less than .38 mm (.015 inch) of the rivet heads. The
saxle. splines on the disc hub and transaxle input shaft
(2) Install universal clutch alignment tool into the should be a snug fit without signs of excessive wear.
clutch assembly (this will prevent the clutch from Metallic portions of disc assembly should be dry and
inadvertently being dropped). clean, and not been discolored from excessive heat.
(3) To avoid distortion of the pressure plate, Each of the arched springs between the facings
remove the clutch pressure plate bolts a few turns at should not be broken and all rivets should be tight.
a time. Use a crisscross pattern until all bolts are Wipe the friction surface of the pressure plate with
loosened. mineral spirits.
(4) Carefully remove the clutch pressure plate and Using a straight edge, check clutch cover (pressure
disc (Fig. 18). plate) for flatness. The clutch cover (pressure plate)
6 - 14 CLUTCH NS/GS
REMOVAL AND INSTALLATION (Continued)
friction area should be slightly concave, with the CLUTCH RELEASE BEARING AND FORK
inner diameter 0.02 mm to 0.1 mm (.0008 in. to .0039 Remove the transaxle from the vehicle. See Group
in.) below the outer diameter. It should also be free 21, for removal and installation procedures.
from discoloration, burned areas, cracks, grooves, or
ridges. REMOVAL
Using a surface plate, test cover for flatness. All (1) Remove clutch release shaft E-clip (Fig. 20).
sections around attaching bolt holes should be in con-
tact with surface plate within .015 inch.
The cover should be a snug fit on flywheel dowels.
If the clutch assembly does not meet these require-
ments, it should be replaced.
INSTALLATION
(1) Position the clutch and pressure plate onto the
flywheel.
(2) Insert the universal clutch alignment tool into
the clutch disc.
(3) To avoid distortion of the pressure plate, bolts
should be tightened a few turns at a time (Fig. 19).
Use a crisscross pattern until all bolts are seated.
Tighten pressure plate bolts to 27 N·m (20 ft. lbs.).
OIL CONTAMINATION
Oil contamination indicates a leak at the rear main
seal and/or transaxle input shaft. Oil leaks produce a
residue of oil on the transaxle housing interior, clutch
cover and flywheel. Heat buildup caused by slippage
can bake the oil residue onto the components. This
glaze-like residue ranges in color from amber to
Fig. 22 Clutch Release Fork black.
COOLING SYSTEM
CONTENTS
page page
DESCRIPTION AND OPERATION CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
WATER PIPES—3.0L ENGINE and distilled water mix is recommended.
The 3.0L engine uses metal piping beyond the
lower radiator hose to route (suction) coolant to the Where required, a 56 percent glycol and 44 percent
water pump, which is located in the V of the cylinder water mixture will provide a freeze point of -59°C
banks (Fig. 10). (-50°F).
These pipes are provided with inlet nipples for
CAUTION: Richer mixtures cannot be measured
thermostat bypass and heater return coolant hoses,
with field equipment. This can lead to problems
and brackets for rigid engine attachment. The pipes
associated with 100 percent glycol.
employ O-rings for sealing at their interconnection
and to the water pump (Fig. 10).
RADIATOR HOSES AND CLAMPS
WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT 15 MINUTES BEFORE WORKING
ON VEHICLE. RELIEVE PRESSURE BY PLACING A
SHOP TOWEL OVER THE CAP AND WITHOUT
PUSHING DOWN ROTATE IT COUNTERCLOCKWISE
TO THE FIRST STOP. ALLOW FLUIDS AND STEAM
TO ESCAPE THROUGH THE OVERFLOW TUBE.
THIS WILL RELIEVE SYSTEM PRESSURE
SERVICE PROCEDURES
COOLANT LEVEL CHECK—ROUTINE
Do not remove radiator cap for routine cool-
ant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without
removing the radiator cap. With the engine cold
and not running, simply observe the level of the
coolant in the reserve tank (Fig. 3). The coolant level
should be between the minimum and maximum
marks. Fig. 15 Coolant Temperature Sensor—2.4L Engine
Drain/Fill
COOLANT—ADDING ADDITIONAL Removal of a sensor is required because the ther-
The radiator cap should not be removed. mostat does not have an air vent. Sensor removal
When additional coolant is needed to maintain this allows an air bleed for coolant to drain from the
level, it should be added to the coolant reserve tank. engine block.
Use only 50/50 mix of ethylene glycol type antifreeze
and water. COOLING SYSTEM—REFILLING
First clean system to remove old coolant, see Cool-
CAUTION: Do not use well water, or suspect water ing System Cleaning.
supply in cooling system. A 50/50 ethylene glycol Fill the system, using the correct antifreeze as
and distilled water mix is recommended. described in the Coolant Section. Fill the system to
50 percent of its capacity with 100 percent glycol.
COOLANT LEVEL SERVICE Then complete filling system with water. The 2.4L
engine requires venting by removal of the coolant
The cooling system is closed and designed to main-
sensor on top of the water outlet connector (Fig. 15).
tain coolant level to the top of the radiator.
When coolant reaches this hole:
When servicing requires a coolant level check in
• Install coolant sensor and tighten to 7 N·m (60
the radiator, the engine must be off and not under
in. lbs.) for 2.4L Engines.
pressure. Drain several ounces of coolant from the
radiator draincock while observing the Coolant
NS COOLING SYSTEM 7 - 17
SERVICE PROCEDURES (Continued)
Continue filling system until full, this provides bet- (2) Assemble pump body to block and tighten
ter heater performance. Be careful not to spill screws to 12 N·m (105 in. lbs.) (Fig. 16). Pressurize
coolant on drive belts or the generator. cooling system to 15 psi with pressure tester and
Fill coolant reserve system to at least the MAX check water pump shaft seal and O-ring for leaks.
mark with 50/50 solution. It may be necessary to add (3) Rotate pump by hand to check for freedom of
coolant to the reserve tank after three or four warm movement.
up/cool down cycles to maintain coolant level between (4) Install rear timing belt cover.
the MAX and MIN mark. This will allow trapped air (5) Install camshaft sprockets and torque bolts to
to be removed from the system. 101 N·m (75 ft. lbs.).
(6) Install timing belt idler pulley and torque
mounting bolt to 61 N·m (45 ft. lbs.).
REMOVAL AND INSTALLATION (7) Install timing belt. Refer to Group 9, Engine,
2.4L Timing Belt.
WATER PUMP—2.4L ENGINE (8) Install right engine mount bracket and engine
mount. Refer to Group 9 for procedure.
REMOVAL
(9) Fill cooling system. See Cooling System Fill-
(1) Disconnect negative cable from battery.
ing.
(2) Raise vehicle on a hoist. Remove right inner
(10) Install accessory drive belts, Refer to Acces-
splash shield.
sory Drive Belts, in this section.
(3) Remove accessory drive belts. Refer to Acces-
(11) Lower vehicle and connect battery cable.
sory Drive Belt service in this section.
(4) Drain cooling system. Refer to Cooling System
Draining in this section.
(5) Support engine from the bottom and remove
right engine mount.
(6) Remove right engine mount bracket.
(7) Remove timing belt. Refer to Group 9, Engine
for procedure.
(8) Remove timing belt idler pulley.
(9) Hold camshaft sprocket with Special tool
C-4687 and adaptor C-4687-1 while removing bolt.
Remove both cam sprockets.
(10) Remove rear timing belt cover.
(11) Remove water pump attaching screws to Fig. 17 Water Pump Body
engine (Fig. 16). WATER PUMP INLET TUBE—2.4L ENGINE
REMOVAL
(1) Drain cooling system. Refer to procedure out-
lined in this section.
(2) Remove upper radiator hose to access the hose
connections at the inlet tube.
(3) Remove lower radiator hose and heater hose
from the inlet tube (Fig. 18).
(4) Remove the 2 fasteners that hold the inlet
tube to the block.
(5) Rotate tube while removing the tube from the
engine block (Fig. 19).
Fig. 16 Water Pump—2.4L Engine
INSTALLATION
INSTALLATION
(1) Inspect the O-ring for damage before installing
(1) Install new O-ring gasket in water pump body
the tube into the cylinder block (Fig. 19).
O-ring groove (Fig. 17).
(2) Lube O-ring with coolant and install into the
CAUTION: Make sure O-ring is properly seated in cylinder block opening.
water pump groove before tightening screws. An (3) Install 2 fasteners and tighten to 12 N·m (105
improperly located O-ring may cause damage to the in. lbs.).
O-ring and cause a coolant leak. (4) Connect lower radiator hose and heater hose
to inlet tube (Fig. 18).
7 - 18 COOLING SYSTEM NS
REMOVAL AND INSTALLATION (Continued)
(5) Install upper radiator hose.
(6) Fill cooling system. Refer to procedure outlined
in this section.
INSPECTION
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks, if the shaft seal is leaking, evi-
dent by traces of coolant leaks from vent hole A in Fig. 22 Water Pipe O-Ring
(Fig. 21).
NS COOLING SYSTEM 7 - 19
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Clean all gasket and O-ring surfaces on pump
and water pipe inlet tube.
(2) Install new O-ring on water inlet pipe (Fig.
22). Wet the O-ring (with water) to ease assembly.
THERMOSTAT—3.0L ENGINE
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. Refer to Draining Cooling System in this
group.
(2) Remove thermostat housing bolts and housing
(Fig. 26). Fig. 27 Thermostat Installed—3.0L Engine
(3) Remove thermostat, discard gasket and clean THERMOSTAT—3.3/3.8L ENGINES
both gasket sealing surfaces.
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. Refer to Cooling System Draining in this
section.
(2) Remove thermostat housing bolts and housing
(Fig. 28).
(3) Remove thermostat, discard gasket and clean
both gasket sealing surfaces.
REMOVAL
To remove the air conditioning compressor drive
belt, first loosen the idler pulley lock nut, then turn
the adjusting screw to lower the idler pulley (Fig.
35).
CHEMICAL CLEANING
One type of corrosion encountered with aluminum
cylinder heads is aluminum hydroxide deposits. Cor-
rosion products are carried to the radiator and depos-
ited when cooled off. They appear as dark grey when
wet and white when dry. This corrosion can be
Fig. 37 Serpentine Drive Belt Wear Patterns removed with a two part cleaner (oxalic acid and
RADIATOR PRESSURE CAP neutralizer) available in auto parts outlets. Follow
manufacturers directions for use.
INSPECTION
Hold the cap in hand, right side up. The vent
ADJUSTMENTS
valve at the bottom of the cap should open. If the
rubber gasket has swollen and prevents the valve
PROPER BELT TENSION
from opening, replace the cap.
Satisfactory performance of the belt driven accesso-
Hold the cleaned cap in hand upside down. If any
ries depends on proper belt tension. Belt tensioning
light shows between vent valve and rubber gasket,
should be performed with the aid of a Burroughs
replace cap. Do not use a replacement cap that
gauge Special Tool C-4162. Because of space limita-
has a spring to hold the vent shut.
tions in the engine compartment, the use of the
Replacement cap must be of the type designed for
gauge may be restricted. Raise the vehicle on a hoist
coolant reserve system with a completely sealed dia-
phragm spring, and rubber gasket to seal to filler
7 - 26 COOLING SYSTEM NS
ADJUSTMENTS (Continued)
and the remove the splash shield to gain access to SPECIFICATIONS
the drive belts.
COOLING SYSTEM CAPACITY
BELT TENSION GAUGE METHOD
Use belt tensioning Special Tool Kit C-4162 for: Engine Standard Duty Trailer Tow or
Heavy Duty
CAUTION: The Burroughs gauge for the Poly-V Front Rear Front Rear
belt is not to be used on the V-belt. These gauges Heater Heater Heater Heater
are not interchangeable.
2.4L 10.6 N/A N/A N/A
• For conventional V-belts affix the Burroughs liters*
gauge (Special Tool C-4162) to the belt. Adjust the (11.23
belt tension for New or Used belt as prescribed in the qts.)*
Belt Tension Chart. 3.0L 12.3 N/A N/A 15.0
• For a Poly-V belt affix the Poly-V Burroughs liters* liters*
gauge to the belt and then apply specified tension to (13.0 (15.9
the belt as prescribed in the Belt Tension Chart qts.)* qts.)*
Adjust belt tension for a New or Used belt as pre- 3.3/3.8L 12.5 15.26 12.5 15.26
scribed in the Belt Tension Chart. liters* liters* liters* liters*
BELT TENSION CHART (13.23 (16.13 (13.23 (16.13
qts.)* qts.)* qts.)* qts)*
ACCESSORY DRIVE
GAUGE *Includes Heater and Coolant Recovery Tank Filled to
BELT Max Level.
2.4L ENGINE
A/C COMPRESSOR / NEW 190 LB. TORQUE CHART
GENERATOR USED 115 LB.
DESCRIPTION TORQUE
POWER STEERING NEW 140 LB. Thermostat Housing
USED 90 LB. Bolts—2.4L & 3.3/3.8L . . . . . .28 N·m (250 in. lbs.)
3.0L ENGINE Bolts—3.0L . . . . . . . . . . . . . . .12 N·m (105 in. lbs.)
Water Pump Mounting
A/C COMPRESSOR NEW 150 LB.
Bolts—2.4L & 3.3/3.8L . . . . . .12 N·m (250 in. lbs.)
USED 80 LB. Bolts—3.0L . . . . . . . . . . . . . . .27 N·m (240 in. lbs.)
GENERATOR / POWER DYNAMIC TENSIONER Water Pump Inlet Tube
STEERING Bolts—2.4L . . . . . . . . . . . . . . .12 N·m (250 in. lbs.)
3.3/3.8L ENGINES Bolts—3.0L . . . . . . . . . . . . . . . .11 N·m (94 in. lbs.)
A/C COMPRESSOR DYNAMIC TENSIONER Water Pump Pulley
Bolts—3.3/3.8L . . . . . . . . . . . .28 N·m (250 in. lbs.)
GENERATOR / WATER DYNAMIC TENSIONER Transaxle Oil Cooler Hose
PUMP / POWER Clamps—All Engines . . . . . . . . .2 N·m (18 in. lbs.)
STEERING
Radiator Mounting Upper Bracket
Nut—All Engines . . . . . . . . . .12 N·m (105 in. lbs.)
SPECIAL TOOLS
COOLING
COOLING SYSTEM
CONTENTS
page page
2.0L GASOLINE
The water has a diecast aluminum body and hous-
ing with a stamped steel impeller. The water pump
7-4 COOLING SYSTEM NS/GS
DESCRIPTION AND OPERATION (Continued)
SERVICE PROCEDURES
ADDING ADDITIONAL COOLANT
2.5L VM DIESEL
Do not remove coolant bottle pressure cap when
the engine is hot. Remove pressure cap and fill cool-
ant bottle between Min and Max lines inside filler
neck. Use only 50/50 mix of ethylene glycol type anti-
freeze and water (Fig. 13). Squeezing radiator hoses
may help purge air from the cooling system.
2.5L VM DIESEL
First clean system to remove old glycol, see Cooling
Fig. 13 Coolant Pressure Bottle—2.5L VM Diesel System Cleaning.
(1) Disconnect upper radiator hose at thermostat
DRAINING COOLING SYSTEM housing.
(2) Remove pressure cap from coolant expansion
2.0L GASOLINE
tank.
To drain cooling system move temperature selector
(3) Fill cooling system through upper radiator hose
for heater to full heat with engine running. Without
until coolant starts to leak out at the thermostat
removing radiator pressure cap and with sys-
housing. Reconnect hose and re-install clamp.
tem not under pressure, Shut engine off and open
(4) Fill expansion tank to top of bottle. Run engine
draincock. The coolant reserve tank should empty
at idle without pressure cap installed for 5 minutes.
first, then remove radiator pressure cap and let the
Squeeze upper radiator hose several times.
radiator drain (if not, see Testing Cooling System for
(5) Shut off engine. Top off coolant and install
leaks).
pressure cap.
2.5L VM DIESEL (6) Inspect system for leaks.
The cooling system does not have a radiator
mounted pressure cap. Instead the pressure cap is REMOVAL AND INSTALLATION
mounted on the coolant pressure bottle (Fig. 14).
(1) Shut off engine. WATER PUMP — 2.0L GASOLINE
(2) Remove radiator pressure cap.
(3) Open draincock and allow coolant to drain. REMOVAL
(1) Remove accessory drive belts and power steer-
ing pump.
(2) Drain cooling system.
7-8 COOLING SYSTEM NS/GS
REMOVAL AND INSTALLATION (Continued)
(3) Remove power steering pump bracket bolts and
set pump and bracket assembly aside. Power steering
lines do not need to be disconnected.
(4) Remove timing belt.
(5) Remove inner timing belt cover.
(6) Remove water pump attaching screws to engine
(Fig. 15).
INSTALLATION
(1) Install generator/power steering belt.
(2) Tighten adjusting nut.
(3) Tighten adjusting bracket bolt.
(4) Tighten generator pivot bolt.
WATER PUMP
Replace the water pump if it has any of the follow-
ing defects.
Fig. 22 Right Side Splash Shield (1) Damage or cracks on the pump body.
NS/GS COOLING SYSTEM 7 - 11
CLEANING AND INSPECTION (Continued)
ADJUSTMENTS
BELT TENSION GAUGE METHOD
Use belt tensioning Special Tool Kit C-4162 for:
SPECIFICATIONS
COOLING SYSTEM CAPACITY
2.0L Gasoline *10.6 liters (11 qts.)
2.5L VM Diesel *10.0 liters (10.6 qts.)
*Includes Heater and Coolant recovery/pressure Tank.
TORQUE CHART
COMPONENT 2.0L 2.5L VM
GASOLINE
Thermostat 105 in-lbs 10.8 N·m (96 in.
Cover Bolts lbs.)
Water Pump 12 N·m (105 in. 22.6 N·m (204
Mounting Bolts lbs.) in. lbs.)
Water Pump N/A 27.5 N·m (240
Pulley Bolts in. lbs.)
Upper Radiator 12 N·m (105 in. 12 N·m (105 in.
Mounting lbs.) lbs.)
Bracket Bolts
Turbocharger N/A 24.5 N·m (215
Oil Supply Line in. lbs.)
Turbocharger N/A 10.8 N·m (96 in.
Oil Return Line lbs.)
Water Pump N/A 9.5 N·m (84 in.
Housing Nuts lbs.)
Water Manifold N/A 11.2 N·m (96 in.
Bolts lbs.)
Coolant Bottle 2.0 N·m (18 in. 10.8 N·m (96 in.
Bolts lbs.) lbs.)
SPECIAL TOOLS
COOLING
BATTERY
CONTENTS
page page
INTRODUCTION
The battery stores, stabilizes, and delivers electri- WARNING: DO NOT ALLOW JUMPER CABLE
cal current to operate various electrical systems in CLAMPS TO TOUCH EACH OTHER WHEN CON-
the vehicle. The determination of whether a battery NECTED TO A BOOSTER SOURCE. DO NOT USE
is good or bad is made by its ability to accept a OPEN FLAME NEAR BATTERY. REMOVE METALLIC
charge. It also must supply high-amperage current JEWELRY WORN ON HANDS OR WRISTS TO AVOID
for a long enough period to be able to start the vehi- INJURY BY ACCIDENTAL ARCING OF BATTERY
cle. The capability of the battery to store electrical CURRENT.
current comes from a chemical reaction. This reac- WHEN USING A HIGH OUTPUT BOOSTING DEVICE,
tion takes place between the sulfuric acid solution DO NOT ALLOW THE DISABLED VEHICLE’S BAT-
(electrolyte) and the lead +/- plates in each cell of the TERY TO EXCEED 16 VOLTS. PERSONAL INJURY
battery. As the battery discharges, the plates react OR DAMAGE TO ELECTRICAL SYSTEM CAN
with the acid from the electrolyte. When the charging RESULT.
system charges the battery, the water is converted to TO PROTECT THE HANDS FROM BATTERY ACID, A
sulfuric acid in the battery. The concentration of acid SUITABLE PAIR OF HEAVY DUTY RUBBER
in the electrolyte is measured as specific gravity GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD
using a hydrometer. The original equipment (OE) BE WORN WHEN REMOVING OR SERVICING A
battery is equipped with a hydrometer (test indica- BATTERY. SAFETY GLASSES ALSO SHOULD BE
tor) built into the battery cover. The specific gravity WORN.
indicates the battery’s state-of-charge. The OE bat-
tery is sealed and water cannot be added.
The battery is vented to release gases that are cre-
DESCRIPTION AND OPERATION
ated when the battery is being charged and dis-
charged. The battery top, posts, and terminals should
BATTERY IGNITION OFF DRAW (IOD)
be cleaned when other under hood maintenance is
A completely normal vehicle will have a small
performed.
amount of current drain on the battery with the key
When the electrolyte level is below the top of the
out of the ignition. It can range from 5 to 25 milli-
plates, Clear in the test Indicator, the battery must
amperes after all the modules time out. If a vehicle
be replaced. The battery must be completely charged,
will not be operated for approximately a 20 days, the
and the battery top, posts, and cable clamps must be
IOD fuse should be pulled to eliminate the vehicle
cleaned before diagnostic procedures are performed.
electrical drain on the battery. The IOD fuse is
8A - 2 BATTERY NS
DESCRIPTION AND OPERATION (Continued)
located in the Power Distribution Center (PDC).
Refer to the PDC cover for proper fuse.
SIZE OF BATTERY
A completely discharged large heavy-duty battery
Fig. 1 Reading Test Indicator
may require more recharging time than a completely
discharged small capacity battery, refer to the Bat- DIAGNOSIS AND TESTING
tery Charging Timetable for charging times.
BATTERY CHARGING TIMETABLE BATTERY BUILT-IN TEST INDICATOR
USING TEST INDICATOR
Charging 5 10 20 The Test Indicator (Fig. 1), (Fig. 2) and (Fig. 3)
Amperage Amperes Amperes Amperes measures the specific gravity of the electrolyte. Spe-
Open Circuit cific Gravity (SG) of the electrolyte will show state-
Hours Charging at 21°C (70°F) of-charge (voltage). The test indicator WILL NOT
Voltage
show cranking capacity of the battery. Refer to Bat-
12.25 to 12.39 6 hours 3 hours 1.5 hours tery Load Test for more information. Look into the
12.00 to 12.24 8 hours 4 hours 2 hours sight glass (Fig. 1), (Fig. 3) and note the color of the
11.95 to 11.99 12 hours 6 hours 3 hours indicator. Refer to the following description of colors:
10.00 to 11.94 14 hours 7 hours 3.5 hours NOTE: GREEN = 75 to 100% state-of-charge
less than 10.00 See Charging Completely
Discharged Battery
TEMPERATURE
A longer time will be needed to charge a battery at
-18°C (0°F) than at 27°C (80°F). When a fast charger
is connected to a cold battery, current accepted by
battery will be very low at first. In time, the battery
will accept a higher rate as battery temperature
warms.
CHARGER CAPACITY
A charger which can supply only five amperes will
require a much longer period of charging than a
charger that can supply 20 amperes or more.
Temperature
Minimum Voltage
°F °C
9.6 volts 70° and above 21° and above
9.5 volts 60° 16°
9.4 volts 50° 10°
Fig. 6 Volt-Ammeter Load Tester Connections 9.3 volts 40° 4°
(3) Allow the battery to stabilize for 2 minutes, 9.1 volts 30° -1°
and then verify open circuit voltage. 8.9 volts 20° -7°
(4) Rotate the load control knob on the tester to
8.7 volts 10° -12°
maintain 50% of the battery cold crank rating for 15
seconds (Fig. 8). Record the loaded voltage reading 8.5 volts 0° -18°
and return the load control to off. Refer to the Bat-
tery Specifications at the rear of this Group. (6) If battery passes load test, it is in good condi-
(5) Voltage drop will vary according to battery tion and further tests are not necessary. If it fails
temperature at the time of the load test. Battery load test, it should be replaced.
8A - 6 BATTERY NS
DIAGNOSIS AND TESTING (Continued)
BATTERY OPEN CIRCUIT VOLTAGE TEST SERVICE PROCEDURES
An open circuit voltage no load test shows the
state of charge of a battery and whether it is ready BATTERY CHARGING
for a load test at 50 percent of the battery’s cold
crank rating. Refer to Battery Load Test. If a battery WARNING: DO NOT CHARGE A BATTERY THAT
has open circuit voltage reading of 12.4 volts or HAS EXCESSIVELY LOW ELECTROLYTE LEVEL.
greater, and will not pass the load test, replace the BATTERY MAY SPARK INTERNALLY AND
battery because it is defective. To test open circuit EXPLODE. EXPLOSIVE GASES FORM OVER THE
voltage, perform the following operation. BATTERY. DO NOT SMOKE, USE FLAME, OR CRE-
(1) Remove both battery cables, negative cable ATE SPARKS NEAR BATTERY. DO NOT ASSIST
first. Battery top, cables and posts should be clean. If BOOST OR CHARGE A FROZEN BATTERY. BAT-
green dot is not visible in indicator, charge the bat- TERY CASING MAY FRACTURE. BATTERY ACID IS
tery. Refer to Battery Charging Procedures. POISON, AND MAY CAUSE SEVERE BURNS. BAT-
(2) Connect a Volt/Ammeter/Load tester to the bat- TERIES CONTAIN SULFURIC ACID. AVOID CON-
tery posts (Fig. 6). Rotate the load control knob of the TACT WITH SKIN, EYES, OR CLOTHING. IN THE
Carbon pile rheostat to apply a 300 amp load. Apply EVENT OF CONTACT, FLUSH WITH WATER AND
this load for 15 seconds to remove the surface charge CALL PHYSICIAN IMMEDIATELY. KEEP OUT OF
from the battery, and return the control knob to off REACH OF CHILDREN.
(Fig. 7).
(3) Allow the battery to stabilize for 2 minutes,
CAUTION: Disconnect the battery NEGATIVE cable
and then verify the open circuit voltage (Fig. 9).
first. (Fig. 4) before charging battery to avoid dam-
(4) This voltage reading will approximate the state
age to electrical systems. Do not exceed 16.0 volts
of charge of the battery. It will not reveal battery
while charging battery. Refer to the instructions
cranking capacity. Refer to Battery Open Circuit
supplied with charging equipment
Voltage table.
CHARGING COMPLETELY DISCHARGED BATTERY (1) Clean top of battery with a solution of warm
The following procedure should be used to recharge water and baking soda.
a completely discharged battery. Unless procedure is (2) Apply soda solution with a bristle brush and
properly followed, a good battery may be needlessly allow to soak until acid deposits loosen (Fig. 11).
replaced. Refer to Battery Charging Rate table.
BATTERY CHARGING RATE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
REMOVAL
(1) Verify that the ignition switch and all accesso-
ries are OFF.
(2) Disconnect battery cable terminals from the
battery posts, negative first (Fig. 14).
BATTERY TRAY
REMOVAL
(1) Remove battery, refer to the above procedures.
(2) Remove nut and two bolts from battery tray
(Fig. 18).
(3) Remove battery tray from vehicle.
(4) Remove speed control servo attaching bolt from
battery tray (if equipped). Use care when disconnect-
ing vacuum lines from reservoir (Fig. 19).
INSTALLATION
For installation, reverse the above procedures.
TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt Clamp
Bolt . . . . . . . . . . . . . . . . . . . .14 N·m (125 in. lbs.)
BATTERY
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION
The battery stores, stabilizes, and delivers electri-
cal current to operate various electrical systems in
the vehicle (Fig. 1). The determination of whether a
battery is good or bad is made by its ability to accept
a charge. It also must supply high-amperage current
for a long enough period to be able to start the vehi-
cle. The capability of the battery to store electrical
current comes from a chemical reaction. This reac-
tion takes place between the sulfuric acid solution
(electrolyte) and the lead +/- plates in each cell of the
battery. As the battery discharges, the plates react
with the acid from the electrolyte. When the charging
system charges the battery, the water is converted to
sulfuric acid in the battery. The concentration of acid Fig. 1 Battery Construction
in the electrolyte is measured as specific gravity SAFETY PRECAUTIONS AND WARNINGS
using a hydrometer. The specific gravity indicates the
battery’s state-of-charge. WARNING:
The battery is vented to release gases that are cre- DO NOT ALLOW JUMPER CABLE CLAMPS TO
ated when the battery is being charged and dis- TOUCH EACH OTHER WHEN CONNECTED TO A
charged. BOOSTER SOURCE.
The battery top, posts, and terminals should be DO NOT USE OPEN FLAME NEAR BATTERY.
cleaned when other under hood maintenance is per- REMOVE METALLIC JEWELRY WORN ON
formed. HANDS OR WRISTS TO AVOID INJURY BY ACCI-
The battery top, posts, cable clamps must be DENTAL ARCING OF BATTERY CURRENT.
cleaned and battery must be completely charged WHEN USING A HIGH OUTPUT BOOSTING
before diagnostic procedures are performed. DEVICE, DO NOT ALLOW THE DISABLED VEHI-
CLE’S BATTERY TO EXCEED 16 VOLTS. PER-
SONAL INJURY OR DAMAGE TO ELECTRICAL
SYSTEM CAN RESULT.
TO PROTECT THE HANDS FROM BATTERY
ACID, A SUITABLE PAIR OF HEAVY DUTY RUB-
8A - 2 BATTERY NS/GS
GENERAL INFORMATION (Continued)
BER GLOVES, NOT THE HOUSEHOLD TYPE, CHARGER CAPACITY
SHOULD BE WORN WHEN REMOVING OR SER- A charger which can supply only five amperes will
VICING A BATTERY. SAFETY GLASSES ALSO require a much longer period of charging than a
SHOULD BE WORN. charger that can supply 20 amperes or more.
STATE OF CHARGE
DESCRIPTION AND OPERATION A completely discharged battery requires more
charging time than a partially charged battery. Elec-
BATTERY IGNITION OFF DRAW (IOD) trolyte is nearly pure water in a completely dis-
A completely normal vehicle will have a small charged battery. At first, the charging current
amount of current drain on the battery with the key amperage will be low. As water is converted back to
out of the ignition. It can range from 5 to 25 milli- sulfuric acid inside the battery, the current amp rate
amperes after all the modules time out. If a vehicle will rise. Also, the specific gravity of the electrolyte
will not be operated for approximately a 20 days, the will rise. The electrolyte should be tested with a
IOD fuse should be pulled to eliminate the vehicle Hydrometer to check the specific gravity.
electrical drain on the battery. The IOD fuse is
located in the Power Distribution Center (PDC). USING HYDROMETER
Refer to the PDC cover for proper fuse. Before performing a hydrometer test, remove the
battery caps and check the electrolyte level. Add dis-
CHARGING TIME REQUIRED tilled water as required.
WARNING: NEVER EXCEED 20 AMPS WHEN NOTE: Periodically disassemble the hydrometer
CHARGING A COLD -1°C (30°F) BATTERY. PER- and wash components with soap and water. Inspect
SONAL INJURY MAY RESULT. the float for possible leaks. If the paper inside has
turned brown, the float is defective.
The time required to charge a battery will vary
depending upon the following factors. Before testing, visually inspect the battery for any
damage:
SIZE OF BATTERY • Cracked container or cover
A completely discharged large heavy-duty battery • Loose post
may require more recharging time than a completely • Corrosion
discharged small capacity battery, refer to (Fig. 2) for and any other thing that would cause the battery
charging times. to be unserviceable. To interpret the hydrometer cor-
rectly, hold it with the top surface of the electrolyte
in the hydrometer at eye level.
Disregard the curvature of the liquid where the
surface rises against the float because of surface
cohesion (Fig. 3). Remove only enough electrolyte
from the battery to keep the float off the bottom of
the hydrometer barrel with pressure on the bulb
released. Keep the hydrometer in a vertical position
while drawing the electrolyte into the hydrometer
and observing the specific gravity. Exercise care
when inserting the tip of the hydrometer into a cell
to avoid damage to the separators. Damaged separa-
Fig. 2 Battery Charging Time tors can cause premature battery failure.
TEMPERATURE Hydrometer floats are generally calibrated to indi-
A longer time will be needed to charge a battery at cate the specific gravity correctly only at one fixed
-18°C (0°F) than at 27°C (80°F). When a fast charger temperature, 20°C (68°F). When testing the specific
is connected to a cold battery, current accepted by gravity at any other temperature, a correction factor
battery will be very low at first. In time, the battery is required, otherwise specific gravity readings will
will accept a higher rate as battery temperature not indicate the true state of charge.
warms. The correction factor is approximately a specific
gravity value of 0.004, referred to as 4 points of spe-
cific gravity for every 5.5°C (10°F). If electrolyte tem-
perature is below 20°C (68°F) you subtract. If the
temperature is above 20°C (68°F) you add to the
NS/GS BATTERY 8A - 3
DESCRIPTION AND OPERATION (Continued)
When the specific gravity of all cells is above 1.235
and variation between cells is less than 50 points
(0.050), the battery may be tested under heavy load.
(6) If battery passes load test, it is in good condi- Fig. 10 Battery Open Circuit Voltage
tion and further tests are not necessary. If it fails
load test, it should be replaced. SERVICE PROCEDURES
CAUTION: Do not overcharge Battery. Fig. 12 Voltmeter Accurate to 1/10 Volt (Connected)
Test the battery until the specific gravity reading enough voltage to activate this circuitry. This may
is 1.285 plus 0.015 or minus 0.010. happen even though the leads are connected properly.
After the battery has been charged to 12.4 volts or (3) Battery chargers vary in the amount of voltage
greater, perform a load test to determine cranking and current they provide. For the time required for
capacity. Refer to Battery Load Test in this Group. If the battery to accept measurable charger current at
the battery passes the load test, return the battery to various voltages, refer to (Fig. 11). If charge current
use. If battery will not endure a load test, it must be is still not measurable after charging times, the bat-
replaced. Properly clean and inspect battery hold tery should be replaced. If charge current is measur-
downs, tray, terminals, cables, posts, and top before able during charging time, the battery may be good,
completing service. and charging should be completed in the normal
manner.
CHARGING COMPLETELY DISCHARGED BATTERY
The following procedure should be used to recharge
VISUAL INSPECTION
a completely discharged battery. Unless procedure is
CAUTION: Do not allow baking soda solution to
properly followed, a good battery may be needlessly
enter vent holes, as damage to battery can result.
replaced (Fig. 11).
(1) Measure the voltage at battery posts with a (1) Clean top of battery with a solution of warm
voltmeter accurate to 1/10 volt (Fig. 12). If below 10 water and baking soda.
volts, charge current will be low, and it could take (2) Apply soda solution with a bristle brush and
some time before it accepts a current in excess of a allow to soak until acid deposits loosen (Fig. 13).
few milliamperes. Such low current may not be (3) Rinse soda solution from battery with clear
detectable on amp meters built into many chargers. water and blot battery dry with paper toweling. Dis-
(2) Connect charger leads. Some chargers feature pose of toweling in a safe manner. Refer to the
polarity protection circuitry that prevents operation WARNINGS on top of battery.
unless charger is connected to battery posts correctly. (4) Inspect battery case and cover for cracks, leak-
A completely discharged battery may not have age or damaged hold down ledge. If battery is dam-
aged replace it.
8A - 8 BATTERY NS/GS
SERVICE PROCEDURES (Continued)
REMOVAL
(1) Verify that the ignition switch and all accesso-
ries are OFF.
(2) Disconnect battery cable terminals from the
battery posts, negative first (Fig. 16).
3
(3) Remove battery hold down (Fig. 17).
(4) Remove battery from vehicle (Fig. 18).
INSTALLATION
Inspect and clean battery and attaching compo-
nents before installation.
(1) Install battery in vehicle making sure that bat-
tery is properly positioned on battery tray.
(2) Install battery hold down.
(3) Connect battery cable terminals, positive cable
first. Make sure the top of battery terminals are
flush with top of posts.
BATTERY TRAY
REMOVAL
(1) Remove battery, refer to the above procedures. Fig. 19 Battery Tray Removal
(2) Remove nut and two bolts from battery tray SPECIFICATIONS
(Fig. 19).
(3) Remove battery tray from vehicle. BATTERY SPECIFICATIONS
(4) Remove speed control servo attaching bolt from
battery tray (if equipped). Use care when disconnect- CRANKING RATING
ing vacuum lines from reservoir (Fig. 20). The current battery can deliver for 30 seconds and
maintain a terminal voltage of 7.2 volts or greater at
INSTALLATION specified temperature.
For installation, reverse the above procedures.
8A - 10 BATTERY NS/GS
SPECIFICATIONS (Continued)
TORQUE
DESCRIPTION TORQUE
Battery Hold Down Bolt Clamp
Bolt . . . . . . . . . . . . . . . . . . . 14 N·m (125 in. lbs.)
NS STARTER 8B - 1
STARTER
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION
The starting system has (Fig. 1):
• Ignition switch
• Starter relay
• Powertrain Control Module (PCM) double start
override
• Neutral starting and back up switch with auto-
matic transmissions only
• Wiring harness
• Battery
• Starter motor with an integral solenoid
• Positive Temperature Coefficient (PTC) is the
circuit protection for the ignition feed to the starter
relay coil. The PTC is located in the Junction Block.
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
IGNITION SWITCH
After testing starter solenoid and relay, test igni-
tion switch and wiring. Refer to Group 8D, Ignition
Systems or Group 8W, Wiring Diagrams. Check all
wiring for opens or shorts, and all connectors for
being loose or corroded.
BATTERY
Refer to Group 8A, Battery for proper procedures.
STARTER—3.0L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 8).
Fig. 11 Starter–3.0L Engine
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding solenoid wire to terminal STARTER—3.3/3.8L ENGINE
(Fig. 10).
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 8).
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding B+ terminal to starter
solenoid (Fig. 12).
SPECIFICATIONS
STARTER
MANUFACTURER NIPPONDENSO
Engine Application 2.4L /3.0L /3.3/3.8L
Power rating 1.2 Kw
Voltage 12 VOLTS
No. of Fields 4
No. of Poles 4
TORQUE
Fig. 14 Starter–3.3/3.8L Engine DESCRIPTION TORQUE
(4) Connect solenoid connector into starter. Starter Mounting Bolts. . . . . . . . .54 N·m (40 ft. lbs.)
(5) Install nut to hold B+ terminal to starter sole- Starter Solenoid Battery Nut . . . .10 N·m (90 in. lbs.)
noid.
(6) Lower vehicle.
(7) Connect battery negative cable.
NS/GS STARTING SYSTEM 8B - 1
STARTING SYSTEM
CONTENTS
page
REMOVAL
(1) Disconnect battery negative cable (Fig. 1).
INSTALLATION
(1) Place starter in position on vehicle.
(2) Install starter attaching bolts to transaxle bell-
housing and tighten to the proper torque
(3) Place solenoid and B+ wires in position on
starter terminals.
(4) Install nut to hold B+ wire to terminal.
(5) Connect solenoid wire connector onto terminal.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
INSTALLATION
(1) Place starter in position on vehicle.
(2) Install starter attaching bolts to transaxle bell-
housing and tighten to the proper torque.
(3) Place solenoid and B+ wires in position on
starter terminals.
(4) Install nut to hold B+ wire to terminal.
(5) Install nut to hold solenoid wire to terminal.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 1).
(3) Hoist and support vehicle on safety stands.
(4) Disconnect solenoid wire connector from termi-
nal.
(5) Remove nut holding B+ wire to terminal.
(6) Disconnect solenoid and B+ wires from starter
terminal.
(7) Remove three bolts holding starter to transaxle
bellhousing (Fig. 9).
(8) Remove starter.
INSTALLATION
For installation, reverse the above procedures and
verify the operation of the starter.
CHARGING SYSTEM
CONTENTS
page page
GENERATOR—3.0L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 3).
(3) Remove windshield wiper housing, refer to
Group 8K, Windshield Wipers and Washers for
proper procedures.
(4) Remove accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
Fig. 4 Wire Connectors (5) Remove bolt holding top of generator to mount
bracket (Fig. 6).
(5) Remove nut holding B+ wire to terminal on (6) Remove bolt holding bottom of generator to
back of generator. lower pivot bracket (Fig. 4).
(6) Separate B+ wire from generator terminal. (7) Disengage push-in field wire connector from
(7) Remove nut holding top of generator to adjust- back of generator.
able T-bolt (Fig. 5). (8) Remove nut holding B+ wire terminal to back
(8) Remove bolt holding bottom generator pivot to of generator.
lower mount. (9) Remove B+ terminal from generator.
(9) Remove generator.
INSTALLATION
INSTALLATION (1) Place B+ terminal in position on generator.
(1) Place generator in position on vehicle. (2) Install nut to hold B+ wire terminal to back of
(2) Install bolt to hold bottom generator pivot to generator
lower mount. (3) Connect the push-in field wire connector into
back of generator.
8C - 10 CHARGING SYSTEM NS
REMOVAL AND INSTALLATION (Continued)
GENERATOR—3.3/3.8 L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 3).
(3) Remove windshield wiper housing, refer to Fig. 8 Generator pivot Bolt
Group 8K, Windshield Wipers and Washers for
proper procedures.
(4) Remove accessory drive belt, refer to Group 7,
Cooling System for proper procedures.
(5) Remove bolt holding top of generator mount
bracket to engine air intake plenum (Fig. 7).
(6) Remove bolts holding outside of generator
mount bracket to generator mount plate.
(7) Remove bolt holding top of generator to mount
bracket.
(8) Remove generator mount bracket from vehicle.
(9) Rotate generator toward rear dash panel.
(10) Disconnect the push-in field wire connector
from back of generator (Fig. 6).
(11) Remove nut holding B+ wire terminal to back
of generator.
(12) Separate B+ terminal from generator. Fig. 9 Generator–3.3/3.8 L Engine
(13) Remove bolt holding bottom of generator to
lower pivot bracket (Fig. 8). INSTALLATION
(14) Remove generator from vehicle (Fig. 9). (1) Place generator in position on vehicle.
NS CHARGING SYSTEM 8C - 11
REMOVAL AND INSTALLATION (Continued)
(2) Install bolt to hold bottom of generator to lower SPECIFICATIONS
pivot bracket.
(3) Place B+ terminal in position on generator. GENERATOR
(4) Install nut to hold B+ wire terminal to back of
generator. Part Num- Amperage out-
(5) Connect the push-in field wire connector into Type
ber put
back of generator.
Nippondenso 90 A 4727220 86 Amp
(6) Rotate generator forward away from dash
HS
panel.
(7) Place generator mount bracket in position on Nippondenso 120 A 4727221 98 Amp
vehicle. HS
(8) Install bolt to hold top of generator to mount
bracket. Part number is located on the side of the generator.
(9) Install bolts to hold outside of generator mount
bracket to generator mount plate. TORQUE
(10) Install bolt to hold top of generator mount
bracket to engine air intake plenum. DESCRIPTION TORQUE
(11) Install accessory drive belt, refer to Group 7, Battery Hold Down Bolt . . . . . . .14 N·m (125 in. lbs.)
Cooling System for proper procedures. Generator Mounting Bolts . . . . . .54 N·m (40 ft. lbs.)
(12) Install windshield wiper housing, refer to Generator B+ Terminal . . . . . . . . .9 N·m (75 in. lbs.)
Group 8K, Windshield Wipers and Washers for Starter Mounting Bolts. . . . . . . . .54 N·m (40 ft. lbs.)
proper procedures. Starter Solenoid Battery Nut . . . .10 N·m (90 in. lbs.)
(13) Connect battery negative cable.
(14) Verify generator charge rate.
NS IGNITION SYSTEM 8D - 1
IGNITION SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INDEX
page page
Fig. 12 Engine Coolant Temperature Sensor—3.3/ Fig. 13 Throttle Position Sensor and Idle Air Control
3.8L Motor
THROTTLE POSITION SENSOR (TPS)
The TPS mounts to the side of the throttle body
(Fig. 13).
The TPS connects to the throttle blade shaft. The
TPS is a variable resistor that provides the Power-
train Control Module (PCM) with an input signal
(voltage). The signal represents throttle blade posi-
tion. As the position of the throttle blade changes,
the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the
TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade
position. The TPS output voltage to the PCM varies
from approximately 0.40 volt at minimum throttle
opening (idle) to a maximum of 3.80 volts at wide
open throttle.
Along with inputs from other sensors, the PCM Fig. 14 Ignition Lock Cylinder Detents
uses the TPS input to determine current engine oper-
ating conditions. The PCM also adjusts fuel injector
KNOCK SENSOR
The knock sensor threads into the side of the cyl-
pulse width and ignition timing based on these
inder block in front of the starter motor. When the
inputs.
knock sensor detects a knock in one of the cylinders,
LOCK KEY CYLINDER it sends an input signal to the PCM. In response, the
PCM retards ignition timing for all cylinders by a
The lock cylinder is inserted in the end of the
scheduled amount.
housing opposite the ignition switch. The ignition key
Knock sensors contain a piezoelectric material
rotates the cylinder to 5 different detents (Fig. 14):
which constantly vibrates and sends an input voltage
• Accessory
(signal) to the PCM while the engine operates. As the
• Off (lock)
intensity of the crystal’s vibration increase, the knock
• Unlock
sensor output voltage also increases.
• On/Run
• Start
8D - 8 IGNITION SYSTEM NS
GENERAL INFORMATION (Continued)
NOTE: Over or under tightening effects knock sen- (3) Plug the test spark plug cable onto #1 coil
sor performance, possibly causing improper spark tower. Make sure a good connection is made; there
control. should be a click sound.
(4) Crank the engine and look for spark across the
electrodes of the spark plug.
DIAGNOSIS AND TESTING CAUTION: Always install the cable back on the coil
tower after testing to avoid damage to the coil and
TESTING FOR SPARK AT COIL—2.4/3.3/3.8L catalytic converter.
ENGINES
(5) Repeat the above test for the remaining coils. If
WARNING: THE DIRECT IGNITION SYSTEMS GEN- there is no spark during all cylinder tests, proceed to
ERATES APPROXIMATELY 40,000 VOLTS. PER- the Failure To Start Test.
SONAL INJURY COULD RESULT FROM CONTACT (6) If one or more tests indicate irregular, weak, or
WITH THIS SYSTEM. no spark, proceed to Check Coil Test.
The coil pack contains independent coils. Each coil TESTING FOR SPARK AT COIL—3.0L
must be checked individually.
WARNING: APPLY PARKING BRAKE AND/OR
CAUTION: Spark plug wire damage may occur if BLOCK THE WHEELS BEFORE PERFORMING ANY
the spark plug is moved more than 1/4 inch away TEST WITH THE ENGINE RUNNING.
from the engine ground.
Fig. 21 Checking Ignition Coil Secondary Fig. 22 Ignition Coil Engine Harness Connector
Resistance (4) Turn the ignition key to the ON position. The
FAILURE TO START TEST test light should flash On and then Off. Do not turn
This no-start test checks the camshaft position sen- the Key to off position, leave it in the On posi-
sor and crankshaft position sensor. tion.
The Powertrain Control Module (PCM) supplies 8 (a) If the test light flashes momentarily, the
volts to the camshaft position sensor and crankshaft PCM grounded the Auto Shutdown (ASD) relay.
position sensor through one circuit. If the 8 volt sup- Proceed to step 5.
ply circuit shorts to ground, neither sensor will pro- (b) If the test light did not flash, the ASD relay
duce a signal (output voltage to the PCM). did not energize. The cause is either the relay or
When the ignition key is turned and left in the On one of the relay circuits. Use the DRB scan tool to
position, the PCM automatically energizes the Auto test the ASD relay and circuits. Refer to the appro-
Shutdown (ASD) relay. However, the controller de-en- priate Powertrain Diagnostics Procedure Manual.
ergizes the relay within one second because it has Refer to the wiring diagrams section for circuit
not received a camshaft position sensor signal indi- information.
cating engine rotation. (5) Crank the engine. (If the key was placed in the
During cranking, the ASD relay will not energize off position after step 4, place the key in the On posi-
until the PCM receives a camshaft position sensor tion before cranking. Wait for the test light to flash
signal. Secondly, the ASD relay remains energized once, then crank the engine.)
only if the controller senses a crankshaft position (6) If the test light momentarily flashes during
sensor signal immediately after detecting the cam- cranking, the PCM is not receiving a crankshaft posi-
shaft position sensor signal. tion sensor signal. Use the DRB scan tool to test the
(1) Check battery voltage. Voltage should be crankshaft position sensor and sensor circuits. Refer
approximately 12.66 volts or higher to perform fail- to the appropriate Powertrain Diagnostics Procedure
ure to start test. Manual. Refer to the wiring diagrams section for cir-
(2) Disconnect the harness connector from the coil cuit information.
pack. (7) If the test light did not flash during cranking,
(3) Connect a test light to the B+ (battery voltage) unplug the crankshaft position sensor connector.
terminal of the coil electrical connector and ground Turn the ignition key to the off position. Turn the
as shown in (Fig. 22). The B+ wire for the DIS coil is key to the On position, wait for the test light to
dark green with an orange tracer. Do not spread momentarily flash once, then crank the engine. If the
the terminal with the test light probe. test light momentarily flashes, the crankshaft posi-
tion sensor is shorted and must be replaced. If the
light did not flash, the cause of the no-start is in
NS IGNITION SYSTEM 8D - 11
DIAGNOSIS AND TESTING (Continued)
either the crankshaft position sensor/camshaft posi-
tion sensor 8 volt supply circuit, or the camshaft
position sensor output or ground circuits. Use the
DRB scan tool to test the camshaft position sensor
and the sensor circuits. Refer to the appropriate Pow-
ertrain Diagnostics Procedure Manual. Refer to the
wiring diagrams section for circuit information.
SERVICE PROCEDURES
SPARK PLUG GAP ADJUSTMENT
Fig. 28 Preignition Damage Check the spark plug gap with a gap gauge. If the
gap is not correct, adjust it by bending the ground
29). The increase in electrode gap will be consider- electrode (Fig. 30).
ably in excess of 0.001 in per 1000 miles of operation.
This suggests that a plug with a cooler heat range CAUTION: The Platinum pads can be damaged dur-
rating should be used. Over advanced ignition tim- ing the measurement of checking the gap if extreme
ing, detonation and cooling system malfunctions also care is not used.
can cause spark plug overheating.
Refer to 3.3/3.8L Spark Plug Gap Measurment in
THROTTLE POSITION SENSOR this section.
To perform a complete test of the this sensor and
its circuitry, refer to the DRB scan tool and appropri- POWERTRAIN CONTROL MODULE
ate Powertrain Diagnostics Procedures manual. To
test the throttle position sensor only, refer to the fol- REMOVAL
lowing: (1) Disconnect both cables from battery, negative
The Throttle Position Sensor (TPS) can be tested cable first.
with a digital voltmeter (DVM). The center terminal (2) Remove 2 screws holding Power Distribution
of the sensor is the output terminal. One of the other Center (PDC) to bracket (Fig. 31).
terminals is a 5 volt supply and the remaining ter- (3) Remove heat shield from battery (Fig. 32).
minal is ground. (4) Remove nut and clamp holding battery to bat-
Connect the DVM between the center and sensor tery tray (Fig. 33).
ground terminal. Refer to Group 8W - Wiring Dia- (5) Remove battery from vehicle.
grams for correct pinout. (6) Rotate PDC toward center of vehicle to remove
from rear bracket (Fig. 34).
8D - 14 IGNITION SYSTEM NS
SERVICE PROCEDURES (Continued)
Fig. 30 Setting Spark Plug Electrode Gap—Typical Fig. 32 Battery Heat Shield
2.4L ENGINE
INDEX
page page
REMOVAL
Always remove cables by grasping at the boot,
rotating the boot 1/2 turn, and pulling straight back
in a steady motion.
Fig. 5 Intake Air Temperature Sensor (1) Prior to removing the spark plug, spray com-
pressed air around the spark plug hole and the area
REMOVAL AND INSTALLATION
around the spark plug.
(2) Remove the spark plug using a quality socket
SPARK PLUG CABLE SERVICE—2.4L
with a foam insert.
The cables insulate the spark plugs and covers the
(3) Inspect the spark plug condition. Refer to
top of the spark plug tube (Fig. 6). To remove the
Spark Plug Condition in this section.
cables, lightly grasp the top of the cable. Rotate the
insulator 90° and pull straight up. To replace the INSTALLATION
cables, disconnect the cable from the ignition coil. (1) To avoid cross threading, start the spark plug
Ensure the #1 and #4 cables run under the #2 into the cylinder head by hand.
and #3 ignition coil towers. Keep #4 cable away (2) Tighten spark plugs to 28 N·m (20 ft. lbs.)
from the oil fill cap. torque.
(3) Install spark plug cables over spark plugs. A
click will be heard and felt when the cable properly
attaches to the spark plug.
IGNITION COIL—2.4L
REMOVAL
REMOVAL
(1) Remove spark plug cables from coil (Fig. 7).
Always twist the coil boots to break the seal with the
coil and pull straight back on the boot.
(2) Remove ignition coil electrical connector.
(3) Remove ignition coil mounting bolts, throttle
cable bracket or clip.
(4) Remove ignition coil.
INSTALLATION
(1) Reverse the above procedure for installation.
Tighten mounting screws to 12 N·m (105 in. lbs.)
torque.
(2) Transfer ignition cables to new coil pack. The
coil pack towers and cables are numbered with cylin-
Fig. 6 Spark Plug Cables
der identification.
SPARK PLUG SERVICE
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them in
NS IGNITION SYSTEM 8D - 19
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Raise and support vehicle.
(2) Disconnect electrical connector from crankshaft
position sensor.
(3) Remove sensor mounting screw.
(4) Pull crankshaft position sensor straight out.
INSTALLATION
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 7 N·m
(60 in. lbs.) torque.
(2) Attach electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
KNOCK SENSOR—2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 14).
REMOVAL
(1) Disconnect electrical connector from knock sen-
sor. Fig. 15 Intake Air Temperature Sensor
(2) Use a crow foot socket to remove the knock REMOVAL
sensors. (1) Remove electrical connector from sensor.
(2) Remove sensor.
INSTALLATION
(1) Install knock sensor. Tighten knock sensor to INSTALLATION
10 N·m (7 ft. lbs.) torque. Over or under tighten- (1) Install sensor. Tighten sensor to 28 N·m (20 ft.
ing effects knock sensor performance, possibly lbs.) torque.
causing improper spark control. (2) Attach electrical connector to sensor.
(2) Attach electrical connector to knock sensor.
SPECIFICATIONS
IGNITION COIL
Primary Resistance at 21°C-27°C Secondary Resistance at 21°C-
Coil Manufacture
(70°F-80°F) 27°C (70°F-80°F)
Weastec (Steel Towers) 0.45 to 0.65 Ohms 7,000 to 15,800 Ohms
Coil Polarity
SPARK PLUG
Engine Spark Plug Gap Thread Size
2.4L RC12YC5 0.048 TO 0.053 14mm (3/4 in.) reach
3.0L ENGINE
INDEX
page page
IGNITION COIL—3.OL
The ignition coil is located at the back of the
intake manifold (Fig. 2).
REMOVAL
(1) With the engine cold, drain coolant until level
drops below cylinder head. Refer to Group 7, Cooling
System.
(2) Disconnect coolant sensor electrical connector.
(3) Remove coolant sensor.
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 7 N·m
(60 in. lbs.) torque.
Fig. 5 Crankshaft Position Sensor and Spacer
(2) Attach electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling (1) Install sensor in transaxle and push sensor
System. down until contact is made with the drive plate.
While holding the sensor in this position, and install
CRANKSHAFT POSITION SENSOR and tighten the retaining bolt to 11.9 N·m (105 in.
lbs.) torque.
REMOVAL (2) Raise and support vehicle.
(1) Raise and support vehicle. (3) Connect crankshaft position sensor electrical
(2) Disconnect crankshaft position sensor electrical connector to the wiring harness connector.
connector from the wiring harness connector (Fig. 4).
(3) Remove crankshaft position sensor retaining THROTTLE POSITION SENSOR
bolt. Refer to Group 14, Fuel Injection Section, for
(4) Pull crankshaft position sensor straight up out Removal/Installation.
of the transaxle housing.
8D - 26 IGNITION SYSTEM NS
DISTRIBUTOR CAP
Remove the distributor cap and inspect the inside
for flashover, cracking of carbon button, lack of
spring tension on carbon button, cracking of cap, and
burned, worn terminals (Fig. 9). Also check for bro-
ken distributor cap towers. If any of these conditions
Fig. 7 Distributor Hold-Down are present the distributor cap and/or cables should
be replaced.
NS IGNITION SYSTEM 8D - 27
CLEANING AND INSPECTION (Continued)
solution of warm water and a mild detergent. Scrub
the cap with a soft brush. Thoroughly rinse the cap
and dry it with a clean soft cloth.
DISTRIBUTOR ROTOR—3.0L
Replace the rotor if it is cracked, the tip is exces-
sively burned or heavily scaled (Fig. 10).
SPECIFICATIONS
SPARK PLUG
Engine Spark Plug Gap Thread Size
3.0L RN11YC4 0.039 TO 0.044 14mm (3/4 in.) reach
3.3/3.8L ENGINE
INDEX
page page
SPARK PLUG #1
REMOVAL
(1) Remove the accessory drive belt, refer to Group
7, Cooling.
(2) Remove the 4 bolts from the upper half of the
generator bracket.
(3) Push the Generator rearward.
(4) Grasp the spark plug boot/shield assembly as
close as possible to the spark plug. Twist the boot/
shield assembly slightly to break its seal with Fig. 2 Ignition Coil Removal
the plug and pull straight out. Do not use pli-
ers, pull on the ignition cable, or pull the spark CRANKSHAFT POSITION SENSOR
plug boot at an angle. This could damage the
spark plug insulator, terminal, or the insulation. REMOVAL
Wipe spark plug insulator clean with a dry cloth (1) Raise and support vehicle.
before installation. (2) Disconnect crankshaft position sensor electrical
(5) Remove spark plug connector from the wiring harness connector (Fig. 3).
INSTALLATION
(1) Install spark plug and tighten to 28 N·m (20 ft.
lbs.).
(2) When installing the spark plug cables, make
sure the coil or spark plug insulator and terminals
are fully seated. A click sound should be heard or
felt when the terminals are properly attached.
(3) Pull Generator back into place.
(4) Install upper Generator bracket with the 4
bolts.
(5) Install the accessory drive belt, refer to Group
7, Cooling.
IGNITION COIL
REMOVAL Fig. 3 Crankshaft Position Sensor Connector
(1) Remove spark plug cables from coil (Fig. 2).
(3) Remove crankshaft position sensor retaining
Always twist the spark plug boots to break the seal
bolt.
with the plug and pull straight back on the boot.
(4) Pull crankshaft position sensor straight up out
(2) Remove ignition coil electrical connector.
of the transaxle housing.
(3) Remove ignition coil mounting screws.
(4) Remove ignition coil. INSTALLATION
INSTALLATION NOTE: If the removed sensor is to be reinstalled,
(1) Reverse the above procedure for installation. clean off the old spacer on the sensor face. A NEW
Tighten mounting screws to 12 N·m (105 in. lbs.) SPACER must be attached to the sensor face before
torque. installation. If the sensor is being replaced, confirm
(2) Transfer spark plug cables to new coil pack. that the paper spacer is attached to the face of the
The coil pack towers and cables are numbered with new sensor (Fig. 4).
the cylinder identification.
(1) Install sensor in transaxle and push sensor
down until contact is made with the drive plate.
NS IGNITION SYSTEM 8D - 31
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Install knock sensor. Tighten knock sensor to
10 N·m (7 ft. lbs.) torque. Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
IGNITION COIL
INDEX
page page
INSTALLATION
(1) Install key in lock cylinder. Turn key to run
position (retaining tab on lock cylinder can be
depressed).
(2) The shaft at the end of the lock cylinder aligns Fig. 12 Socket in Lock Cylinder Housing
with the socket in the end of the housing. To align
(7) Connect negative cable to battery.
the socket with the lock cylinder, ensure the socket is
in the Run position (Fig. 12).
IGNITION INTERLOCK
(3) Align the lock cylinder with the grooves in the
Refer to Group 21, Transaxle for Shifter/Ignition
housing. Slide the lock cylinder into the housing
Interlock Service.
until the tab sticks through the opening in the hous-
ing.
LOCK CYLINDER HOUSING
(4) Turn the key to the Off position. Remove the
Refer to Steering Column in Group 19, Steering,
key.
for Lock Cylinder Housing Service.
(5) Install lower steering column shroud.
(6) Install steering column cover.
NS INSTRUMENT PANEL AND SYSTEMS 8E - 1
page page
HEADLAMP SWITCH
Using a Digital Multimeter, equipped with a diode
test to perform the Headlamp Switch Test below (Fig.
1).
Switch position possibilities are open (no continu-
ity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine
meter setting. If Headlamp Switch is not within spec-
ifications replace as necessary.
The Chrysler Town and Country is available with
optional Automatic Headlamps. For diagnosis, refer
to the proper Body Diagnostic Procedures Manual.
U
NS INSTRUMENT PANEL AND SYSTEMS 8E - 11
DIAGNOSIS AND TESTING (Continued)
TEMPERATURE GAUGE DIAGNOSIS
POSSIBLE
CONDITION CORRECTION
CAUSES
NO DISPLAY 1. No CCD 1. Use a scan tool to check the BCM. Refer to the BCM section of
Odometer Bus the manual to properly diagnose and repair.
Message from Body
Control Module.
2. Internal Cluster 2. (a) Perform Cluster Self Diagnostic Test and check for fault
Failure. codes.
• If odometer passes the dim test and segment check and
fault codes 110 or 111 don’t appear in the odometer display
then failure is not in the cluster. Look for another possible
cause of failure.
• If odometer doesn’t work go to Step (b).
•If fault code 110 is displayed in the odometer, go to Step (b).
• If fault code 920 or 921 is displayed use a scan tool to check
BCM.
(b) Remove cluster from instrument panel and verify that
odometer assembly is properly connected to main pc board. If
OK, go to Step (c). If not OK, reconnect odometer assembly to
main pc board.
(c) Replace odometer assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness.
Place it back into the proper position in the instrument panel.
DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT
PANEL UNTIL UNIT IS TESTED. Go to Step (e).
(e) Perform Self Diagnostic Test. If OK, continue installation. If
not OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to
calibrate cluster. If not OK, look at another possible cause for
the odometer failure.
8E - 14 INSTRUMENT PANEL AND SYSTEMS NS
DIAGNOSIS AND TESTING (Continued)
POSSIBLE
CONDITION CORRECTION
CAUSES
ERRATIC DISPLAY 1. Internal Cluster 1. (a) Perform Cluster Self Diagnostic Test and check for fault
Failure. codes.
• If odometer passes the dim test and segment check and fault
codes 110 or 111 don’t appear in the odometer displayed then
failure is not in the cluster. Look for another possible cause of
failure.
• If odometer doesn’t work go to Step (b).
• If fault code 110 is displayed in the odometer, go to Step (b).
• If fault code 920 or 921 is displayed use a scan tool to check
BCM.
(b) Remove cluster from instrument panel and verify that odometer
assembly is properly connected to main pc board. If OK, go to
Step (c). If not OK, reconnect odometer assembly to main pc
board.
(c) Replace odometer assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness. Place it
back into the proper position in the instrument panel. DO NOT
COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL
UNTIL UNIT TESTED. Go to Step (e).
(e) Perform Self diagnostic Test. If OK, continue installation. If not
OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the odometer
failure.
2. Bad CCD Bus 2. Use a scan tool to check the BCM. Refer to the BCM section of
Message from Body the manual to properly diagnose and repair.
Controller Module.
ODOMETER WON’T 1. Trip Switch 1. Use a scan tool to perform trip switch activation test. If OK, look
GO INTO TRIP Doesn’t Work. for another possible cause of failure. If not OK, replace odometer
MODE. assembly.
TRIP ODOMETER 1. Reset Switch 1. Use a scan tool to perform reset switch activation test. If OK,
WON’T RESET. Doesn’t Work. look for another possible cause of failure. If not OK, replace
odometer assembly.
NS INSTRUMENT PANEL AND SYSTEMS 8E - 15
DIAGNOSIS AND TESTING (Continued)
ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS
POSSIBLE
CONDITION CORRECTION
CAUSES
NO DISPLAY 1. Internal Cluster 1. (a) Perform Cluster Self Diagnostic Test and check for fault
Failure. codes.
• If PRND3L passes the dim test and segment check and fault
codes 110 or 111 don’t appear in the odometer display then
failure is not in the cluster. Look for another possible cause of
failure.
• If PRND3L doesn’t work go to Step (b).
• If fault code 110 is displayed in the odometer, go to Step (b)
• If fault code 905 is displayed use a scan tool to check
electronic TCM.
(b) Remove cluster from instrument panel and verify that
PRND3L assembly is properly connected to main pc board. If
OK, go to Step (c). If not OK, reconnect PRND3L assembly to
main pc board.
(c) Replace PRND3L assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness.
Place it back into the proper position in the instrument panel.
DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT
PANEL UNTIL UNIT IS TESTED. Go to Step (e).
(e) Perform Self Diagnostic Test. If OK, continue installation. If
not OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to
calibrate cluster. If not OK, look at another possible cause for
the PRND3L failure.
8E - 16 INSTRUMENT PANEL AND SYSTEMS NS
DIAGNOSIS AND TESTING (Continued)
POSSIBLE
CONDITION CORRECTION
CAUSES
ERRATIC DISPLAY 1. Internal Cluster 1. (a) Perform Cluster Self Diagnostic Test and check for fault
Failure. codes.
• If PRND3L passes the dim test and segment check and fault
codes 110 or 111 don’t appear in the odometer display then failure
is not in the cluster. Look for another possible cause of failure.
• If PRND3L doesn’t work go to Step (b).
• If fault code 110 is displayed in the odometer, go to Step (f).
• If fault code 111 is displayed in the odometer display then use a
scan tool to calibrate cluster.
• If fault code 905 is displayed use a scan tool to check electronic
TCM.
(b) Remove cluster from instrument panel and verify that odometer
assembly is properly connected to main pc board. If OK, go to
Step (c). If not OK, reconnect PRND3L assembly to main pc board.
(c) Replace PRND3L assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness. Place it
back into the proper position in the instrument panel. DO NOT
COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL
UNTIL UNIT IS TESTED. Go to Step (e).
(e) Perform Self Diagnostic Test. If OK, continue installation. If not
OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the PRND3L
failure.
2. Bad CCD Bus 2. Use a scan tool to check the electronic TCM. Refer to the
Message from the electronic TCM section of the manual to properly diagnose and
Electronic repair.
Transmission
Control Module
(TCM).
ALL SEGMENTS 1. No CCD bus 1. (a) Perform Cluster Self Diagnostic test. If PRND3L passes test
ARE ON message from the go to Step (b). If PRND3L fails test go to Step (c).
electronic (b) Check electronic TCM using a scan tool. Refer to the electronic
Transmission TCM section of the manual to properly diagnose and repair.
Control Module (c) Replace PRND3L assembly. Connect cluster into instrument
(TCM). panel wiring harness. Place it back into the proper position in the
instrument panel. DO NOT COMPLETELY INSTALL CLUSTER TO
INSTRUMENT PANEL UNTIL UNIT IS TESTED. Go to Step (d).
(d) Perform Self Diagnostic Test. If OK, continue installation. If not
OK, go to Step (e).
(e) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the PRND3L
failure.
NS INSTRUMENT PANEL AND SYSTEMS 8E - 17
DIAGNOSIS AND TESTING (Continued)
TRACTION CONTROL SWITCH
MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) DIAGNOSIS
INSTALLATION INSTALLATION
For installation, for reverse the above procedures. For installation, reverse the above procedures.
INSTALLATION
(1) Install odometer and transmission range indi-
cator and attach to cluster shell.
(2) Connect wire connector into odometer and
Fig. 8 Body Control Module Location
transmission range indicator.
(5) Remove Junction Block from mounting bracket. (3) Install cluster lens.
(6) Remove screws holding Body Control Module to (4) Install instrument cluster.
Junction Block.
(7) Slide Body Control Module downward to disen- GLOVE BOX
gage guide studs on Junction Block from channels on
BCM mounting bracket. REMOVAL (FIG. 4)
(8) Remove Body Control Module from Junction (1) Open glove box (Fig. 9).
Block. (2) Disengage clip holding checkstraps to glove box
door.
INSTALLATION (3) Pivot glove box downward and disengage hinge
For installation, reverse the above procedures. hooks from instrument panel.
(4) Remove glove box.
INSTRUMENT CLUSTER LENS - MECHANICAL
TRANSMISSION RANGE INDICATOR (PRND21) INSTALLATION
(1) Place glove box in position.
REMOVAL (2) Engage hinge hooks into instrument panel and
(1) Remove the instrument cluster and disconnect pivot glove box upward.
the range indicator cable at both attaching points. (3) Engage clip to hold checkstraps to glove box
Refer to Instrument Cluster with Mechanical Trans- door.
mission Range Indicator Reval and Installation pro- (4) Close glove box door.
cedures.
(2) Remove the screws holding the cluster lens to GLOVE BOX LAMP AND SWITCH
the rear shell from around perimeter of lens.
(3) Remove the lens from the cluster, guide the REMOVAL
shift indicator cable through cluster shell. (1) Open glove box door (Fig. 10).
(4) Remove the screws holding the shift indicator (2) Using a trim stick, lightly pry glove box lamp/
to the lens. switch from instrument panel.
(3) Disengage wire connector from glove box lamp
and switch.
8E - 20 INSTRUMENT PANEL AND SYSTEMS NS
REMOVAL AND INSTALLATION (Continued)
GLOVE BOX LOCK STRIKER
REMOVAL
(1) Open glove box door (Fig. 12).
HEADLAMP SWITCH
REMOVAL
(1) Remove instrument cluster bezel (Fig. 13).
NOTE: Speedometer and/or Tachometer will not INSTRUMENT CLUSTER WITH ELECTRONIC
operate properly until all gauges have been cali- TRANSMISSION RANGE INDICATOR
brated
REMOVAL
(1) Remove instrument cluster bezel (Fig. 22).
INSTRUMENT CLUSTER SUBDIAL (2) Remove screws holding instrument cluster to
instrument panel.
REMOVAL (3) Rotate top of cluster outward.
(1) Remove the instrument cluster. (4) Remove instrument cluster from instrument
(2) Remove the cluster lens. panel.
(3) Disconnect the temperature/fuel gauge and the (5) Disconnect wire connector from back of instru-
tachometer terminals from the connectors in cluster ment cluster.
by pulling the subdial straight away from the cluster (6) Remove instrument cluster.
(Fig. 21).
(4) Remove the subdial from the cluster. INSTALLATION
(1) Place instrument cluster in instrument panel,
bottom first.
8E - 24 INSTRUMENT PANEL AND SYSTEMS NS
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
For installation, reverse the above procedures.
REMOVAL
(1) Remove the instrument cluster bezel. Refer to
Instrument Cluster Bezel removal and installation
procedures.
(2) Place cluster bezel on a clean surface face down
with the head lamp switch to the right side (Fig. 33).
(3) Using a flat bladed tool, release the louver
housing locks tabs (Fig. 34).
(4) Release the upper left lock tab first, then the
two lower louver tabs.
(5) Applying pressure on the housing, release the
Fig. 31 Driver’s Side instrument Panel upper right lock tab and the lower right.
(6) Push out the louver housing from the cluster
INSTRUMENT PANEL LEFT END COVER bezel.
REMOVAL
(1) Open driver side front door (Fig. 32).
REMOVAL
(1) Using medium flat blade tool, position it in
between the right side of louver and the housing
(Fig. 35).
(2) Twist the tool to release the pivot pin from the
louver and pull outward till released from pin.
(3) Place tool on the other side of louver and
release the other pivot pin and pull housing free from Fig. 36 Passenger Side Louver and Housings
the instrument panel. Use the same procedure for PASSENGER SIDE LOUVER OUTER HOUSINGS
either inner or outer louver.
REMOVAL
INSTALLATION (1) Using a trim stick, insert trim stick between
The inner and outer louvers have different size the outer edge of the housing and the pad/panel vinyl
pivot pins on the housing. The outer housing has a covering (Fig. 37).
larger pin on the right side then the inner housing
NS INSTRUMENT PANEL AND SYSTEMS 8E - 29
REMOVAL AND INSTALLATION (Continued)
(2) Lightly pry housing inward and by hand pull
the housing free from panel (Fig. 38).
INSTALLATION
For installation, reverse the above procedures.
JUNCTION BLOCK
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove lower steering column cover and knee
blocker reinforcement.
(3) Disconnect four, forty-way connectors from
Junction Block (Fig. 41). Fig. 42 Knee Blocker Reinforcement
(3) Remove reinforcement.
INSTALLATION
(1) Place reinforcement in position.
(2) Install screws to hold knee blocker reinforce-
ment to instrument panel.
(3) Install lower steering column cover.
LOWER CONSOLE
REMOVAL
(1) Remove screws holding lower console to floor
bracket and instrument panel (Fig. 43).
INSTALLATION
For installation, reverse the above procedures.
INSTALLATION
(1) Place message center in position on top cover.
(2) Install screws to hold message center to instru-
ment panel top cover.
(3) Connect wire connector into back of message
center.
(4) Install instrument panel top cover.
(5) Install A-pillar trim.
INSTALLATION
For installation, reverse the above procedures.
Fig. 47 Park Brake Release Handle
(5) Disengage cable end pivot from slot on release OUTLET (12 VOLT) BASE
handle (Fig. 47).
REMOVAL
INSTALLATION (1) Look inside and note position of the retaining
For installation, reverse the above procedures, bosses (Fig. 49).
(2) Using external snap ring pliers with 90 degree
MECHANICAL TRANSMISSION RANGE INDICATOR tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
REMOVAL (3) Pull out the base through mounting ring by
(1) Remove instrument cluster. gently rocking pliers. A tool can be made to do the
(2) Remove cluster lens. same. Refer to (Fig. 50).
(3) Remove screws holding mechanical transmis- (4) Disconnect the base wires.
sion range indicator to back of cluster lens. (5) Set base aside. Remove light ring and discon-
(4) Remove mechanical transmission range indica- nect wire.
tor from cluster lens.
INSTALLATION
INSTALLATION (1) Position mount ring to the instrument panel
(1) Position transmission range indicator on clus- and feed the wires through ring. Index the cap and
ter lens. the mount ring with the index tab at 9 o’clock to the
(2) Install mechanical range indicator and attach- key in the instrument panel. Install the ring.
ing screws to back of cluster lens. (2) Connect wires to base. Orient base alignment
(3) Install cluster lens. rib at 11 o’clock to mate the groove in mount ring at
(4) Install instrument cluster. the same location
(3) Push base into the bezel till it locks.
MESSAGE CENTER (4) Install 12 volt outlet cap and check operation of
outlet or element.
REMOVAL
(1) Remove A-pillar trim. OVER STEERING COLUMN BEZEL
(2) Remove instrument panel top cover. Refer to
instrument panel top cover removal procedures. REMOVAL
(3) Disconnect the wire connector from back of (1) Remove the lower steering column cover.
message center.
NS INSTRUMENT PANEL AND SYSTEMS 8E - 33
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Place the over steering column bezel in position
Fig. 50 Tool For Outlet Removal and engage clips to the cluster bezel. If equipped
8E - 34 INSTRUMENT PANEL AND SYSTEMS NS
REMOVAL AND INSTALLATION (Continued)
with traction control switch connect the wire pigtail
before engaging clips.
(2) Install the screws to hold the over steering col-
umn bezel to the cluster bezel.
(3) Install the lower column cover.
INSTALLATION
For installation, reverse the above procedures.
page page
HEADLAMP SWITCH
Using a Digital Multimeter, equipped with a diode
Fig. 1 Headlamp and Mirror Switch Lamps test to perform the Headlamp Switch Test below (Fig.
INSTRUMENT CLUSTER 3).
The mechanical instrument cluster with a tachom- Switch position possibilities are open (no continu-
eter is equipped with a electronic vacuum fluorescent ity), continuity, resistance value in ohms, or diode
odometer, and trip odometer display. test. Use the values in the third column to determine
The instrument cluster is equipped with the follow- meter setting. If Headlamp Switch is not within spec-
ing warning lamps (Fig. 2). ifications replace as necessary.
• Battery Voltage
• Lift Gate Ajar
DTC DESCRIPTION
110 Memory Fault in cluster
111 Calibration fault in cluster
921 Odometer fault from BCM
940 No tachometer messages from BCM
DIM TEST
When CHEC-0 is displayed in the odometer win-
dow, the cluster’s vacuum fluorescent (VF) displays
will dim down. If the VF display brightness does not
change, a problem exists in the cluster.
INSTALLATION
For installation, reverse the above procedures.
INSTALLATION
For installation, reverse the above procedures.
INSTALLATION
(1) Connect wire to light ring and install ring.
(2) Connect wires to base.
(3) Push base into the bezel till it locks.
(4) Install lighter element and check operation of
element.
Fig. 8 Body Control Module Location
(5) Remove Junction Block from mounting bracket.
(6) Remove screws holding Body Control Module to
Junction Block.
NS/GS INSTRUMENT PANEL AND SYSTEMS 8E - 17
REMOVAL AND INSTALLATION (Continued)
GLOVE BOX
REMOVAL (FIG. 4)
(1) Open glove box (Fig. 10).
INSTALLATION INSTALLATION
For installation, reverse the above procedures. For installation, reverse the above procedures.
8E - 18 INSTRUMENT PANEL AND SYSTEMS NS/GS
REMOVAL AND INSTALLATION (Continued)
HEADLAMP SWITCH
REMOVAL
(1) Remove instrument cluster bezel (Fig. 14).
INSTALLATION
For installation, reverse the above procedures.
INSTALLATION
For installation, reverse the above procedures.
INSTALLATION
(1) Connect wire connectors into back of the bezel.
(2) Place cluster bezel in position on instrument
panel. Use care not to place hands on louvers.
(3) Connect clips to hold cluster bezel to instru-
ment panel. Use care not to add pressure on the A/C
louvers to seat the cluster bezel clips.
(4) Install screws to hold cluster bezel to instru-
ment panel on each side of steering column.
(5) Install screw at left end of cluster bezel and Fig. 20 Instrument Cluster Printed Circuit Board
headlamp switch.
(6) Install left end cover. (4) Remove the screws holding wire connector
(7) Install over steering column bezel. insulator to the instrument cluster shell and the
(8) Install lower steering column cover. printed circuit board.
8E - 20 INSTRUMENT PANEL AND SYSTEMS NS/GS
REMOVAL AND INSTALLATION (Continued)
(5) Remove the screws holding printed circuit
board to the cluster shell.
(6) Remove the printed circuit board from the clus-
ter.
INSTALLATION
For installation, reverse the above procedures.
After installing the print circuit board it will have to
be calibrated using a scan tool (DRB III). Refer to the
proper Body Diagnostic Procedure Manual for cali-
bration procedures.
REMOVAL
(1) Disconnect the battery, negative cable first.
(2) Remove the lower console.
(3) Remove the screw holding the lower heat duct
to the instrument panel support (Fig. 23).
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER
REMOVAL
(1) Remove instrument cluster bezel (Fig. 22).
(2) Remove screws holding instrument cluster to
instrument panel.
(3) Rotate top of cluster outward. Fig. 23 Heat Duct
(4) Remove instrument cluster from instrument (4) Disconnect the heat duct from the vehicle.
panel. (5) Remove the bolts holding the lower supports to
the instrument panel frame (Fig. 24).
NS/GS INSTRUMENT PANEL AND SYSTEMS 8E - 21
REMOVAL AND INSTALLATION (Continued)
(16) Disconnect the instrument panel wire harness
connector from the bottom of Body Control Module.
(17) Disconnect the two forty pin connectors from
the right of the steering column (Fig. 26).
INSTALLATION
For installation, reverse the above procedures.
REMOVAL
(1) Remove the instrument cluster bezel. Refer to
Fig. 28 Driver’s Side instrument Panel Instrument Cluster Bezel removal and installation
procedures.
(30) Loosen, but do not remove, the pivot bolts
(2) Place cluster bezel on a clean surface face down
holding the instrument panel to the cowl panels.
with the head lamp switch to the right side (Fig. 30).
(31) Remove the bolts holding the instrument
(3) Using a flat bladed tool, release the louver
panel frame to the dash panel below windshield
housing locks tabs (Fig. 31).
opening.
(4) Release the upper left lock tab first, then the
(32) Remove the instrument panel from vehicle.
two lower louver tabs.
NS/GS INSTRUMENT PANEL AND SYSTEMS 8E - 23
REMOVAL AND INSTALLATION (Continued)
(5) Applying pressure on the housing, release the (3) Using a flat bladed tool, release the louver
upper right lock tab and the lower right. housing locks tabs.
(6) Push out the louver housing from the cluster (4) Release the upper left lock tab first, then the
bezel. other upper lock tab.
(5) Applying pressure on the housing, release the
lower lock tabs.
(6) Push out the louver housing from the cluster
bezel.
INSTALLATION
(1) Verify the function of the vanes.
(2) Set louver housing into the cluster bezel and
align the slot of the housing with the T location pins.
(3) Using care do not push on the vanes, apply
pressure on outer edge of the housing and push lou-
ver housing into place.
(4) After in place check function of the vanes.
REMOVAL
(1) Remove the instrument cluster bezel. Refer to
Instrument Cluster Bezel Removal and Installation
procedures.
(2) Place cluster bezel on a clean surface face down
with the head lamp switch to the right side (Fig. 30). Fig. 32 Removing Passenger Louver
8E - 24 INSTRUMENT PANEL AND SYSTEMS NS/GS
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
The inner and outer louvers have different size
pivot pins on the housing. The outer housing has a
larger pin on the right side then the inner housing
(Fig. 33). The louver have a surface cut out on the
right side of the housings to note the proper side.
(1) The right pivot pin is slotted on both housings.
So when aligning louver tab with the pin ensure that
they are lined up.
(2) Using care, apply pressure on outer edge of the
louver and push into place.
(3) Rotate louver to ensure proper engagement.
REMOVAL
(1) Using a trim stick, insert trim stick between
the outer edge of the housing and the pad/panel vinyl
covering (Fig. 34).
(2) Lightly pry housing inward and by hand pull
the housing free from panel (Fig. 35). Fig. 35 Housing Being Removed
INSTALLATION
(1) Place the slotted pin on the right side of the
opening.
(2) Set housing in to position and push into place.
The housing may need to be rocked to get the best fit
within the opening.
INSTALLATION
For installation, reverse the above procedures.
INSTALLATION
For installation, reverse the above procedures.
JUNCTION BLOCK
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove lower steering column cover and knee
blocker reinforcement. Fig. 39 Knee Blocker Reinforcement
(3) Disconnect four, forty-way connectors from (2) Remove screws holding knee blocker reinforce-
Junction Block (Fig. 38). ment to instrument panel.
8E - 26 INSTRUMENT PANEL AND SYSTEMS NS/GS
REMOVAL AND INSTALLATION (Continued)
(3) Remove reinforcement. INSTALLATION
(1) Place lower console in position.
INSTALLATION (2) Slide console forward around instrument panel
(1) Place reinforcement in position. supports.
(2) Install screws to hold knee blocker reinforce- (3) Install screws to hold lower console to floor
ment to instrument panel. bracket and instrument panel.
(3) Install lower steering column cover.
LOWER INSTRUMENT PANEL
LOWER CONSOLE
REMOVAL
REMOVAL (1) Remove right end cover.
(1) Remove screws holding lower console to floor (2) Remove steering column bezel.
bracket and instrument panel (Fig. 40). (3) Remove radio bezel and HVAC control.
(4) Remove lower console.
(5) Remove ash receiver cup holder and track.
(6) Remove glove box.
(7) Remove glove box latch striker.
(8) Remove glove box lamp.
(9) Disconnect wire connector from glove box lamp.
(10) Remove screws holding lower instrument
panel to reinforcement frame around glove box open-
ing (Fig. 41).
INSTALLATION
For installation, reverse the above procedures.
MESSAGE CENTER
Fig. 42 Park Brake Release Handle REMOVAL
(2) Remove screws holding bottom of lower steer- (1) Remove A-pillar trim.
ing column cover to instrument panel (Fig. 43). (2) Remove instrument panel top cover. Refer to
(3) Remove screw holding right side of lower steer- instrument panel top cover removal procedures.
ing column cover to instrument panel. (3) Disconnect the wire connector from back of
(4) Disengage park brake release cable case from message center.
groove on end of release handle (Fig. 44). (4) Remove screws holding message center to
(5) Disengage cable end pivot from slot on release instrument panel top cover.
handle (Fig. 44). (5) Remove message center from instrument panel
top cover.
8E - 28 INSTRUMENT PANEL AND SYSTEMS NS/GS
REMOVAL AND INSTALLATION (Continued)
INSTALLATION POWER MIRROR SWITCH
(1) Place message center in position on top cover.
(2) Install screws to hold message center to instru- REMOVAL
ment panel top cover. (1) Remove instrument cluster bezel (Fig. 46).
(3) Connect wire connector into back of message
center.
(4) Install instrument panel top cover.
(5) Install A-pillar trim.
INSTALLATION
For installation, reverse the above procedures.
INSTALLATION
(1) Place the over steering column bezel in position
and engage clips to the cluster bezel. If equipped
with traction control switch connect the wire pigtail Fig. 47 Power Mirror Switch Lamp
before engaging clips.
(2) Rotate bulb socket counterclockwise one quar-
(2) Install the screws to hold the over steering col-
ter turn.
umn bezel to the cluster bezel.
(3) Pull bulb socket from back of power mirror
(3) Install the lower column cover.
switch.
NS/GS INSTRUMENT PANEL AND SYSTEMS 8E - 29
REMOVAL AND INSTALLATION (Continued)
INSTALLATION REAR HEATER-A/C SWITCH
For installation, reverse the above procedures. REMOVAL
(1) Remove radio bezel and HVAC Control (Fig. 49).
RADIO BEZEL AND HVAC CONTROL
REMOVAL
(1) Remove screw access cover (Fig. 48).
INSTALLATION
For instrument, reverse the above procedures.
INSTALLATION
(1) Hold the radio bezel up and connect the wire
connector into the back of the HVAC control.
(2) Connect the wire connector into back of the
rear blower switch, if equipped.
(3) Place the radio bezel in position on the instru-
ment panel.
(4) Install screws to hold the top of radio bezel to
instrument panel. Fig. 50 Rear Heater-A/C Switch Lamp Bulb
(5) Install screws to the hold bottom of the radio
(3) Pull bulb socket from switch.
bezel to the instrument panel.
(6) Install the access cover. INSTALLATION
For installation, reverse the above procedures.
NS AUDIO SYSTEMS 8F - 1
AUDIO SYSTEMS
CONTENTS
page page
TEST 1
Test 1 determines if the antenna mast is insulated
from the base. Proceed as follows:
(1) Unplug the antenna coaxial cable connector
from the radio chassis and isolate.
(2) Connect one ohmmeter test lead to the tip of
the antenna mast. Connect the other test lead to the
antenna base. Check for continuity.
Fig. 6 Remote Radio Switch Operational View
(3) There should be no continuity. If continuity is
These switches are resistor multiplexed units that found, replace the faulty or damaged antenna base
are hard-wired to the Body Control Module (BCM) and cable assembly.
through the clockspring. The BCM sends the proper
8F - 4 AUDIO SYSTEMS NS
DIAGNOSIS AND TESTING (Continued)
(1) Connect one ohmmeter test lead to the vehicle
fender. Connect the other test lead to the outer crimp
on the antenna coaxial cable connector.
(2) The resistance should be less then (1) ohm.
(3) If the resistance is more then (1) ohm, clean
and/or tighten the antenna base to fender mounting
hardware.
AUDIO SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Fig. 12 Radio
(3) Pull radio rearward to gain access to back of
radio (Fig. 13).
Fig. 14 Left Instrument Panel Speaker
(4) Remove bolt holding ground strap to back of
radio. (3) Remove anti rocking finger screw.
(5) Disconnect antenna cable from back of radio. (4) Disconnect wire connector from speaker.
(6) Disconnect the wire connectors from back of (5) Remove speaker.
radio.
(7) Remove radio from vehicle. INSTALLATION
For installation, reverse the above procedure.
INSTALLATION
For installation, reverse the above procedure.
NS AUDIO SYSTEMS 8F - 9
REMOVAL AND INSTALLATION (Continued)
REMOTE RADIO SWITCHES
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the airbag system capac-
Fig. 15 Right Instrument Panel Speaker itor to discharge before further service.
(2) From the underside of the steering wheel,
FRONT DOOR SPEAKER remove the (3) bolts that secure the driver side air-
bag module to the steering wheel.
REMOVAL (3) Pull the airbag module away from the steering
(1) Remove front door trim panel as necessary to wheel far enough to access the wire harness connec-
gain access to door speaker. Refer to Group 23, Body tors on the back of the airbag module.
for proper procedures. (4) Unplug the airbag module and horn switch
(2) Remove screws holding speaker to bracket (Fig. wire harness connectors from the back of the airbag
16). module.
(5) Remove the driver side airbag module from the
vehicle.
(6) Remove the steering wheel from the steering
column. Refer to Group 19–Steering, for service pro-
cedure.
(7) Unplug the wire harness connector from the
remote radio switch (s).
(8) Remove three screws securing steering wheel
rear cover. Refer to Group 19, Steering for serivce
procedure.
(9) Remove the remote radio switch from the steer-
ing wheel by depressing tabs on each side of switch..
HORNS
CONTENTS
page page
INTRODUCTION HORN
(1) Disconnect wire connector at horn.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (2) Using a voltmeter, connect one lead to ground
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR terminal and the other lead to the positive wire ter-
SAFETY PRECAUTIONS. DISCONNECT THE NEGA- minal (Fig. 3).
TIVE CABLE FROM THE BATTERY BEFORE SER- (3) Depress the horn switch, battery voltage
VICING COMPONENTS INVOLVING THE AIRBAG should be present.
SYSTEM. ACCIDENTAL DEPLOYMENT OF AIRBAG (4) If no voltage, refer to Horn Will Not Sound. If
AND PERSONAL INJURY CAN RESULT. voltage is OK, go to step Step 5.
(5) Using ohmmeter, test ground wire for continu-
The horn circuit consists of a horn switch, clock- ity to ground.
spring, horn relay, horns and Body Control Module (6) If no ground repair as necessary.
(Fig. 1). The horn switch is a membrane switch (7) If wires test OK and horn does not sound,
located in the airbag cover. The horns are located for- replace horn.
ward of the left front wheel behind the bumper fas-
cia. The horn relay plugs into the junction block. For HORN RELAY
circuit information and component locations refer to (1) Remove horn relay.
Group 8W, Wiring Diagrams. (2) Using ohmmeter, test between relay connector
terminals 85 to 86 for 70 to 75 ohms resistance (Fig.
2). If resistance not OK, replace relay.
(3) Test for continuity between ground and termi-
nal 85 of horn relay.
(a) When the horn switch is not depressed, no
continuity should be present.
(b) Continuity to ground when horn switch is
depressed.
(c) If continuity is not correct repair horn
switch or wiring as necessary, refer to Group 8W,
Wiring Diagrams Group 8M Restraint System for
Driver’s Airbag Module removal procedures.
(4) Using voltmeter, test voltage at:
(a) Terminals 30 and 86 of the horn relay to
body ground.
(b) If NO voltage check fuse 7 of the BCM.
(c) If incorrect voltage repair as necessary. Refer
to Group 8W, Wiring Diagrams.
(5) Insert a jumper wire between terminal 30 and
Fig. 1 Horn System 87 of the power distribution center.
(a) If horn sounds replace relay.
8G - 2 HORNS NS
DIAGNOSIS AND TESTING (Continued)
(b) If the horn does not sound, install horn relay FUSE OK
and refer to Horn Test. (1) Remove the horn relay from the Junction
Block.
(2) Using a continuity tester, Depress horn switch
and test continuity from the X3 cavity of the horn
relay to ground. Refer to Group 8W, Wiring Diagrams
for circuit information.
(a) If continuity is detected, proceed to Step 3.
(b) If NO continuity, proceed to Step 4.
(3) Using a suitable jumper wire, jump across the
fuse F62 cavity and the X2 cavity of the horn relay in
the Junction Block.
(a) If the horn sounds, replace the horn relay.
Fig. 2 Horn Relay (b) If the horn does not sound, proceed to Step 4.
HORNS WILL NOT SOUND (4) Remove airbag/horn pad from steering wheel.
Check horn fuse 6 in the Power Distribution Cen- Refer to Group 8M, Restraint Systems for proper pro-
ter and fuse 7 in the Junction Block. If fuse is blown cedures.
refer to FUSE BLOWN section. If fuse is OK, refer to (5) Test continuity across horn switch connectors
FUSE OK section. with horn switch depressed.
(a) If continuity is detected, repair open circuit
FUSE BLOWN between the relay and the horn switch.
(1) Verify condition of battery terminals and volt- (b) If NO continuity, replace airbag cover.
age, refer to Group 8A, Battery. If battery connec- (6) Install horn relay into Junction Block.
tions and battery charge is OK proceed to Step 2. (7) Disengage wire connectors from horns.
(2) Using a voltmeter, test for battery voltage at (8) Using a voltmeter, with the horn switch
both sides of horn fuse 7. If voltage is OK, on both depressed test voltage across horn connector termi-
sides of fuse, proceed to Fuse OK. If voltage is OK, nals of the wire harness (Fig. 3).
on one side of fuse, the fuse is blown, proceed to Step (a) If voltage is detected, replace horns.
3. (b) If NO voltage, proceed to step Step 9.
(3) Using a suitable ammeter in place of the fuse,
test amperage draw of the horn circuit. If amperage
draw is greater than 20 amps without the horn
switch depressed, a grounded circuit exists between
the fuse and the horn relay. Proceed to Step 4. If
amperage draw is greater than 20 amps with the
horn switch depressed, a grounded circuit exists
between the horn relay and the horn. Proceed to step
Step 5.
(4) Remove the horn relay from the Junction
Block. If the amperage draw drops to 0 amps, the
horn switch or circuit is shorted. Refer to group 8W,
Wiring Diagrams for circuit information. If the
amperage draw does not drop to 0 amps, repair short
at the Junction Block.
(5) Disengage a wire connector from one of the
horns. If amperage drops and the connected horn Fig. 3 Horn and Connector
sounds, replace the faulty horn. If amperage does not
drop with both horns disconnected and the horn (9) With the horn switch depressed, test for volt-
switch depressed, proceed to Step 6. age between the X2 circuit and ground.
(6) Using a continuity tester, with the horns dis- (a) If voltage OK, repair system ground at right
connected test continuity of the X2 cavity of the horn cowl area. Refer to Group 8W, Wiring Diagrams.
relay to ground. Refer to Group 8W, Wiring Diagrams (b) If NO voltage, repair open X2 circuit between
for circuit information. If continuity is detected, the the relay and the horns.
circuit is grounded between the Junction Block and
the horns. Locate and repair pinched harness.
NS HORNS 8G - 3
DIAGNOSIS AND TESTING (Continued)
HORNS SOUND CONTINUOUSLY HORN SYSTEM
Refer to Horn System Test below. If the horn does
CAUTION: Continuous sounding of horns may not sound, check horn fuse located in the Power Dis-
cause relay to fail. tribution Center. If the fuse is blown, replace with
the correct fuse. If the horn fail to sound and the
The horn switch (membrane) sometimes can be the new fuse blows when depressing the horn switch, a
cause without the switch being depressing. short circuit in the horn or the horn wiring between
(1) Remove the horn relay from the junction block. the fuse terminal and the horn is responsible, or a
(2) Using a continuity tester, test continuity from defective horn switch allowed the horn to burn out is
the X3 cavity of the horn relay to ground. Refer to responsible.
Group 8W, Wiring Diagrams for circuit information. If the fuse is OK, test horn relay refer to Horn
(a) If continuity is detected, proceed to step Step Relay Test.
3. If the relay is OK, test horn. Refer to Horn System
(b) If NO continuity, replace the horn relay. Test.
(3) Remove the airbag/horn pad from the steering
wheel and disengage horn connector. CAUTION: Continuous sounding of horn may
(4) Install horn relay into junction block. cause horn relay to fail.
(a) If horn does not sound, replace airbag cover/
horn pad. Should the horn sound continuously:
(b) If horn sounds, repair grounded X3 circuit • Unplug the horn relay from Power Distribution
from junction block to clockspring in steering in Center.
steering column. Refer to Group 8W, Wiring Dia- • Refer to Horn Relay Test.
grams. Refer to Group 8W, Wiring Diagrams for circuit
and wiring information.
HORNS
REMOVAL
(1) Hoist and support the front of the vehicle on
safety stands.
(2) From behind the front fascia and forward of
the left front wheel, disconnect the wire connectors
from horn.
(3) Remove the mount bracket attaching nut from Fig. 4 Horn Removal/Installation
the bottom of radiator closure panel. Do not remove
the horn from mounting bracket (Fig. 4).
(4) Separate the horn from vehicle.
INSTALLATION
For installation reverse the above procedures.
NS VEHICLE SPEED CONTROL SYSTEM 8H - 1
page page
Refer to Group 25, for further information and use- The other test method uses a volt/ohm meter. The
age of the DRB scan tool and a more complete list of volt/ohm meter method is described in the following
Diagnostic Trouble Code. tests.
If any information is needed concerning wiring,
SPEED CONTROL SLOWS DOWN BY ITSELF refer to Group 8W, Wiring Diagrams (Fig. 2).
Test vehicle speed sensor, refer to group 8E. If sen-
sor fails replace sensor, if it passes perform the fol- CAUTION: When test probing for voltage or conti-
lowing test: nuity at electrical connectors, care must be taken
(1) Perform the speed control switch test on the not to damage connector, terminals, or seals. If
DECEL switch, if it fails replace switch. these components are damaged, intermittent or
(2) If the switch passes, conduct the vacuum sup- complete system failure may occur.
ply test.
(3) If it passes, conduct the servo vacuum test. If it When electrical connections are removed, corrosion
fails replace servo. should be removed from electrical terminals and a
(4) If continuity, replace the PCM. light coating of Mopar Multi-Purpose Grease, or
equivalent, applied. Inspect connectors for damage
SPEED CONTROL ELECTRICAL TEST terminals.
Electronic speed control systems may be tested A poor connection can cause a complete or inter-
using two different methods. One involves use of a mittent malfunction and is also the only connection
DRB. If this test method is desired, refer to the Pow- in the circuit, that can not be tested. For this reason,
ertrain Diagnostic Test Procedures for charging and a loose connection may be misdiagnosed as a compo-
speed control system manual. nent malfunction.
NS VEHICLE SPEED CONTROL SYSTEM 8H - 5
DIAGNOSIS AND TESTING (Continued)
INSTALLATION
Before installing the switch, reset the adjustable
switch plunger by pulling on the plunger head until
the plunger reaches the end of its travel. A ratchet-
ing sound will be heard during this procedure.
Connect the wiring harness to the switch. Mount
the switch into the bracket by holding the switch
Fig. 10 Speed Control Servo
with the plunger facing forward in car. There is an
INSTALLATION index key on the switch that mates with the bracket
Transfer speed control cable to replacement speed slot at the top of the square hole. Align key and push
control servo. Reverse the preceding operation. switch into square hole in bracket while depressing
the brake pedal. Once the switch is seated in the
SPEED CONTROL SWITCHES hole, rotate clockwise approximately 30 degrees to
lock into place. The switch will automatically adjust
REMOVAL when the pedal is released. Pull back on the pedal to
(1) Release hood latch and open hood. assure correct adjustment.
(2) Disconnect battery negative cable.
(3) Remove airbag/horn pad from steering wheel, SPEED CONTROL CABLE
refer to Group 8M, Restraint Systems for proper pro-
cedures. REMOVAL
(4) Disconnect wire connector from horn switch, (1) Release hood latch and open hood.
airbag, and speed control switches. (2) On vehicles with 3.3/3.8 L engine, remove air
(5) Remove screws holding speed control switch to cleaner resonator. Refer to Group 14, Fuel System for
airbag/horn pad (Fig. 11). proper procedure.
(6) Separate speed control switch from airbag/horn (3) Disconnect throttle and speed control cable
pad. ends from throttle body (Fig. 8).
(4) Depress lock tabs holding speed control cable
casing to cable mount bracket (Fig. 12).
(5) Remove tie wrap holding vacuum line, throttle
cable, and speed control cable together.
(6) Remove nuts holding speed control cable case
to servo.
(7) Remove cable case from servo.
(8) Remove hairpin clip holding cable end to servo
diaphragm (Fig. 12).
(9) Remove speed control cable.
INSTALLATION
Reverse the preceding operation.
INSTALLATION
(1) Connect vacuum hoses to vacuum reservoir.
(2) Install battery tray
(3) Install battery, Refer to Group 8B, for Battery
Removal/Installation.
(4) Connect negative cable to battery.
page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
page page
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect and isolate battery negative cable.
(3) Remove upper and lower steering column
shrouds, refer to Group 19, Steering for proper pro-
cedures.
(4) Disconnect wire connector from back of turn Fig. 6 Turn Signal Multi-Function Switch
signal multi-function switch (Fig. 6).
(5) Remove screws holding turn signal switch to (3) Pull combination flasher from junction block.
steering column adapter collar.
INSTALLATION
(6) Remove turn signal switch.
For installation, reverse the above procedures.
INSTALLATION
For installation, reverse the above procedures. Ver-
ify switch operation by placing the control stalk in
either the right or left position and turning the steer-
ing wheel to ensure the automatic cancellation of the
switch.
COMBINATION FLASHER WITH / WITHOUT DRL
MODULE
REMOVAL
(1) Remove lower steering column cover.
(2) Remove knee blocker.
NS WINDSHIELD WIPERS AND WASHERS 8K - 1
page page
INDEX
page page
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect and isolate battery negative cable.
(3) Remove upper and lower steering column
shrouds, refer to Group 19, Steering for proper pro-
cedures.
(4) Disconnect wire connector from back of turn
signal multi-function switch (Fig. 2).
(5) Remove screws holding turn signal switch to
steering column adapter collar.
(6) Remove turn signal switch.
Fig. 3 Windshield Washer Bottle
INSTALLATION
For installation, reverse the above procedures. Ver- (5) If washer bottle has fluid in it place a suitable
ify switch operation by placing the control stalk in drain pan under the hose connections.
NS WINDSHIELD WIPERS AND WASHERS 8K - 5
REMOVAL AND INSTALLATION (Continued)
(6) Disconnect front washer hose at front wiper INSTALLATION
unit in the engine compartment (Fig. 4). The front For installation, reverse the above procedure.
hose will be removed with the bottle.
WINDSHIELD WIPER BLADE
REMOVAL
(1) Lift the wiper arm away from windshield.
(2) Disengage the release tab holding the wiper
blade to the wiper arm and remove the wiper blade
from the wiper arm (Fig. 6).
(3) Remove the wiper blade from the wiper arm.
INSTALLATION
For installation, reverse the above procedure.
INSTALLATION
(1) Insert the element vertebra (Fig. 8) into claw
at the open end of the wiper blade and through each
claw location along the blade.
REMOVAL
(1) Disengage the clip holding outside end of the
wiper arm pivot cover to the wiper arm.
(2) Lift the arm cap upward.
(3) Remove the nut holding wiper arm to the wiper
pivot.
(4) Using a suitable two jaw puller, separate the
wiper arm from the wiper pivot (Fig. 11).
Fig. 12 Wiper Arm Adjustment
ADJUSTMENTS
WIPER ARM ALIGNMENT
(1) Verify wiper blade element condition and wiper
arm spring tension. Run wipers in low speed mode
while applying water to the windshield. Observe the
Fig. 15 Wiper Linkage
wiper blade that is chattering or skipping across the
(6) Remove the wiper linkage from the wiper unit. windshield. If the wiper element is not rolling over
(7) Disconnect the wire connectors from back of when the wiper direction reverses, align the wiper arm.
the wiper motor (Fig. 16). The extension bar portion of the wiper arm must be
twisted in the proper direction to allow the wiper ele-
INSTALLATION ment to roll over when the direction reverses.
For installation, reverse the above procedure. (2) Place two small adjustable wrenches placed 50
mm (2 in.) apart on the wiper arm extension rod.
CLEANING AND INSPECTION (3) Twist the extension rod slightly in the opposite
direction that the element is laying on the wind-
WIPER BLADES shield while holding the wrench closest to the pivot
Wiper blades exposed to the weather for a long stationary.
period of time tend to lose their wiping effectiveness. (4) Repeat step Step 1, and align as necessary
until wiper stops chattering and wipes the wind-
shield clear.
NS WINDSHIELD WIPERS AND WASHERS 8K - 9
INDEX
page page
INSTALLATION
For installation, reverse the above procedure.
INSTALLATION
For installation, reverse the above procedure.
INSTALLATION
REAR WIPER BLADE ELEMENT
Refer to Windshield Wiper Blade Element in this
For installation, reverse the above procedure.
section.
NS/GS WIPER AND WASHER SYSTEMS 8K - 1
page page
HEADLAMP WASHERS
INDEX
page page
GENERAL INFORMATION (5) Partially remove the front fascia to aid in the
removal of the reservoir.
INTRODUCTION (6) Remove the reservoir mounting bolts. (Fig. 1)
Headlamp washers are available as a factory-in- (7) Slide the reservoir rearward and remove from
stalled option on this model. The headlamp washers the vehicle.
on this vehicle work in conjunction with the wind-
shield washers. The headlamp washers are enabled Installation
with the headlamps “ON” and the windshield wash- (1) For installation, reverse the above procedures
ers activated. With the windshield washers activated
the headlamp washers will spray for a preset amount HEADLAMP WASHER NOZZLE
of time controlled by a relay.
Removal
The headlamp washer system utilizes a separate pump
(1) Remove the headlamp assembly. Refer to
that is attached to the windshield washer reservoir. The
Group 8L, Lamps.
headlamp washer pump feeds two nozzles that are
(2) Disconnect the hose at the headlamp washer nozzle.
mounted in the front fascia of the vehicle. These nozzles
(3) Remove the headlamp washer nozzle retaining
spray the headlamps when the system is activated.
nuts and remove the nozzle from the front fascia.
Installation
(1) For installation, reverse the above procedures.
LAMPS
CONTENTS
page page
LAMP DIAGNOSIS
INDEX
page page
HEADLAMP ALIGNMENT
INDEX
page page
HEADLAMP ADJUSTMENT
A properly aimed low beam headlamp will project
the center of the low beam hot spot on the alignment
screen 229 mm (9 in.) 6 50 mm (2 in.) below the
headlamp center line. The center of the hot spot
should be 100 mm (4 in.) 6 50 mm (2 in.) right of the
headlamp center line (Fig. 2). The high beams on a
vehicle with aero headlamps cannot be aligned. The
high beam pattern should be correct when the low
beams are aligned properly.
To adjust headlamp alignment, rotate adjusting
screws to achieve the specified low beam hot spot
location (Fig. 3).
INDEX
page page
REMOVAL AND INSTALLATION (3) Rotate headlamp bulb retaining ring clockwise.
(4) Connect wire connector into headlamp bulb
HEADLAMP BULB base.
(5) Verify headlamp alignment.
REMOVAL
(1) Release hood latch and open hood. HEADLAMP BULB – TOWN & COUNTRY
(2) From behind radiator closure panel, disconnect
wire connector from back of headlamp bulb base. HEADLAMP HIGH BEAM
(3) Rotate headlamp bulb retaining ring counter-
clockwise. REMOVAL
(4) Remove retaining ring from headlamp (Fig. 1). (1) Release hood latch and open hood.
(5) Pull headlamp bulb from back of headlamp. (2) From behind radiator closure panel, disconnect
wire connector from back of high headlamp bulb
base.
(3) Rotate headlamp bulb counterclockwise and
pull bulb from back of headlamp module (Fig. 2).
INSTALLATION
INSTALLATION
(1) Align key on bulb base to groove in socket and
insert bulb into socket (Fig. 13).
(2) Insert socket into back of lamp.
(3) Rotate lamp socket clockwise one quarter turn.
(4) Engage hook to hold outer end of lamp to quar-
ter panel opening.
(5) Place lamp in position on quarter panel.
(6) Install screws to hold lamp to rear door open-
ing trough.
Fig. 10 Front Parking and Turn Signal Lamp – T&C (7) Verify tail, stop, turn signal and back-up lamp
operation.
INSTALLATION
(1) Insert bulb into socket.
(2) Insert bulb socket into housing.
NS LAMPS 8L - 13
REMOVAL AND INSTALLATION (Continued)
INDEX
page page
GENERAL INFORMATION
HEADLAMP MODULE
Minor amounts of fogging may occur around the
edges of the headlamp lens when exposed to humid
conditions. This is considered normal. The fogging
will dissipate with increased ambient temperature or
headlamp usage.
HEADLAMP SWITCH
Service procedures for the headlamp switch can be
found in Group 8E, Instrument Panel and Gauges.
More information can be found in Group 8W, Wiring
Diagrams.
INTERIOR LAMPS
INDEX
page page
REMOVAL AND INSTALLATION (5) Snap lens onto lamp lens pivots.
INSTALLATION
(1) Push bulb into glove box lamp.
Fig. 4 Reading/Courtesy Lamp Light Shield (2) Install glove box lamp/switch in instrument
INSTALLATION panel.
(1) Carefully press forward lamp bulb contact
toward opposite contact and rotate bulb into position. IGNITION HALO LAMP BULB
(2) Position bulb to lamp bulb contacts.
(3) Release lamp bulb contacts. REMOVAL
(4) Insert outer edge of light shield into lamp (1) Remove steering column trim covers. Refer to
housing (Fig. 4). Group 19, Steering, for proper procedures.
8L - 20 LAMPS NS
REMOVAL AND INSTALLATION (Continued)
(5) Using needle-nose pliers, carefully squeeze the
vertical metal legs of the lamp hood.
(6) Lift the lamp hood upward from the cup holder
tray.
(7) Carefully pull the lamp and wiring rearward
from the instrument panel (Fig. 10).
(8) Pull the lamp hood from the lamp socket.
(9) Pull bulb from socket.
INSTALLATION
For installation, reverse the above procedures.
Fig. 6 Glove Box Lamp Bulb
(2) Rotate bulb socket counterclockwise one quar-
ter turn (Fig. 7).
(3) Pull bulb socket from halo lamp.
BULB APPLICATION
INDEX
page page
LAMPS
CONTENTS
page page
LAMP DIAGNOSIS
INDEX
page page
HEADLAMP DIAGNOSIS
HEADLAMP ALIGNMENT
INDEX
page page
INDEX
page page
CAUTION: Do not touch the glass of halogen bulbs Fig. 3 Headlamp Bulb
with fingers of other possibly oily surface. Reduced (5) Engage wire connector to headlamp bulb base.
bulb life will result. (6) Install headlamp module into vehicle
(7) Verify headlamp alignment.
(1) Insert headlamp bulb to headlamp.
(2) Pivot spring clip over headlamp bulb. FRONT TURN SIGNAL LAMP BULB
(3) Engage retaining spring clip to headlamp.
(4) Install rubber seal boot. REMOVAL
(1) Remove headlamp module from vehicle
NS/GS LAMPS 8L - 9
REMOVAL AND INSTALLATION (Continued)
(2) Rotate front turn signal lamp socket one quar-
ter turn counterclockwise.
(3) Pull socket from back of lamp.
(4) Pull bulb from socket (Fig. 4).
INSTALLATION
(1) Push and twist bulb into socket.
(2) Push side repeater lamp socket into side
repeater lamp.
(3) Position side repeater lamp to hole in fender.
(4) Push side repeater lamp to one side and seat
retaining tab into fender.
(5) Verify lamp operation.
INSTALLATION
(1) Align bulb to bulb holder socket.
(2) Push bulb into bulb holder socket.
(3) Position bulb holder to CHMSL housing.
(4) Snap bulb holder into CHMSL housing.
(5) Position CHMSL cover to liftgate trim panel. Fig. 16 CHMSL Bulb
(6) Engage clips to hold CHMSL cover to liftgate
trim panel.
NS/GS LAMPS 8L - 13
LAMP SERVICE
INDEX
page page
HEADLAMP SWITCH
Service procedures for the headlamp switch can be
found in Group 8E, Instrument Panel and Gauges.
More information can be found in Group 8W, Wiring
Diagrams.
BULB APPLICATION
INDEX
page page
RESTRAINT SYSTEM
CONTENTS
page page
Fig. 2 Vacuum Heater and A/C Outlets WARNING: THE ACM CONTAINS THE IMPACT
SENSOR WHICH ENABLES THE SYSTEM TO
SERVICE OF DEPLOYED AIRBAG MODULE DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL
DEPLOYMENT, NEVER CONNECT ACM ELECTRI-
DRIVER AIRBAG
CALLY TO THE SYSTEM WHILE VEHICLE BATTERY
If a Driver Airbag Module has been deployed, but IS CONNECTED. DISCONNECT AND ISOLATE THE
not due to a collision, replace the following: BATTERY NEGATIVE CABLE BEFORE BEGINNING
• Driver Airbag Module ANY AIRBAG SYSTEM COMPONENT SERVICE PRO-
• Clockspring assembly CEDURES. THIS WILL DISABLE THE AIRBAG SYS-
• Driver airbag cover/horn switch TEM. FAILURE TO DISCONNECT THE BATTERY
The components above must be replaced because COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
they cannot be reused. Replace any other driver air- MENT AND POSSIBLE PERSONAL INJURY. ALLOW
bag system components if damaged. SYSTEM CAPACITOR TO DISCHARGE FOR TWO
MINUTES BEFORE REMOVING AIRBAG COMPO-
PASSENGER AIRBAG
NENTS.
If a Passenger Airbag Module has been deployed,
but not due to a collision, replace the following:
• Passenger Airbag Module REMOVAL
• Upper instrument panel with pad (1) Disconnect and isolate battery negative cable.
The component above must be replaced because Allow at least two minutes for the reserve capacitor
they cannot be reused. Inspect the heat duct near the in the Airbag Control Module (ACM) to discharge.
passenger airbag for any damage replace as neces-
8M - 4 RESTRAINT SYSTEM NS
REMOVAL AND INSTALLATION (Continued)
(2) Remove forward lower console from instrument
panel, refer to Group 8E, Instrument Panel and Sys-
tems for proper procedures.
(3) Remove screw holding lower heat duct to
instrument panel support (Fig. 3).
REMOVAL
(1) Position steering wheel and front wheels
straight ahead.
(2) Release hood latch and open hood.
(3) Disconnect and isolate battery negative cable.
Allow at least two minutes for the reserve capacitor
in the ACM to discharge.
(4) Remove driver airbag from steering wheel (Fig.
7). Fig. 8 Steering Wheel
(5) Disconnect wire connectors from back of airbag
module.
(6) Remove steering wheel (Fig. 8).
(7) Remove steering column shrouds (Fig. 9).
REMOVAL
(1) Disconnect battery negative cable. Allow at
least two minutes for the reserve capacitor in the
Airbag Control Module (ACM) to discharge.
(2) Remove screws attaching airbag/horn switch to
steering wheel (Fig. 7).
(3) Remove Driver Airbag Module from steering
wheel.
(4) Disconnect wire connectors from airbag mod-
ule, horn switch, and speed control switches, if
equipped.
(5) Remove screws holding vehicle speed control
switches to airbag cover and remove.
INSTALLATION
For installation, reverse the above procedures and
do not connect battery negative cable. Do not connect
battery negative cable. Refer to Diagnosis and Test-
ing for Airbag System Test procedures.
page page
INTRODUCTION
The electrically heated Rear Window Defogger (Fig.
1), Heated Power Side View Mirrors, and Heated
Windshield Wiper De-icer (Fig. 2) is available on NS
vehicles.
The Rear Window Defogger system consists of two
vertical bus bars linked by a series of grid lines on
the inside surface of the rear window. The electrical
circuit consists of the rear defogger switch in the
HVAC and a relay with timer switch to turn OFF the
system after ten minutes. The main feed circuit is
protected by fuse one (40 amp) in the Junction Block.
The rear defogger switch and relay also activates the
heated power side view mirrors and heated wind-
Fig. 1 Rear Window Defogger
shield wiper de-icer. The HVAC rear defogger switch
is protected by fuse ten (10 amp) in the Junction
Block. The heated mirror circuit is protected by fuse
12 (10 amp) in the junction block. The heated wind-
shield wiper de-icer circuit is protected by fuse 21 (25
amp) in the Junction Block.
The Heated Windshield Wiper Deicer is also acti-
vated when the DEFROST mode is selected on the
HVAC. In the DEFROST mode the rear defogger
relay/timer is bypassed, the heated windshield wiper
de-icer will stay ON until the another mode is
selected. For circuit information and component loca-
tion refer to Group 8W, Wiring Diagrams.
page page
INDEX
page page
INSTALLATION
For installation, reverse the above procedures.
SERVICE PROCEDURES
INSTALLATION
For installation, reverse the above procedures.
INDEX
page page
SPECIFICATIONS
RKE TRANSMITTER BATTERY
The batteries can be removed without special tools
and are readily available at local retail stores. The
recommended battery is Duracell DL 2016 or equiva-
lent. Battery life is about one to two years.
page page
GENERAL INFORMATION engine run cycles. When this has occurred the total
VTSS will function.
INTRODUCTION If during alarm being set the BCM receives a
Vehicles equipped with the Vehicle Theft Security request from the RKE module to enter PANIC mode
System (VTSS) system, the doors, liftgate, hood and the BCM will cancel the alarm, return VTSS armed
ignition circuit are monitored by the Body Control state and then perform the RKE PANIC feature.
Module (BCM) when the system is armed. The VTSS
will prevent the engine from starting until the BCM
DESCRIPTION AND OPERATION
receives a disarm signal. If the VTSS is triggered,
the horn will pulse, headlamps/marker lamps will
ARMING PROCEDURE
flash, and the VTSS warning lamp will flash. If BCM
determines the threat to be false and the VTSS is not METHOD-A
triggered again, the system will shut down and (1) With the key removed from the ignition lock
rearm itself after three minutes. The VTSS monitor- and any door open, actuate one of the following:
ing portion of the system is split into two sections. • Power door lock button to LOCK,
The engine compartment section and the passenger • Key fob LOCK button
compartment section. If a malfunction occurs in the • Door lock key cylinder to locked position.
engine compartment section, the passenger compart- (2) Close all opened doors.
ment section would still arm and function normally. (3) After the last door is closed, an arming time-
If an electrical malfunction occurs in either section of out period of sixteen seconds will start, then the
the system a Diagnostic Trouble Code (DTC) would VTSS will become armed.
be stored the BCM memory to aid system repair.
DTCs can be retrieved using scan tool (DRB) METHOD-B
attached to the diagnostic connector above the accel- Actuating the key fob transmitter LOCK button,
erator pedal. key locking the front doors or liftgate with the doors
closed and the ignition locked will begin the arming
ENABLING time-out period. If method-A, 16 second time-out
To initialize the VTSS feature the operator must, sequence was in process when method-B was actu-
with the engine compartment hood open, cycle the ated, the 16 second time-out will restart from the
key in the liftgate key cylinder to the unlock position time of the second actuation.
giving the BCM a disarm signal. At this time the If the security lamp does not illuminate at all upon
visual alarm outputs the headlamps and marker final door closure, it indicates that the system is not
lamps will function. However the audio alarm output arming.
the horn and engine disable portion of the VTSS will The current VTSS status armed or disarmed shall
not function until there has been twenty consecutive be maintained in memory to prevent battery discon-
nects from disarming the system.
8Q - 2 VEHICLE THEFT SECURITY SYSTEM NS
DESCRIPTION AND OPERATION (Continued)
TIME-OUT PERIOD
The VTSS requires 16 consecutive seconds to time-
out and arm the alarm. If a door is key unlocked, key
fob unlocked. or the ignition is switched ON, the
VTSS will cancel out. To reset the VTSS, perform
methods A or B.
REMOVAL INSTALLATION
(1) Disconnect the battery negative cable. For installation, reverse the above procedure.
(2) Remove the lower steering column cover and
the knee blocker reinforcement.
(3) Disconnect the two wire connectors from the
bottom of the Body Control Module (BCM) (Fig. 1).
(4) Remove the bolts holding the Junction Block to
the dash panel mounting bracket.
(5) Remove the Junction Block from the mounting
bracket.
(6) Remove the screws holding BCM to Junction
Block.
(7) Slide the BCM downward to disengage guide
studs on Junction Block from the channels on the
BCM mounting bracket.
(8) Remove the BCM from Junction Block.
INSTALLATION
For installation, reverse the above procedure. Fig. 2 Door Lock Cylinder Switch
FRONT DOOR AJAR (VTSS TRIGGER) SWITCH
DOOR LOCK CYLINDER SWITCH
REMOVAL
REMOVAL (1) Open the front door.
(1) Remove the door trim and water shield. (2) Remove the screw holding the door ajar switch
(2) Close the door window. to the door B-pillar (Fig. 3).
(3) Remove the door ajar switch from the B-pillar.
NS VEHICLE THEFT SECURITY SYSTEM 8Q - 3
REMOVAL AND INSTALLATION (Continued)
LIFTGATE AJAR (VTSS TRIGGER) SWITCH
REMOVAL
(1) Remove the liftgate latch from the vehicle.
Refer to group 23, Body for proper procedures.
(2) Disconnect the wire connector from the liftgate
ajar switch.
(3) Remove the screw holding the ajar switch to
the liftgate latch and remove the switch (Fig. 5).
INSTALLATION
For installation, Reverse the above procedure.
Fig. 3 Front Door Ajar Switch
(4) Disconnect the wire connector from the back of
the ajar switch and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
INSTALLATION
For installation, reverse the above procedure.
page page
POWER WINDOWS
CONTENTS
page page
POWER SEATS
CONTENTS
page page
POWER SEATS
INDEX
page page
GENERAL INFORMATION • If seat motors test OK, refer to the Seat Switch
in the Diagnostic and Testing in this section.
INTRODUCTION • Refer to Group 8W Wiring Diagrams for wire
Power seats can be adjusted in eight directions; up, circuit information.
down, forward, back, tilt forward, or tilt rearward.
Four reversible motors and a transmission located on SEAT MOTORS
the seat tracks provide the various seat movements. (1) Remove power seat switch from seat. Refer to
The electrical circuit is protected by a 40 amp fuse in Group 23 Body for procedures.
the Power Distribution Center (PDC) and a 30 amp (2) Disconnect wire connector.
circuit breaker located in the wire harness under the (3) Using a voltmeter check for battery voltage at
driver’s seat. Pin 5. Using an ohmmeter, check Pin 1 for ground.
(4) To test the seat motors, refer to (Fig. 1) and
verify proper seat responses. Using two jumper
DIAGNOSIS AND TESTING wires, connect one to a battery supply and the other
to a ground. Connect the other ends to the seat wire
DIAGNOSTIC PROCEDURES harness connector as described in (Fig. 1). If any
Before testing the seat functions, verify that the motor fails to operate, check wire connectors to the
battery is fully charged and the terminals cleaned motor. If not OK, repair as necessary. If OK, replace
and tightened to ensure proper connections. If the seat motor/track assembly.
battery is not fully charged, refer to Group 8A Bat-
tery for proper testing procedures. POWER SEAT SWITCH
The following test will determine if the circuit is (1) Remove power seat switch from seat. Refer to
complete through the body harness to the switch: Group 23 Body for procedures.
Using a voltmeter, verify the condition of the power (2) Using an ohmmeter, perform the switch conti-
seat circuit breaker located under the driver’s seat. nuity tests in (Fig. 2). If there is no continuity at any
The circuit breaker also protects the passenger side of the switch positions, replace switch.
power seat track circuit. Check both sides of the cir-
cuit breaker connector for voltage, on the wire side.
• If not OK replace circuit breaker.
• If battery voltage is detected on both sides of the
circuit breaker. Refer to Seat Motor in the Diagnostic
and Testing in this section.
8R - 2 POWER SEATS NS
DIAGNOSIS AND TESTING (Continued)
INDEX
page page
MODE 2
Diagnostic mode 2 provides a way to determine if
the seat/mirror motors and position sensors are con-
nected properly.
ACTIVATION- Press and hold the S and 2 buttons
for 5 seconds to enter diagnostic mode 2. This mode
is exited after 5 seconds of switch inactivity or upon
grounding the RKE input by moving the transmis-
sion out of the PARK position.
Mode 2 will:
• Place the seat and mirror motors at their mid-
point
Fig. 3 Memory Seat/Mirror Module • When a single axis of seat or mirror motion is
requested by pressing a switch, the corresponding
ACTIVATION- Press and hold the S and 1 buttons
motor is energized. This tests switch input and motor
for 5 seconds to enter diagnostic mode 1. This mode
output
is exited at the completion of the mode 1 tasks or
• When the switch is released, the motor will
upon grounding the RKE input to the Memory Seat/
automatically return to its original position. If the
Mirror Module.
corresponding sensor is out of range, then the motor
Mode 1 will:
will not return to its original position. This tests the
• Clear all soft limits to their default hard limit
integrity of the sensors and motor outputs. Refer to
values
(Fig. 3), (Fig. 4), (Fig. 5) and (Fig. 6) for module con-
• Load memory 1 with default settings corre-
nector call outs.
sponding to horizontal rearward, front down, rear
down, and recliner rearward positions
POWER MIRRORS
CONTENTS
page page
INSTALLATION
For installation, reverse the above procedures.
Fig. 4 Power Mirror/Window Switch
page page
page page
OVERHEAD CONSOLE
CONTENTS
page page
COMPASS
The CMTC is self calibrating and usually requires
no adjustment. The compass will continuously per-
form a slow calibration to compensate for small mag-
netic variations common to any automobile.
Uncommon magnetic shifts may be caused by items
such as magnetic base antennas, which can perma-
nently alter the magnetic field of the vehicle roof
panel. If excessive magnetic field continues for 5 min-
utes, the compass heading will go blank and only the
CAL symbol will illuminate. When this occurs, the
Fig. 2 Universal Transmitter Location
vehicle roof panel may require demagnetizing. Refer
to the demagnetizing procedure in this section. The transmitter operates off your vehicle’s battery
Moderate magnetic shifts may, on very rare occa- and charging system; no batteries are needed.
sions, cause the compass heading to display only one The Universal Transmitter incorporates a Rolling
or two of the eight possible headings. Although the Code technology (random digital code signals from
compass will eventually compensate for this shift, it the remote transmitter) within the transmitter mod-
could take several ignition cycles. The compensation ule. This is done so, as an added security measure.
process can be expedited by manually activating the Features of the Universal Transmitter are:
fast calibration routine. Refer to the fast calibrating • Can be used with most other Radio Frequency
procedure in this section. This procedure may be per- (RF) activated devices.
• Individual channels can be trained.
NS OVERHEAD CONSOLE 8V - 3
DESCRIPTION AND OPERATION (Continued)
INSTALLATION
For installation, reverse the above procedures.
When installing the lamp lens, first guide the switch
contact tab on the lens between the lamp switch
plunger and the lamp bezel. Then snap lens onto the
two lens pivots on the bezel.
OVERHEAD CONSOLE
Fig. 6 Compass Mini-Trip Computer
REMOVAL
(4) Remove CMTC module from console. (1) Open the transmitter bin door (Fig. 9).
(2) Remove screw holding the overhead console to
INSTALLATION the headliner. With the screw removed the console is
For installation, reverse the above procedures. retained by one engagement tab located inside the
eyeglass storage bin.
COMPASS MINI-TRIP COMPUTER (CMTC) LAMP (3) Open the eyeglass bin door.
BULBS (4) Press the retaining tab which is located
directly above the door latch.
REMOVAL (5) Lower rear of console away from headliner.
(1) Remove overhead console. (6) Pull console rearward to disengage clips hold-
(2) Rotate bulb socket counterclockwise one quar- ing front of console to roof armature and lower con-
ter turn (Fig. 7). sole.
(7) Disconnect wire connectors from back of CMTC
and reading lamps. Ensure the connectors lock tabs
are fully depressed before disconnecting.
(8) Remove overhead console.
INSTALLATION
For installation, reverse the above procedures.
READING/COURTESY LAMP
Removal
(1) Using a trim stick, lightly pry outward the for-
ward end of reading lamp lens (Fig. 10).
(2) Rotate reading/courtesy lamp socket one quar-
ter turn counterclockwise.
(3) Pull socket out of lamp (Fig. 11).
(4) Pull lamp from socket.
Fig. 7 CMTC Lamp Bulbs
NS OVERHEAD CONSOLE 8V - 7
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
For installation, reverse the above procedures. The
Universal Transmitter will need to be retrained.
Refer to SERVICE PROCEDURES in this section.
SPECIAL TOOLS
SPECIAL TOOL
Degausser 6029
NS/GS WIRING DIAGRAMS 8W - 1
WIRING DIAGRAMS
CONTENTS
page page
INDEX
page page
DESCRIPTION AND OPERATION Components are shown two ways. A solid line
around a component indicates that the component is
INTRODUCTION complete. A dashed line around a component indi-
Chrysler wiring diagrams are designed to provide cates that the component being shown is not com-
information regarding the vehicles wiring content. In plete. Incomplete components have a reference
order to effectively use Chrysler wiring diagrams to number to indicate the page where the component is
diagnose and repair a Chrysler vehicle, it is impor- shown complete.
tant to understand all of their features and charac- It is important to realize that no attempt is made
teristics. on the diagrams to represent components and wiring
Diagrams are arranged such that the power (B+) as they appear on the vehicle. For example, a short
side of the circuit is placed near the top of the page, piece of wire is treated the same as a long one. In
and the ground (B-) side of the circuit is placed near addition, switches and other components are shown
the bottom of the page. as simply as possible, with regard to function only.
All switches, components, and modules are shown
in the at rest position with the doors closed and the
key removed from the ignition.
8W - 01 - 2 8W-01 GENERAL INFORMATION NS/GS
DESCRIPTION AND OPERATION (Continued)
NS/GS 8W-01 GENERAL INFORMATION 8W - 01 - 3
DESCRIPTION AND OPERATION (Continued)
8W - 01 - 4 8W-01 GENERAL INFORMATION NS/GS
DESCRIPTION AND OPERATION (Continued)
CIRCUIT INFORMATION CIRCUIT FUNCTIONS
Each wire shown in the diagrams contains a code All circuits in the diagrams use an alpha/numeric
which identifies the main circuit, part of the main code to identify the wire and its function. To identify
circuit, gage of wire, and color (Fig. 1). 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 second-
ary codes that may apply to some models.
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS (GAUGES)
H OPEN
I NOT USED
Fig. 1 Wire Code Identification J OPEN
STANDARD K POWERTRAIN CONTROL MODULE
COLOR CODE COLOR TRACER L EXTERIOR LIGHTING
COLOR M INTERIOR LIGHTING
BL BLUE WT N NOT USED
BK BLACK WT O NOT USED
BR BROWN WT P POWER OPTION (BATTERY FEED)
DB DARK BLUE WT Q POWER OPTIONS (IGNITION FEED)
DG DARK GREEN WT R PASSIVE RESTRAINT
GY GRAY BK S SUSPENSION/STEERING
LB LIGHT BLUE BK T TRANSMISSION/TRANSAXLE/
LG LIGHT GREEN BK TRANSFER CASE
OR ORANGE BK U OPEN
PK PINK BK or WT V SPEED CONTROL, WIPER/WASHER
RD RED WT W OPEN
TN TAN WT X AUDIO SYSTEMS
VT VIOLET WT Y OPEN
WT WHITE BK Z GROUNDS
YL YELLOW BK
* WITH TRACER
NS/GS 8W-01 GENERAL INFORMATION 8W - 01 - 5
DESCRIPTION AND OPERATION (Continued)
SECTION IDENTIFICATION GROUP TOPIC
The wiring diagrams are grouped into individual
8W-01 thru 8W-09 General Information and
sections. If a component is most likely found in a par-
Diagram Overview
ticular group, it will be shown complete (all wires,
connectors, and pins) within that group. For exam- 8W-10 thru 8W-19 Main Sources of Power and
ple, the Auto Shutdown Relay is most likely to be Vehicle Grounding
found in Group 30, so it is shown there complete. It 8W-20 thru 8W-29 Starting and Charging
can, however, be shown partially in another group if 8W-30 thru 8W-39 Powertrain/Drivetrain
it contains some associated wiring. Systems
8W-40 thru 8W-49 Body Electrical items and A/C
SYMBOLS 8W-50 thru 8W-59 Exterior Lighting, Wipers, and
International symbols are used throughout the wir- Trailer Tow
ing diagrams. These symbols are consistent with 8W-60 thru 8W-69 Power Accessories
those being used around the world.
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-90 Connector Locations
(including grounds)
8W-95 Splice Locations
8W - 01 - 6 8W-01 GENERAL INFORMATION NS/GS
DESCRIPTION AND OPERATION (Continued)
TAKE OUTS
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
Fig. 13 Connector Locking Wedge
(2) Disconnect the connector that is to be repaired
from its mating half/component (4) Position the connector locking finger away from
the terminal using the proper pick from special tool
8W - 01 - 12 8W-01 GENERAL INFORMATION NS/GS
SERVICE PROCEDURES (Continued)
kit 6680. Pull on the wire to remove the terminal (5) Remove 1 inch of insulation from each wire on
from the connector (Fig. 14) (Fig. 15). the harness side.
(5) Reset the terminal locking tang, if it has one. (6) Stagger cut the matching wires on the repair
(6) Insert the removed wire in the same cavity on connector assembly in the opposite order as was done
the repair connector. on the harness side of the repair. Allow extra length
(7) Repeat steps four through six for each wire in for soldered connections. Check that the overall
the connector, being sure that all wires are inserted length is the same as the original (Fig. 16).
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the
repaired connector, if required.
(9) Connect connector to its mating half/component.
(10) Connect battery and test all affected systems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half. Remove connector locking wedge, if
required (Fig. 19).
(3) Remove connector locking wedge, if required
(Fig. 19).
(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 Fig. 21 Terminal Removal Using Special Tool
from the connector (Fig. 20) (Fig. 21).
(5) Cut the wire 6 inches from the back of the con- (7) Select a wire from the terminal repair assem-
nector. bly that best matches the color wire being repaired.
(6) Remove 1 inch of insulation from the wire on (8) Cut the repair wire to the proper length and
the harness side. remove 1 inch of insulation.
8W - 01 - 14 8W-01 GENERAL INFORMATION NS/GS
SERVICE PROCEDURES (Continued)
(9) Place a piece of heat shrink tubing over one SPECIAL TOOLS
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area. WIRING/TERMINAL
(10) Spread the strands of the wire apart on each
part of the exposed wires.
(11) Push the two ends of wire together until the
strands of wire are close to the insulation.
(12) Twist the wires together.
(13) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
Probing Tool Package 6807
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge, if
required, and reconnect the connector to its mating
half/component.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(18) Connect battery, and test all affected systems.
DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 22).
POWER
DISTRIBUTION
SPARE CENTER
30 30 1
CIGAR/
86
87A
85 86
87A
85 ACC.
87 87 2
RELAY
HORN
RELAY 30 30 3
WIPER
86
87A
85 86
87A
85 HIGH/
87 87 4
LOW
A/C RELAY
COMPRESSOR
CLUTCH 30 30 5
WIPER
RELAY 86
87A
85 86
87A
85 ON
87 87 6
RELAY
SPARE 30 30 7
HIGH
86
87A
85 86
87A
85 BEAM
87 87 8
RELAY
FRONT
BLOWER
MOTOR 30 30 9
LOW
RELAY 86
87A
85 86
87A
85 BEAM
87 87 10
RELAY
ENGINE
STARTER 19
MOTOR 30 11
RELAY 86 85
87A
20
87 12
PARK
LAMP 21
30 13
RELAY
86 87A 85
22
TRANSMISSION 87 14
CONTROL
RELAY 86
23
(GAS) 87A 87 30
15
FUEL 85
PUMP 24
RELAY 16
(GAS) 25
FUEL 86
HEATER 87A 87 30
17
85
AUTOMATIC RELAY 26
SHUT (DIESEL)
DOWN 18
86
27
RELAY 87A 87 30
(GAS) 85
DIESEL
POWER
RELAY 28
IOD
J988W-1 GS001002
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 3
FUSES
3 - SPARE A0 6RD
14 - SPARE A0 6RD
A5 18RD/DB
15* 20A A0 6RD
INTERNAL
A14 18RD/WT*
16 20A A0 6RD
INTERNAL
17 20A INTERNAL A0 6RD
* GAS
** DIESEL
BUILT-UP-EXPORT
EXCEPT BUILT-UP-EXPORT
GS001003 J988W-1
8W - 10 - 4 8W-10 POWER DISTRIBUTION NS/GS
87A - -
86 A0 6RD B (+)
87A - -
CIGAR/ACCESSORY RELAY
85 Z1 18BK GROUND
87A - -
86 A0 6RD B (+)
87A - -
*GAS
**DIESEL
J988W-1 GS001004
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 5
87A - -
85 Z1 18BK GROUND
87A - -
85 Z1 20BK GROUND
87A - -
87A - -
EATX
MTX
GS001005 J988W-1
8W - 10 - 6 8W-10 POWER DISTRIBUTION NS/GS
86 A0 6RD B (+)
87A - -
HORN RELAY
86 A0 6RD B (+)
87A - -
86 A0 6RD B (+)
87A - -
87A - -
* CHRYSLER
J988W-1 GS001006
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 7
87A - -
WIPER ON RELAY
GS001007 J988W-1
8W - 10 - 8 8W-10 POWER DISTRIBUTION NS/GS
ES26
FUSIBLE ES09
GAS DIESEL LINK
A54 ES11
10
A0 A0 RD
6 2 ES28 GAS DIESEL
RD RD
A54 A11
10 6
RD FUSIBLE BK/GY
BATTERY LINK
(8W-20-2) 1 A0
ENGINE GLOW A11 GENERATOR
(8W-20-3) 6 10
STARTER PLUG RD DG
(8W-20-2)
MOTOR RELAY (8W-20-3)
(8W-21-2) (DIESEL)
(8W-21-3) (8W-30-32)
POWER
DISTRIBUTION
CENTER
FUSE FUSE FUSE FUSE FUSE
27 26 25 24 23
40A 40A 40A 40A 40A
(8W-10-12) (8W-10-13) (8W-10-15) (8W-10-15) (8W-10-16)
6 C1 5 C4 6 C4 6 C7 3 C4
A4 A2 A10 A16 A1 30
12 12 12 12 12 ENGINE
BK/RD PK/BK RD/DG GY RD STARTER
MOTOR
GAS DIESEL RELAY
TO TO TO TO (8W-21-2)
(8W-21-3)
JUNCTION JUNCTION CONTROLLER IGNITION
BLOCK BLOCK ANTI-LOCK TO TO SWITCH
BRAKE RADIATOR RADIATOR
FAN FAN RELAY
RELAY NO. 2
4 C7
A17
12
RD/BK
TO
RADIATOR
FAN RELAY
NO. 3
J988W-1 GS001008
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 9
POWER
FROM DISTRIBUTION
FUSE CENTER
19 (PDC)
(8W-10-8)
A
5 C3 2 C2
M1 M1 F41
20 20 20
PK PK PK/VT
TO TO TO
JUNCTION MEMORY JUNCTION
BLOCK SEAT/ BLOCK
MIRROR
MODULE
9 C6 10 C8
A14 A5
18 18
RD/WT RD/DB
TO TO
POWERTRAIN TRANSMISSION
CONTROL CONTROL
MODULE MODULE
GS001009 J988W-1
8W - 10 - 10 8W-10 POWER DISTRIBUTION NS/GS
POWER
FROM
FUSE
DISTRIBUTION
15 (PDC) CENTER
(8W-10-9)
B
TO TO TO
STOP CONTROLLER JUNCTION
LAMP ANTI-LOCK BLOCK
SWITCH BRAKE
86 30 86 30
FUSE LOW HIGH
8 BEAM BEAM
20A RELAY RELAY
(8W-10-31) (8W-50-2) (8W-50-2)
87 87
30
CIGAR/
ACCESSORY
RELAY FUSE FUSE FUSE FUSE
(8W-41-3) 7 6 5 4
15A 20A 10A 10A
(8W-10-33) (8W-10-33) (8W-10-33) (8W-10-33)
(8W-10-34) (8W-10-34) (8W-10-34) (8W-10-34)
1 C3 8 C5 6 C5 1 C5
EXCEPT EXCEPT
BUILT-UP BUILT-UP BUILT-UP BUILT-UP
-EXPORT -EXPORT -EXPORT -EXPORT OTHER CHRYSLER OTHER CHRYSLER
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
28 (8W-10-9)
10A
5 C3
M1 M1 16 C1
20 20 MEMORY
PK PK SEAT/
MIRROR
MODULE
(8W-62-3)
13 C1 (8W-63-4)
JUNCTION
BLOCK
9 (8W-12-2)
BODY
CONTROL
MODULE
(8W-45-2)
6 C4 13 C4 17 C4
M1 M1 M1 M1 M1
20 20 20 20 20
PK PK PK PK PK
M1 2 16
20 INSTRUMENT 1 C3 DATA LINK
PK CLUSTER IGNITION CONNECTOR
(8W-40-2) SWITCH (8W-30-3)
*8 1 START (8W-30-30)
12 2 RUN
MESSAGE 1 4 0 OFF
3 LOCK
CENTER 2 0 3
4 ACC
(8W-46-2)
(8W-10-14) 7 C1
RADIO
(8W-47-2)
2 C3
3
REMOTE A81
KEYLESS 20
DG/RD
ENTRY
MODULE M1
(8W-61-5) 22 15 C4
PK JUNCTION
D1 BLOCK
(8W-12-2)
D3
7 P50 FUSE
NOT 2 * RHD
USED 10A
(8W-12-9)
GS001011 J988W-1
8W - 10 - 12 8W-10 POWER DISTRIBUTION NS/GS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
(8W-10-8)
FUSE
27
40A
6 C1
A4
12
BK/RD
35 C1
JUNCTION
30 BLOCK
REAR (8W-12-2)
WINDOW
DEFOGGER
RELAY
(8W-48-2)
87
FUSE
7
10A
(8W-12-10)
6 C1 20 C4
C15
12
BK/WT
12 B17
LJ01
C15
12
C16
BK/WT
20
C16
LB/YL
20
1 J03A LB/YL
L16 4 C1
PASSENGER
C15
12
POWER
BK/WT MIRROR
(8W-48-2)
4 C1
REAR DRIVER
WINDOW POWER
DEFOGGER MIRROR
(8W-48-2) (8W-48-2)
J988W-1 GS001012
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 13
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
(8W-10-8)
FUSE
26
40A
5 C4
A2
12
PK/BK
4 C1
JUNCTION
WASHER BLOCK
MODULE (8W-12-2)
PTC (BUILT-UP
3 -EXPORT
9A P (8W-53-5)
(8W-12-14)
(8W-12-15)
33 C1 4 C4
HEATED
OTHER SEATS
A2 B09 A2
12 3
PK/BK
HS5D 12
PK/BK
A2
B09 12
2 PK/BK
S02 C
A3 TO
12 IGNITION
PK/BK HS6D SWITCH
2
S02 (8W-10-14)
1
POWER
SEAT
CIRCUIT
BREAKER
30A
(8W-63-2)
(8W-63-3)
(8W-63-4)
GS001013 J988W-1
8W - 10 - 14 8W-10 POWER DISTRIBUTION NS/GS
FROM 9 8 C3
JUNCTION *11
BLOCK
(8W-10-13) G9
20
C
GY/BK BODY
CONTROL
BATT M1 MODULE
(8W-45-5)
(8W-10-11)
4 C2
A2 A1 M1 G9 G26
12 12 20 20 20
PK/BK RD PK GY/BK LB
3 C1 7 C1 1 C3 2 C1 1 C2
IGNITION
KEY-IN
SWITCH
SWITCH 1 START
1 4 1 4 1 4 1 4 1 4 2 RUN
2 3 2 3 2 3 2 3 2 3 0 OFF
0 0 0 0 0 3 LOCK
4 ACC
4 C1 10 C1 8 C1 9 C1 2 C3 1 C1 2 C2
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
(8W-10-8)
FUSE FUSE
25 24
40A 40A
6 C4 6 C7
A16
12
GY
GAS DIESEL
A10
12
RD/DG
A16 A16
12 12
GY GY
25 4 8
CONTROLLER RADIATOR RADIATOR
ANTI-LOCK FAN FAN
BRAKE RELAY RELAY
(8W-35-2) (8W-42-8) NO. 2
(8W-42-10)
GS001015 J988W-1
8W - 10 - 16 8W-10 POWER DISTRIBUTION NS/GS
ST F45 ST T141
(8W-12-16) (8W-12-16)
F45 T141
20 20
YL/RD YL/RD
EATX MTX
BATT A0 (8W-10-8)
3 C2
POWER
DISTRIBUTION
30 86
ENGINE CENTER
FUSE (8W-10-8)
23 STARTER
40A MOTOR
RELAY
87 85
3 C4 3 C7 4 C6 7 C8
DIESEL GAS
A1 T40 BATT M1 F45
12 12 E95 18
6
RD BR B107 K90 K90 (8W-12-20) YL/RD
K90 18 18
20 TN TN M1
B4 B23 ENGINE TN 20 8
4 P18 STARTER PK TRANSMISSION
A1 MOTOR 3 31 C1 CONTROL
12 (8W-21-2) POWERTRAIN POWERTRAIN
RD MODULE
(8W-21-3) CONTROL CONTROL (8W-31-5)
MODULE MODULE
(8W-30-28) (8W-30-6)
7 C1 (8W-30-20) 1 C3
IGNITION
SWITCH
1 START
2 RUN
1 4 1 4 1 4 0 OFF
2 0 3 2 0 3 2 0 3 3 LOCK
4 ACC
(8W-10-14)
10 C1 8 C1 9 C1 2 C3
A41 A31 A21 A81
12 12 12 20
YL BK/WT DB DG/RD
7 C4 31 C3 31 C4 15 C4
JUNCTION
D1 BLOCK
(8W-12-2)
FUSE FUSE FUSE PTC D3
8 9 PTC 1
10 8
10A 15A 9A FUSE
10A 9A
(8W-12-11) (8W-12-11) (8W-12-13) 2
(8W-12-16) (8W-12-16) 10A
(8W-12-9)
30 14
BODY PTC
NAME PTC 9 FUSE
BRAND CONTROL 6
MODULE 7 9A
SPEAKER 9A (8W-12-16) 20A
RELAY (8W-45-2) (8W-12-9)
(8W-12-16)
(8W-47-4)
J988W-3 GS001016
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 17
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-8)
22
40A
86 30
PARK
LAMP
RELAY
85 87
10 C3 4 C1
L97 L7
18 12
PK/DB BK/YL
9 C2 2 C1
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
3 5
15A 15A
(8W-12-8) (8W-12-8)
FUSE
4
FUSE 15A
1 (BUILT-UP
10A -EXPORT)
(8W-12-8) (8W-12-8)
16 1
BODY
CONTROL
MODULE
(8W-45-3)
GS001017 J988W-3
8W - 10 - 18 8W-10 POWER DISTRIBUTION NS/GS
7 C2
F20
20
WT
BATT A0 (8W-10-8)
5 C2
POWER
DISTRIBUTION
CENTER
(8W-10-8)
FUSE
21
40A
86 30
FRONT
BLOWER
MOTOR
RELAY
85 87
2 C4 3 C1
C71
12
Z1 DB
18
BK
B35 B23
35 P18
C71
12
DB
10 1
G300 FRONT
(8W-15-7) BLOWER
MOTOR
(8W-42-2)
J988W-3 GS001018
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 19
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-8)
20 19
40A 30A
(DIESEL)
86 87 87A
WIPER
ON
RELAY
(8W-53-2)
(8W-53-3)
85 30
86 30
WIPER
HIGH/
LOW
RELAY
(8W-53-2)
85 87 87A
4 C7 7 C5 5 C5 4 C5 3 C5 2 C4
B1 B23
1 P18
V16 10
20
WT
G300
(8W-15-7)
5
FRONT
WIPER
SWITCH 3 1
(PART OF WIPER
8 MULTI- MODULE
RADIATOR FUNCTION (8W-53-2)
FAN SWITCH)
RELAY 73 C1 (8W-53-2)
NO. 3 BODY (8W-53-3)
(8W-42-10) CONTROL
MODULE
(8W-45-4)
GS001019 J988W-3
8W - 10 - 20 8W-10 POWER DISTRIBUTION NS/GS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-9)
18
15A
2 C2
F41
20
PK/VT
15 C2
JUNCTION
BLOCK
(8W-12-2)
D
TO
COURTESY
LAMP
RELAY
(8W-10-21)
19 C2 16 C3 20 C3
UNIVERSAL
F41 F41 F41 F41
20 20 20 20
GARAGE
PK/VT PK/VT PK/VT PK/VT DOOR
B75 1
OPENER
2
C20 9 1 SENTRY 4 (PART OF
POWER GLOVE KEY FRONT
OVERHEAD MIRROR BOX IMMOBILIZER F41 READING
OTHERS CONSOLE SWITCH LAMP MODULE 20 LAMPS/
(8W-62-2) (8W-44-2) PK/VT SWITCH)
(BUILT-UP
(8W-62-4) (8W-49-3)
-EXPORT)
(8W-39-5)
CS02
F41 F41 F41 F41 F41 F41 F41
20 20 20 20 20 20 20
PK/VT PK/VT PK/VT PK/VT PK/VT PK/VT PK/VT
4 3 3 B
FRONT RIGHT RIGHT RIGHT
READING MID REAR VISOR/
F41 LAMPS/ READING READING VANITY
20 SWITCH LAMP LAMP MIRROR
PK/VT
(8W-44-2) (8W-44-4) (8W-44-4) LAMPS
(8W-44-3)
3 3 3 B
FRONT LEFT LEFT LEFT
READING MID REAR VISOR/
LAMPS/ READING READING VANITY
SWITCH LAMP LAMP MIRROR
(8W-44-2) (8W-44-4) (8W-44-4) LAMPS
(8W-44-3)
J988W-3 GS001020
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 21
JUNCTION
FROM BLOCK
JUNCTION (8W-12-2)
BODY BLOCK
CONTROL (8W-10-20)
MODULE F
(8W-45-4) D
TO
POWER
17 MIRROR
UNFOLD
86 30 RELAY
COURTESY (BUILT-UP-EXPORT)
LAMP (8W-10-22)
RELAY
85 87
D4
10 C3 34 C3 28 C3 22 C2 6 C2 29 C2 29 C3
M112 M111 M113 M113 M11 M11
22 22 20 20 20 20
BR/LG BR/WT LB/PK LB/PK PK/LB PK/LB
3 C1 9 C1 11 C1 B75 M11
4
HEADLAMP C20 20 M11
PK/LB 20
SWITCH PK/LB
(8W-50-9) CS1 B17
(8W-50-10) 3 2
LJ01
KEY-IN
M113 HALO
20 LAMP
CS01 LB/PK M11 B01 (8W-44-3)
20 3
PK/LB
D02
M113 M113 2
20 20
LB/PK LB/PK
CENTER B03
DOME 6
D01P
1 M113 1 LAMP
RIGHT 20 RIGHT (8W-44-4) M11 M11
MID LB/PK REAR 20 20
M113 M113
20 READING READING 20
PK/LB PK/LB
LB/PK LAMP LAMP LB/PK 1
(8W-44-4) (8W-44-4)
J02A PASSENGER
1 1 2 3
L15 DOOR
LEFT LEFT REAR
COURTESY
MID REAR DOME
LAMP
READING READING LAMP 1 (8W-44-3)
LAMP LAMP (8W-44-4)
DRIVER
(8W-44-4) (8W-44-4)
DOOR
M11 COURTESY
M11
20 20 LAMP
PK/LB PK/LB (8W-44-3)
1 1
RIGHT LEFT
LIFTGATE LIFTGATE
FLOOD FLOOD
LAMP LAMP
(8W-44-4) (8W-44-4)
GS001021 J988W-3
8W - 10 - 22 8W-10 POWER DISTRIBUTION NS/GS
BUILT-UP-EXPORT
JUNCTION
FROM BLOCK
COURTESY (8W-12-2)
LAMP
RELAY
(8W-10-21)
F
86 87 87A 86 87 87A
POWER POWER
MIRROR MIRROR
UNFOLD FOLD
RELAY RELAY
(8W-62-8) (8W-62-8)
85 30 85 30
11 C4 11 C3
5 C2 6 C2
PASSENGER
POWER
M
MIRROR
(8W-62-8)
5 C2 6 C2
DRIVER
POWER
M
MIRROR
(8W-62-8)
J988W-3 GS001022
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 23
GAS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-9)
17
20A
86 30
AUTOMATIC
SHUT
DOWN
RELAY
85 87
8 C6 5 C6
K51 A142
18 18
DB/YL DG/OR
67 C2
POWERTRAIN
CONTROL
MODULE
(8W-30-2)
ES12
A142 A142 A142 A142 A142 A142
18 18 18 18 18 18
DG/OR DG/OR DG/OR DG/OR DG/OR DG/OR
E43 2
2
B70 UPSTREAM 6 C1
HEATED POWERTRAIN
A142 OXYGEN CONTROL
18 SENSOR MODULE
DG/OR (8W-30-2)
(8W-30-7)
*3
(8W-30-21)
2 1 **2
DOWNSTREAM GENERATOR IGNITION
HEATED (8W-20-2) COIL
OXYGEN PACK
(8W-30-8)
SENSOR
(8W-30-14)
(8W-30-7)
(8W-30-22)
(8W-30-21)
2.4L 2.0L 3.3L/3.8L
E69
10 A142 A142
F09
18 18
FS03 DG/OR DG/OR
(2.4L)
A142 A142 A142 A142 G E
18 18 18 18
DG/OR DG/OR DG/OR DG/OR TO TO
2 2 2 2 ES99 E78
(8W-10-24) (8W-10-24)
FUEL FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR INJECTOR
NO. 1 NO. 2 NO. 3 NO. 4 * 3.3L/3.8L
(8W-30-15) (8W-30-15) (8W-30-15) (8W-30-15) ** 2.0L/2.4L
GS001023 J988W-3
8W - 10 - 24 8W-10 POWER DISTRIBUTION NS/GS
GAS
FROM FROM
ES12 ES12
(8W-10-23) (8W-10-23)
E G
A142 A142
18 18
DG/OR DG/OR
1 E78
F02 ES99
(2.0L)
2 2 2 2
FUEL FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR INJECTOR
NO. 1 NO. 2 NO. 3 NO. 4
(8W-30-9) (8W-30-9) (8W-30-9) (8W-30-9)
FS01
(3.3L/3.8L)
1 1 1
FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR
NO. 2 NO. 4 NO. 6
(8W-30-23) (8W-30-23) (8W-30-23)
1 1 1
FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR
NO. 1 NO. 3 NO. 5
(8W-30-23) (8W-30-23) (8W-30-23)
J988W-3 GS001024
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 25
DIESEL
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-9)
17
20A
86 30
DIESEL
POWER
RELAY
85 87
8 C6 5 C6
K51
20
DB/YL A142
18
3 E96 DG/OR
B108
42
POWERTRAIN
CONTROL
MODULE
(8W-30-28)
ES06
1 7 E96
B108
A142 A142 A142 A142 A142 A142 A142
18 18 18 18 18 18 18
DG/OR DG/OR DG/OR DG/OR DG/OR DG/OR DG/OR
1
BS33 EGR GENERATOR
A142 A142 A142 SOLENOID (8W-20-3)
16 16 16 (8W-30-29)
DG/OR DG/OR DG/OR
68 23 45 9 10
POWERTRAIN FUEL
CONTROL PUMP
MODULE MODULE
(8W-30-28) (8W-30-33)
ES29
1 C6
POWER A142 A142 A142
86 18 18 18
A/C
DISTRIBUTION
A142 DG/OR DG/OR DG/OR
COMPRESSOR CENTER
(8W-10-10) 18 4 4
CLUTCH
DG/OR RADIATOR RADIATOR
RELAY
4
(8W-42-9) 3 FAN FAN
GLOW RADIATOR
85 RELAY RELAY
PLUG FAN
NO. 1 NO. 3
RELAY (8W-42-10) RELAY (8W-42-10)
(8W-30-32) NO. 2
GS001025 (8W-42-10) J988W-3
8W - 10 - 26 8W-10 POWER DISTRIBUTION NS/GS
GAS
30 C1
F87
18
WT/BK
BATT A0 (8W-10-8)
6 C2
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-9)
16
20A
86 30
FUEL
PUMP
RELAY
85 87
3 C6 7 C2 9 C6
A141
K31 16 A14
18 DG/WT 18
BR RD/WT
4 B13
AW4
4
FUEL
TANK
MODULE
(8W-30-6)
74 C2 (8W-30-20) 46 C2
POWERTRAIN
CONTROL
MODULE
(8W-30-2)
(8W-30-6)
(8W-30-20)
J988W-3 GS001026
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 27
DIESEL
ST-RUN A21 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
PTC
1
9A
(8W-12-13)
30 C1
F87
18
F87 WT/BK
18 BATT A0 (8W-10-8)
WT/BK 6 C2
POWER
DISTRIBUTION
38 CENTER
POWERTRAIN (8W-10-9)
FUSE
CONTROL 16
MODULE 20A
(8W-30-36)
86 30
FUEL
HEATER
RELAY
85 87
6 C6 3 C6 7 C2
F87 Z1 A141
18 20 16
WT/BK BK DG/WT
1 4 B33
VEHICLE E120
SPEED
A141
SENSOR 18
(8W-30-36) DG/WT
BATTERY ES40
(8W-20-3)
A141 A141
18 18
DG/WT DG/WT
1 1
FUEL CRANK
HEATER CASE
Z0 Z0 Z0
2 8 10
(8W-30-29) HEATER
BK BK BK (8W-30-29)
86 30
TRANSMISSION
CONTROL
RELAY
85 87
3 C8 4 C8 2 C8 10 C8
Z16
18
BK
T15 T16 A5
18 18 18
LG RD RD/DB
ES11
(8W-15-2)
BATTERY
(8W-20-2)
Z0
10 ES01
BK
G100
15 16 17 56
TRANSMISSION
CONTROL
MODULE
(8W-31-2)
J988W-3 GS001028
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 29
FUSE FUSE 86 30
13 12 A/C
20A 25A COMPRESSOR
CLUTCH
RELAY
85 87
8 C3 6 C3 7 C6 2 C6 9 C5
F32 A20 C3 L9
18 12 18 18
PK/DB RD/DB DB/BK BK/WT
9 1
CONTROLLER A/C
ANTI-LOCK COMPRESSOR
BRAKE CLUTCH
(8W-35-2) (8W-42-7)
(8W-42-9)
6 27 C2
STOP JUNCTION
GAS DIESEL
LAMP BLOCK
1
SWITCH COMBINATION (8W-12-2)
C13 C13
(8W-33-5) FLASHER/
18 20
(8W-51-7) DRL
DB/OR DB/OR
MODULE
64 C2 9 E97 (8W-50-11)
POWERTRAIN B106 (8W-50-12)
CONTROL 28
MODULE POWERTRAIN
(8W-30-5) CONTROL
MODULE
(8W-30-37)
GS001029 J988W-3
8W - 10 - 30 8W-10 POWER DISTRIBUTION NS/GS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-10)
9
20A
86 30
HORN
RELAY
(8W-41-2)
85 87
4 C2 8 C2
X4 X2
20 18
GY/OR DG/RD
4 C2 BS19
JUNCTION
BLOCK X2 X2
(8W-12-2) 18 18
18 DG/RD DG/RD
HORN BODY
RELAY CONTROL A A
MODULE
CONTROL
(8W-45-3)
HIGH LOW
HORN NOTE NOTE
RELAY
CONTROL
HORN HORN
(8W-41-2) (8W-41-2)
20 C2
X3
20
BK/RD
1 C2
CLOCKSPRING
X3
20
BK/RD
HORN
SWITCH
J988W-3 GS001030
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 31
16 C2
F1
20
DB
BATT A0 (8W-10-8)
9 C2
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-10)
8
20A
86 30
CIGAR/
ACCESSORY
RELAY
(8W-41-3)
85 87
2 C4 10 C2
F30
16
RD
A22 B23
Z1 22 P34
18
BK
F30 F30
16 16
RD RD
10 1 1
G300 FRONT REAR
(8W-15-7) CIGAR CIGAR
LIGHTER/ LIGHTER/
POWER POWER
OUTLET OUTLET
(8W-41-3) (8W-41-3)
GS001031 J988W-3
8W - 10 - 32 8W-10 POWER DISTRIBUTION NS/GS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
(8W-10-10)
86 30 86 30
LOW HIGH
BEAM BEAM
RELAY RELAY
85 87 85 87
L94 L324
20 20
OR/WT WT/LG
J988W-3 GS001032
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 33
EXCEPT BUILT-UP-EXPORT
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
(8W-10-10)
86 30 86 30
LOW HIGH
BEAM BEAM
RELAY RELAY
(8W-50-2) (8W-50-2)
85 87 85 87
8 C5 1 C3 1 C5 6 C5
TO TO TO TO 1
BS15 RIGHT LEFT LEFT MESSAGE
(8W-50-6) HEADLAMP HEADLAMP HIGH CENTER
(8W-50-6) (8W-50-6) HEADLAMP (8W-46-4)
(8W-50-8) (8W-50-5)
TO
RIGHT
DODGE/
LOW PYLMOUTH CHRYSLER
TO HEADLAMP
FOG (8W-50-4)
LAMP L34 L34
RELAY 20 20
(IN JB) RD/OR RD/OR
(8W-50-5)
TO TO
RIGHT RIGHT
HEADLAMP HIGH
(8W-50-6) HEADLAMP
(8W-50-8) (8W-50-4)
GS001033 J988W-3
8W - 10 - 34 8W-10 POWER DISTRIBUTION NS/GS
BUILT-UP-EXPORT
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
(8W-10-10)
86 30 86 30
LOW HIGH
BEAM BEAM
RELAY RELAY
(8W-50-2) (8W-50-2)
85 87 85 87
8 C5 1 C3 1 C5 6 C5
2 1 B18 B23
LEFT 18 P18
HEADLAMP
(8W-50-6) L34
20
RD/OR
*6
1
MESSAGE
BS16 CENTER
(8W-46-4)
L44
20 L44
VT/RD 20
VT/RD
B3 B23
3 P18 3
L44 RIGHT
20
VT/RD HEADLAMP
L44 LEVELING
20 L44
MOTOR 20
VT/RD
3 (8W-50-8) VT/RD
LEFT
2 C1 HEADLAMP 2 1
HEADLAMP LEVELING RIGHT
SWITCH MOTOR HEADLAMP
(8W-50-10) (8W-50-8) (8W-50-8)
* RHD
J988W-3 GS001034
NS/GS 8W-10 POWER DISTRIBUTION 8W - 10 - 35
30 C1 31 C2
F87 A22
18 12
WT/BK BK/OR
6 C2 1 C4
POWER
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-8)
2 1
10A 10A
2 C5 10 C5
F14 F23
18 18
LG/YL DB/YL
1 C2 2 C2
AIRBAG
CONTROL
MODULE
(8W-43-2)
GS001035 J988W-3
NS/GS 8W - 12 JUNCTION BLOCK 8W - 12 - 1
TOP OF
JUNCTION BLOCK
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 8 9 10 11 12 13 14
C1 15 16 17 18 15 16 17 18
C2
19 20 21 22 19 20 21 22
23 24 25 26 27 28 29 23 24 25 26 27 28 29
30 31 32 33 34 35 36 30 31 32 33 34 35 36
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 8 9 10 11 12 13 14
C4 15 16 17 18 15 16 17 18
C3
19 20 21 22 19 20 21 22
23 24 25 26 27 28 29 23 24 25 26 27 28 29
30 31 32 33 34 35 36 30 31 32 33 34 35 36
1 2 3 4 5 6 7 8 9 10 PTC’S
12 9 2 8
D3 85
87A
86 85
87A
86
D4
1 5 2
10 11 1 3
30 30
2 4 1
7 6
DRIVER
DOOR UNLOCK WASHER POWER MIRROR POWER MIRROR
D1 RELAY MODULE FOLD RELAY UNFOLD RELAY D2
1 87 P 87 87 1
30 30 30 30
85 85 85
1 2 3 4 5 6 7 8 9 10 11 12 FUSES
J988W-3 GS001202
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 3
FUSES
PTC’S
(POSITIVE TEMPERATURE COEFFICIENT)
2 - - -
3 9A INTERNAL INTERNAL
4 - - -
5 - - -
6 - - -
7 9A INTERNAL INTERNAL
8 9A INTERNAL INTERNAL
10 - - -
FOG LAMPS
GS001203 J988W-3
8W - 12 - 4 8W-12 JUNCTION BLOCK NS/GS
11 INTERNAL GROUND
- - -
J988W-3 GS001204
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 5
87A - -
85 INTERNAL GROUND
- - -
* CHRYSLER
GS001205 J988W-3
8W - 12 - 6 8W-12 JUNCTION BLOCK NS/GS
- - -
J988W-3 GS001206
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 7
WASHER MODULE
(BUILT-UP-EXPORT)
DIODES
D1
2 INTERNAL CATHODE
D2
(NOT USED)
2 - CATHODE
D3
2 INTERNAL CATHODE
D4
2 INTERNAL CATHODE
GS001207 J988W-3
8W - 12 - 8 8W-12 JUNCTION BLOCK NS/GS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER 1
FUSE (8W-10-8)
22
LEFT
40A FOG
(8W-10-17) LAMP
(BUILT-UP
-EXPORT)
86 30 F39 (8W-50-7)
PARK 18
LAMP PK/LG
RELAY
1
F39 RIGHT
85 87
18 FOG
PK/LG LAMP
10 C3 4 C1
L97 L7
(BUILT-UP
18 12 -EXPORT)
PK/DB BK/YL (8W-50-7)
9 C2 2 C1 3 C1
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE
1 3 5
10A 15A 15A
FUSE
56 4
16 1 15A
BODY WASHER
CONTROL MODULE
MODULE (BUILT-UP
(8W-45-3) -EXPORT)
(8W-53-5)
23 C1 5 C1 18 C1
L78 L77 L77
20 L77 L77
18 20 20
DG/YL 20 BR/LB BR/LB
BR/YL BR/YL
L78 TRAILER TRAILER
20 TOW OTHERS TOW OTHERS
DG/YL B28 B23 B17
5
28 P18 LJ01 B99
4 B98 4
T08 L77 T05
L78 5 C2 20
HEADLAMP BR/LB
18
L77
BR SWITCH
TRAILER L78 20
2 20 (BUILT-UP BR/LB
TOW J02A
DG/YL *1
-EXPORT) 6 *3
*1 CONNECTOR (8W-50-10) L15 4
2 (8W-54-2) *3 2 L77
4 LEFT LEFT
RIGHT 20
REAR
FRONT RIGHT FRONT BR/LB
REAR PARK/ LAMP
PARK/ ASSEMBLY
TURN LAMP TURN 2
(8W-51-4)
SIGNAL ASSEMBLY SIGNAL LICENSE (8W-51-5)
(8W-51-4) LAMP LAMP
LAMP (8W-51-6)
(8W-51-5) (8W-50-11) (8W-51-2)
(8W-50-11) (8W-51-6)
(8W-50-12) (8W-50-12)
J988W-3 * BUILT-UP-EXPORT GS001208
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 9
FUSE FUSE
2 6
10A 20A
7 11 12 13
BODY
CONTROL
MODULE
(8W-45-2)
20 C1 10 C4 14 C4 14 C1 7 C1
V23
18
F11 F11 F11 V23 BR/PK V23
20 20 20 18 18
RD/WT RD/WT RD/WT BR/PK B75 BR/PK
11
C20
8 B17
LJ01
4 P50 CS04
NOT V23
USED 18
C19 BR/PK
V23 1
EC1
18
BR/PK 3 J03A
V23 L16
18
8 B33 BR/PK
E36 11 V23
INSTRUMENT 18
1 BR/PK
CLUSTER
(8W-40-2) AUTOMATIC
2
F11 DAY/NIGHT
18 REAR
MIRROR
RD/WT (8W-44-6) WIPER
MOTOR
(8W-53-4)
10 C1
11 A/C
TRANSMISSION V23
HEATER 18
CONTROL CONTROL BR/PK
MODULE (8W-42-4)
(8W-31-5)
4
10 OVERHEAD
MESSAGE COMPASS/ CONSOLE
CENTER MINI-TRIP (8W-49-2)
(8W-46-2) COMPUTER
GS001209 J988W-3
8W - 12 - 10 8W-12 JUNCTION BLOCK NS/GS
BATT A4 (8W-10-12)
JUNCTION
BLOCK
30 (8W-12-2)
REAR
WINDOW
DEFOGGER
RELAY
(8W-48-2)
87
FUSE
7
10A
6 C1 20 C4
12 B17
LJ01
C15
12
BK/WT
1 J03A
L16
4 C1
PASSENGER
C15 POWER
12 MIRROR
BK/WT (8W-48-2)
4 C1
REAR DRIVER
WINDOW POWER
DEFOGGER MIRROR
(8W-48-2) (8W-48-2)
J988W-3 GS001210
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 11
86 30
NAME
BRAND
SPEAKER
RELAY
(PREMIUM
85 87 RADIO)
(8W-12-19)
13 C3 2 C2 22 C1 24 C3 15 C3 12 C2
X12
X60 Z1 X1 20 X12 V20 C40
20 14 16 RD/WT 18 18 12
RD/DG BK DG/RD RD/WT RD BR/WT
6 P50
NOT
USED
1 C1 3
ELECTRIC REAR
WIPER A/C
1
DE-ICER HEATER
RADIO (8W-48-3) UNIT
CHOKE (8W-42-6)
(8W-47-4)
8
G300
(8W-15-6)
1 C2 6 C1
RADIO
(8W-47-2)
(8W-47-4)
GS001211 J988W-3
8W - 12 - 12 8W-12 JUNCTION BLOCK NS/GS
FUSE
12
10A
86 6
REAR COMBINATION
WINDOW FLASHER/
DEFOGGER DRL
RELAY MODULE
(8W-48-2) (8W-51-3)
85
32 C4 14 C2 18 C2 7 C2
F20
C14 F20 18 F20 F20 F20
22 20 WT 20 20 20
WT/RD WT WT WT WT
23
CONTROLLER B56
4
ANTI-LOCK HS5P
1 C1
BRAKE
A/C B09 (8W-35-2)
4
HEATER HS5D HS4
CONTROL MTX EATX F20 F20
(8W-42-4) 20 20
F20 WT WT
F20 20 F20
20 WT 20 D B
WT WT PASSENGER
DIESEL GAS
HEATED
SEAT
B33 B33
HS2 5 B33 5
E36 5 SWITCH
E120 E36 (8W-63-8)
F20 F20 F20 F20 F20
20 20 20 18 18
WT WT WT WT WT
5 C2
POWER
D B 86 DISTRIBUTION
DRIVER FRONT CENTER
HEATED BLOWER (8W-10-8)
SEAT MOTOR
RELAY
SWITCH (8W-42-2)
(8W-63-7)
85
1 1
BACK-UP TRANSMISSION
SWITCH RANGE
(8W-51-5) SENSOR
(8W-31-3)
J988W-3 GS001212
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 13
86 (8W-42-9) 85
GAS DIESEL
6 C6 1 C6 1 C6 2 C5
BUILT-UP EXCEPT BUILT-
-EXPORT UP-EXPORT
F87 F87
18 18
A142
WT/BK BK/WT
18
DG/OR F14 F14
ES07 18 20
(GAS) LG/YL LG/YL
F87
F87 18 F87
18 WT/BK 18
WT/BK WT/BK
3 TO
EVAP ES29
LEAK (8W-10-25) B23 B23
23 P18
DETECTION
PUMP
(EXCEPT BUILT- F14
UP-EXPORT) 18
(8W-30-18) LG/YL
(8W-30-26)
20 C1 2 1 C2
POWERTRAIN EGR AIRBAG
CONTROL SOLENOID CONTROL
MODULE (8W-30-20)
MODULE
(8W-30-2) (8W-43-2)
GS001213 J988W-3
8W - 12 - 14 8W-12 JUNCTION BLOCK NS/GS
BATT A2 (8W-10-13)
JUNCTION
BLOCK
(8W-12-2)
PTC
3
9A
(8W-10-13)
86 87 87A 86 87 87A
DRIVER DOOR
DOOR UNLOCK
UNLOCK RELAY
RELAY (8W-61-3)
(RKE) (8W-61-4)
(8W-61-7) (8W-61-7)
85 30 (8W-61-8) 85 30
(8W-61-8)
5 6
BODY
CONTROL
MODULE
(8W-45-7)
RKE OTHER
9 C1 19 C1 15 C1
5 J02A
2 L15 2
RIGHT LEFT
F131 F136 REAR F136 REAR
20 20 SLIDING 20 SLIDING
BK/PK VT/YL DOOR VT/WT DOOR
CONTACT CONTACT
(8W-61-4) (8W-61-4)
1 1 (8W-61-8) 3 (8W-61-8)
DRIVER PASSENGER LIFTGATE
DOOR DOOR LOCK
LOCK LOCK MOTOR
MOTOR MOTOR (8W-61-3)
(8W-61-3) (8W-61-3) (8W-61-7)
(8W-61-7) (8W-61-7)
J988W-3 GS001214
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 15
BATT A2 (8W-10-13)
JUNCTION
BLOCK
(8W-12-2)
PTC
3
9A
(8W-10-13)
P
86 87 87A WASHER
DOOR MODULE
LOCK (BUILT-
RELAY UP-EXPORT)
(8W-61-3) (8W-53-5)
(8W-61-4)
85 30 (8W-61-7)
(8W-61-8)
8
BODY
CONTROL
MODULE
(8W-45-7)
32 C1 11 C1 26 C1
15 B75
B02 B03 9 B17 C20
12 10
D01D D01P LJ01J01A F133
20
BR/YL
GS001215 J988W-3
8W - 12 - 16 8W-12 JUNCTION BLOCK NS/GS
3 C2 5 C3 16 C2 34 C2 17 C2 13 C2 10 C2
B03
12
D01P
MTX EATX
F1 F1 F1 F1
20 20 20 20
F21 F55 F45 F45
DB DB DB DB
16 12 20 20
TN TN/DG YL/RD YL/RD
1
7 1 CLUTCH
F55 CLUTCH
FRONT 12
INTERLOCK
WIPER TN/DG INTERLOCK SWITCH
SWITCH SWITCH JUMPER
T141
(PART OF B02 20
MULTI- 2 YL/RD
14 7 D01D
FUNCTION 1
F21 F55 2
SWITCH) 16 14 PASSENGER
(8W-53-2) TN TN/DG POWER T141 F45
WINDOW 20 20
YL/RD YL/RD
SWITCH
11 9 (8W-60-3)
DRIVER
POWER
WINDOW
SWITCH
(8W-60-2)
9 C2 3 C2
POWER
DISTRIBUTION
CENTER
(8W-10-8)
86 86
CIGAR/ ENGINE
ACCESSORY STARTER
RELAY MOTOR
(8W-41-3) RELAY
(8W-21-2)
85 85 (8W-21-3)
A
REAR
WASHER
7 C8
MOTOR F45
(8W-53-4) 18
YL/RD
A
FRONT 8
WASHER TRANSMISSION
MOTOR CONTROL
(8W-53-3) MODULE
(8W-31-5)
J988W-3 GS001216
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 17
POWER
86
HORN
DISTRIBUTION
RELAY CENTER
(8W-41-2) (8W-10-10)
85
4 C2
X4
20
GY/OR
BATT L9 (8W-10-29) 4 C2
JUNCTION
BLOCK
(8W-12-2)
1 18
COMBINATION HORN BODY
FLASHER/ RELAY CONTROL
DRL CONTROL MODULE
MODULE (8W-45-3)
(8W-46-3)
(8W-52-2)
9 7 8 10
EATX MTX
26 C3 4 C3 22 C3 1 C2 9 C3 8 C2 8 C3
L91 G9 G9 G9 G9
20 20 20 20 20
DB/PK GY/BK GY/BK GY/BK GY/BK
TO
5 P50 TURN
NOT SIGNAL/
TO TO TO
USED HAZARD
BRAKE PARK IGNITION
SWITCH
PRESSURE BRAKE SWITCH
(PART OF SWITCH SWITCH (8W-10-14) TO
MULTI-FUNCTION (8W-46-3) (8W-46-3)
SWITCH) MESSAGE
(8W-52-2) CENTER
(8W-46-3)
(8W-52-3)
GS001217 J988W-3
8W - 12 - 18 8W-12 JUNCTION BLOCK NS/GS
FROM
HEADLAMP
DIMMER
SWITCH
(8W-50-2)
L93
22
PK
33 C3
JUNCTION
BLOCK
(8W-12-2)
12 4 5 21 19 15
COMBINATION BODY
FLASHER/ CONTROL
DRL MODULE
MODULE (8W-45-5)
(8W-50-2)
3 2 (8W-50-12)
(8W-51-3)
5 C2 11 C2 28 C2 36 C2 14 C3 21 C3
L61
L60 18 L63 L62 L62 L63
18 L63 18 18 18 18
LG
TN 18 DG/RD BR/RD BR/RD DG/RD
DG/RD
L62
TO TRAILER TOW OTHERS 18
LEFT BR/RD
FRONT L63 L62 L63 L62 TO
PARK/ 18 18 18 18
TO
DG/RD BR/RD DG/RD BR/RD
MESSAGE
TURN LEFT CENTER
SIGNAL REPEATER (8W-46-5)
LAMP LAMP
(8W-50-11) TO TO
TO (BUILT-UP LEFT RIGHT TO
RIGHT -EXPORT) REAR REAR RIGHT
FRONT (8W-51-3)
LAMP LAMP REPEATER
1 B99
PARK/ ASSEMBLY ASSEMBLY LAMP
T05
TURN (8W-51-4) (8W-51-4) (BUILT-UP
SIGNAL L63 L63 (8W-51-5) (8W-51-5) -EXPORT)
LAMP 18 18 1 B98 (8W-51-3)
(8W-50-11) DG/RD DG/RD T08
L62 18 BR/RD
L63 18 DG/RD L62 18 BR/RD
TO TO TO TO TO TO
LEFT LEFT LEFT RIGHT RIGHT RIGHT
COMBINATION STOP/ REAR REAR COMBINATION STOP/
RELAY TURN LAMP LAMP RELAY TURN
(8W-54-2) SIGNAL ASSEMBLY ASSEMBLY (8W-54-2) SIGNAL
RELAY (8W-51-4) (8W-51-4) RELAY
(8W-54-2) (8W-51-5) (8W-51-5) (8W-54-2)
J988W-3 GS001218
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 19
22 C4 28 C4 35 C4 36 C4
JUNCTION
BLOCK
30 30
(8W-12-2)
DOOR DRIVER COMBINATION
LOCK DOOR FLASHER/
RELAY UNLOCK DRL
(8W-61-3) RELAY MODULE
(8W-61-4) (RKE) (8W-50-13)
(8W-61-7) (8W-61-7)
87 87A 87 87A 11
(8W-61-8) (8W-61-8)
30 86
DOOR NAME BODY
UNLOCK BRAND CONTROL
RELAY SPEAKER MODULE
(8W-61-3) RELAY (8W-45-2)
(8W-61-4) (8W-47-4)
87 87A (8W-61-7) 85 3 4
(8W-61-8)
2 C2 21 C4 29 C4
10 C2 14 C2
Z1 Z2 Z2
14 20 20
BK BK/LG BK/LG
Z1 Z1
18 20
BK BK
8 2 C2 6 C1
G300 HEADLAMP
(8W-15-6) SWITCH
(8W-50-9)
(8W-50-10) * RHD
GS001219 J988W-3
8W - 12 - 20 8W-12 JUNCTION BLOCK NS/GS
BATT M1 (8W-10-11)
JUNCTION
BLOCK
9 (8W-12-2)
BODY
CONTROL
MODULE
(8W-45-2)
6 C4 13 C4 17 C4
M1 M1 M1 M1 M1 M1
20 20 20 20 20 20
PK PK PK PK PK PK
2 1 C3 16
INSTRUMENT IGNITION DATA LINK
CLUSTER SWITCH CONNECTOR
(8W-40-2) 1 START (8W-30-3)
2 RUN (8W-30-30)
1 4 0 OFF
*8 2 3 3 LOCK
12 0 4 ACC
MESSAGE (8W-10-14) 7 C1
CENTER RADIO
(8W-46-2) (8W-47-2)
2 C3
3
REMOTE M1 A81
22 20
KEYLESS PK DG/RD
ENTRY
MODULE
(8W-61-5) 7 P50
NOT
USED
15 C4
JUNCTION
D1 BLOCK
(8W-10-16) (8W-12-2)
D3
FUSE
2
10A
(8W-12-9)
* RHD
J988W-3 GS001220
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 21
TO
COURTESY
LAMP
RELAY
(8W-12-22)
19 C2 16 C3 20 C3
OVERHEAD
OTHERS CONSOLE 1
SENTRY
KEY
IMMOBILIZER
MODULE
F41 F41 (BUILT-UP
20 20 -EXPORT)
PK/VT PK/VT (8W-39-5)
9 1
TO POWER GLOVE
CS02 MIRROR BOX
(8W-10-20) SWITCH LAMP
(8W-62-2) (8W-44-2)
(8W-62-4)
TO
FRONT
READING
LAMPS/
SWITCH
(8W-44-2)
GS001221 J988W-3
8W - 12 - 22 8W-12 JUNCTION BLOCK NS/GS
JUNCTION
FROM BLOCK
JUNCTION
(8W-12-2)
BLOCK
BODY (8W-12-21)
CONTROL
MODULE A
(8W-45-4)
17
86 30
COURTESY
LAMP
RELAY
85 87
D4
10 C3 34 C3 28 C3 22 C2 6 C2 29 C2 29 C3
B01 B03
TO TO 3 6
D02 D01P
CS01 CS1
(8W-44-4) (8W-44-4) 3 J02A
L15
1
DRIVER
DOOR
COURTESY
LAMP
(8W-44-3)
J988W-3 GS001222
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 23
TO TO
TO DRIVER TO PASSENGER
TO TO DRIVER DOOR PASSENGER DOOR
FRONT FRONT POWER LOCK POWER LOCK
WASHER WIPER WINDOW SWITCH WINDOW SWITCH
(8W-61-2) (8W-61-2)
MOTOR SWITCH SWITCH SWITCH (8W-61-6)
(8W-53-3) (8W-60-2) (8W-61-6) (8W-60-3)
(PART OF
MULTI-
FUNCTION
V10 E2 E2 E2 E2
20 SWITCH) 20 20 20 20
BR (8W-53-3) OR OR OR OR
4 D01D 11 D01P
V10 B02 B03
20 E2 E2
BR 20 20
OR OR
21 C2 18 C3 8 C1
JUNCTION
BLOCK
(8W-12-2)
20 31
BODY WASHER
CONTROL MODULE
PANEL MODULE (BUILT-UP
LAMPS (8W-45-4) -EXPORT)
DRIVER (8W-53-5)
2
30 C4 8 C4 23 C4 1 C4 1 C1
E2 E2 E2 E2 E2 E2 E2 E2 E2 E2
20 20 20 20 20 18 20 20 20 20
OR OR OR OR OR OR OR OR OR OR
17 B75
C20
TO
REAR TO TO TO TO
BLOWER A/C HEADLAMP RADIO UNIVERSAL
FRONT HEATER SWITCH (8W-47-2) GARAGE
CONTROL CONTROL (8W-50-9) DOOR
SWITCH E2 (8W-50-10)
20 (8W-42-3) OPENER
(8W-42-6) (PART OF
OR
FRONT
HEADER
READING
TO TO TO TO TO TO LAMPS)
TRACTION FRONT INSTRUMENT ASH POWER REAR (8W-49-3)
CONTROL CIGAR CLUSTER RECEIVER MIRROR BLOWER
SWITCH LIGHTER/ (8W-40-4) LAMP SWITCH REAR
(GAS) POWER (8W-44-7) (8W-62-2) CONTROL
(8W-35-2) OUTLET (8W-62-4) SWITCH
(8W-41-3) (8W-42-6)
GS001223 J988W-3
8W - 12 - 24 8W-12 JUNCTION BLOCK NS/GS
BUILT-UP-EXPORT
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
30
PARK CENTER
FUSE (8W-10-8)
22 LAMP
40A RELAY
(8W-10-17) (8W-50-11)
87
4 C1
L7
12
BK/YL
RUN-ACC A31 (8W-10-16) BATT A4 (8W-10-12)
2 C1
JUNCTION
BLOCK
(8W-12-2)
S 56 P
WASHER
MODULE
LOGIC
31 30
BODY
CONTROL
MODULE
(8W-45-4)
20
18 C3 21 C2 34 C1
V10
20 V10 V53
BR 20 18
11 BR RD/YL
FRONT
WIPER B B
SWITCH FRONT HEADLAMP
(PART OF WASHER WASHER
MULTI- MOTOR (8W-53-5)
FUNCTION (8W-53-3)
SWITCH)
J988W-3 (8W-53-3) GS001224
NS/GS 8W-12 JUNCTION BLOCK 8W - 12 - 25
EXCEPT BUILT-UP-EXPORT/CHRYSLER
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
30
LOW CENTER
BEAM (8W-10-10)
RELAY
(8W-50-2)
87
FUSE
6
20A
(8W-10-33)
8 C5
L43
18
VT
16 C1
JUNCTION
86 30 BLOCK
FOG (8W-12-2)
LAMP
L43 RELAY
18 (8W-50-5)
VT
85 87
12 C1 31 C1 25 C1
L39
A L94 18
20 LB
LEFT OR/WT
LOW L39
HEADLAMP L39 18 B3 B23
(8W-50-5) 18 LB 3 P18
LB
2 C2
F41
20
PK/VT
15 C2
JUNCTION
BLOCK
(8W-12-2)
86 87 87A 87A 87 86
POWER POWER
MIRROR MIRROR
FOLD UNFOLD
RELAY RELAY
(8W-62-8) (8W-62-8)
(8W-12-19)
85 30 30 85
30 C2 11 C3 11 C4 36 C1 36 C4 2 C2
2
POWER
FOLDING
MIRROR
1 2 SWITCH
1 1 UNFOLD
2 FOLD
(8W-62-8)
P174 P136 8
20 20 G300
YL/RD YL (8W-15-6)
71 C1 74 C1 39 C2
POWER POWER POWER BODY
MIRROR MIRROR FOLDING CONTROL
FOLD UNFOLD MIRROR MODULE
RELAY RELAY SWITCH
(8W-45-10)
SIGNAL
J988W-3 GS001226
NS/GS 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1
POWERTRAIN TRANSMISSION
DATA LINK CONTROL CONTROL
CONNECTOR MODULE MODULE
(8W-30-3) (8W-30-2) (8W-31-2)
5 10 C1 50 C2 53 57
Z11
20
86 POWER
BK/WT DISTRIBUTION
TRANSMISSION
24 P34 CONTROL CENTER
RELAY (8W-10-9)
A24 B23 (8W-31-2)
Z11 Z12 Z12 Z14 Z13
20 18 18 85 16 16
BK/WT BK/TN BK/TN BK/YL BK/RD
B70 4 C8
9
E43
Z11 Z16
18 18
BK/WT BK
ES11
Z0 Z1 Z1 Z1 Z1
10 18 18 12 12
BK BK BK BK BK
ES18 RFS2
Z1 Z1 Z1
14 18 12
BK BK BK
ES23
Z0 Z0 Z1 Z1
8 6 10 12
BK BK BK BK
J988W-3 GS001502
NS/GS 8W-15 GROUND DISTRIBUTION 8W - 15 - 3
DIESEL
ENGINE NEEDLE
SPEED MOVEMENT
SENSOR SENSOR
SHIELD (8W-30-35) SHIELD (8W-30-35)
Z122 Z122
18 18
BK BK
ES30 ES31
POWERTRAIN Z122 Z122
CONTROL 18 18
MODULE BK BK
(8W-30-28) 7 2 E97
1 24 46
B106
Z1 Z1
Z12 18 18
18 BK BK
BK
Z12 Z12 Z12
16 16 16 BS40 BS41
BK/TN BK/TN BK/TN B
Z1 Z1
TO 18 18
G301 BK BK
(8W-15-12)
BS31
POWER Z12
86
FUEL
DISTRIBUTION 14
HEATER CENTER BK/TN
(8W-10-9)
RADIATOR RADIATOR
RELAY
(8W-30-29) FAN FAN A
DISCONNECT RELAY
(8W-42-10) NO. 1 TO
85
(8W-42-10) G300
1 2 (8W-15-5)
Z12
3 C6 Z1 Z1
14 12 12
BK/TN BK BK
B107 ES12
3
E95
Z1
Z1 Z1 12
16 20 BK
BK BK A/C
G102 COMPRESSOR
ES01 CLUTCH
(8W-42-9)
2
BATTERY Z1
(8W-20-3) 18
Z0
10 BK CRANK
BK FUEL LOW CASE
HEATER COOLANT HEATER
(8W-30-29)
(8W-30-29) LEVEL
SWITCH 2
2 2 (8W-45-9)
Z0 Z0 Z1 Z1 Z1 Z1
6 2 16 18 20 18
BK BK BK BK BK BK
Z1
12
CLOCKSPRING BK
G201 G104
3 12 14 13 11 9 7 6 10 2 8 5 1
G200
J988W-3 GS001504
NS/GS 8W-15 GROUND DISTRIBUTION 8W - 15 - 5
2 (8W-47-6) 2 (8W-47-6) 2 2
(8W-47-7) (8W-47-7)
X15 X15 X15 X15
16 16 16 16
BK/DG BK/DG BK/DG BK/DG
RADIO
1 D02 1 D01P (8W-47-2)
B01 B03
X15 X15
16 16
BK/DG BK/DG
BS08
AUTOMATIC A11 B23
DAY/NIGHT 11 P34
MIRROR
(8W-44-6) X15 X15
16 16
2 BK/DG BK/DG
WIPER
MODULE
(8W-53-2) G202
4 MEMORY
PASSENGER SEAT/
Z1 POWER MIRROR
20 SEAT MODULE
BK SWITCH (8W-62-3)
7 C2 (8W-63-4)
(8W-63-3)
1 MEMORY
EC1 POWER
LEFT 2
C19 Z1 SEAT
REPEATER 14 SWITCH
LAMP BK Z1 (8W-63-5)
(BUILT-UP 14 1
Z1 DRIVER
-EXPORT) 20 BK
2 Z1 POWER
(8W-52-2) BK
20 SEAT
BK
FROM SWITCH
C20 BS31 (8W-63-2)
12 1
B75 (DIESEL)
Z1 (8W-15-3) Z1
18 14
A
BK DOWNSTREAM BK
HEATED
S02 OXYGEN MEMORY OTHER
1 SENSOR
B56
1 (8W-30-7) S02
Z12 1
(8W-30-21) B09
14
Z1 Z1 Z1 BK/TN Z12 Z1
20 14 12 20 12
BK BK BK BK/TN BK
14 12 7 3 2
G300
GS001505 J988W-3
8W - 15 - 6 8W-15 GROUND DISTRIBUTION NS/GS
22 C4 28 C4 35 C4 36 C4
JUNCTION
BLOCK
30 30
(8W-12-2)
DOOR DRIVER COMBINATION
LOCK DOOR FLASHER/
RELAY UNLOCK DRL
(8W-61-3) RELAY MODULE
(8W-61-4) (RKE) (8W-50-13)
87 87A (8W-61-7) 87 87A (8W-61-7) 11
(8W-61-8) (8W-61-8)
30 86
DOOR NAME BODY
UNLOCK BRAND CONTROL
RELAY SPEAKER MODULE
(8W-61-3) RELAY (8W-45-2)
(8W-61-4) (8W-47-4)
87 87A (8W-61-7) 85 3 4
(8W-61-8)
2 C2 21 C4 29 C4
10 C2 14 C2
Z1 Z2 Z2
14 20 20
BK BK/LG BK/LG
Z1 Z1
18 20
BK BK
8 2 C2 6 C1
G300 HEADLAMP
SWITCH
(8W-50-9)
(8W-50-10) * RHD
J988W-3 GS001506
NS/GS 8W-15 GROUND DISTRIBUTION 8W - 15 - 7
POWER
86 86 DISTRIBUTION
CIGAR/ FRONT CENTER
ACCESSORY BLOWER (8W-10-8)
RELAY MOTOR
(8W-41-3) RELAY
(8W-42-2)
85 85 30
WIPER
ON
RELAY
(8W-53-2)
(8W-53-3)
87 87A
2 C4
FROM
STOP Z1 Z1 Z1
20 20 12
LAMP BK BK BK
SWITCH
(LHD)
(8W-33-3)
(8W-33-5)
DS01
5 D01P 10 D01D
B03 B02
Z1 Z1
18 12
BK BK
6 10 11 5
G300
* BUILT-UP-EXPORT
GS001507 J988W-3
8W - 15 - 8 8W-15 GROUND DISTRIBUTION NS/GS
LEFT
HEADLAMP
(8W-50-6)
LEFT 2
LOW
HEADLAMP
(8W-50-5)
B
Z1 Z1
20 20
BK BK
LEFT LEFT
HIGH HEADLAMP
HEADLAMP LEVELING
Z1 Z1 (CHRYSLER) MOTOR
20 20 B (8W-50-5) 1 (8W-50-8)
BK BK
SEAT CLUTCH
BELT SWITCH
EXCEPT BUILT- BUILT-UP SWITCH (DIESEL)
UP-EXPORT -EXPORT (8W-40-4) (8W-30-39)
2 2
Z1 Z1 Z1
20 20 20
BRAKE BK BK BK
Z1 Z1
PRESSURE 20 20
SWITCH BK BK
(8W-46-3)
B
Z1
20
BK
J988W-3 GS001508
NS/GS 8W-15 GROUND DISTRIBUTION 8W - 15 - 9
HEATED SEATS
DRIVER
HEATED
SEAT
MODULE
(8W-63-7) PASSENGER
F
HEATED
DRIVER SEAT
HEATED MODULE
SEAT F (8W-63-8)
SWITCH
E (8W-63-7)
PASSENGER
DRIVER HEATED
HEATED SEAT
SEAT SWITCH
CUSHION E (8W-63-8)
D (8W-63-7)
DRIVER PASSENGER
HEATED HEATED
SEAT SEAT
BACK CUSHION
B (8W-63-7) D (8W-63-8)
Z1 Z1 Z1 Z1
18 18 18 18
BK BK BK BK PASSENGER
HEATED
SEAT
HS1
BACK
MEMORY B (8W-63-8)
POWER
SEAT
SWITCH
1 (8W-63-5) Z1 Z1 Z1 Z1
MEMORY 18 18 18 18
SEAT/ BK BK BK BK
MIRROR
Z1 MODULE
20 (8W-62-3)
BK 7 C2 HS3
(8W-63-4)
Z1 (8W-63-5)
14
BK Z1 Z1
14 14
S02 BK BK
1
HS6D
1 HS5P
Z1 14BK
B56
1 HS5D
B09
Z1
Z1 12
12 BK
BK
2 7
G300
GS001509 J988W-3
8W - 15 - 10 8W-15 GROUND DISTRIBUTION NS/GS
RIGHT
HIGH
HEADLAMP
(CHRYSLER)
B (8W-50-4)
PASSENGER PASSENGER
DOOR DOOR
RIGHT LOCK
ARM/
RIGHT LOW SWITCH
DISARM
FRONT HEADLAMP (8W-61-2)
1 SWITCH 3
PARK/ (CHRYSLER) (8W-39-3) (8W-61-6)
TURN B (8W-50-4) RKE OTHER
3 SIGNAL
Z2
LAMP 20
(8W-50-11) Z2 Z2
RIGHT BK/LG 20 20
(8W-50-12)
HEADLAMP BK/LG BK/LG
(DODGE/
RIGHT PLYMOUTH)
FRONT 2 (8W-50-6)
PARK/ RIGHT
TURN HEADLAMP
2 SIGNAL (8W-50-8)
LAMP
(8W-50-11) RIGHT Z2
3 HEADLAMP 20
Z1 Z1
20 18 LEVELING BK/LG
BK BK Z1 Z1 Z1 Z1
MOTOR
20 20 20 20 1 (BUILT-UP
BK BK BK BK -EXPORT)
(8W-50-8)
EXCEPT BUILT-UP RIGHT D01P
BUILT- -EXPORT 3
UP- REPEATER B03
EXPORT LAMP
(BUILT-UP
2 -EXPORT) Z2
(8W-51-3) 20
EXCEPT BUILT BUILT-UP BK/LG
-UP-EXPORT -EXPORT
HOOD
LOW AJAR
NOTE SWITCH
(8W-44-5)
HORN
(8W-41-2) 2
B HEADLAMP
Z1
Z1 Z1 18
WASHER
Z1 20 18 BK (BUILT-UP
18 BK BK -EXPORT)
BK (8W-53-5)
A
Z1
18
BK
8 13 7 9 10 12 11 2
G301
J988W-3 GS001510
NS/GS 8W-15 GROUND DISTRIBUTION 8W - 15 - 11
GAS
Z1 Z2
18 20 Z2 Z2
BK BK/LG 20 20
BK/LG BK/LG
OVERHEAD Z2
COMPASS/ 20
MINI-TRIP CONSOLE
(8W-49-2) BK/LG
COMPUTER
GROUND
LOW
WASHER
3 FLUID 3 D01D
UNIVERSAL SWITCH B02
GARAGE A (8W-53-3)
DOOR
OPENER
3 (PART OF
FRONT
READING
Z2
18 LAMPS/
Z1 Z2 SWITCH) Z1 Z2
BK/LG
18 18 (8W-49-3) 20 20
BK BK/LG BK BK/LG
CS06
9 C20
B75
Z2
18
BK/LG
1 5 14 3
G301
GS001511 J988W-3
8W - 15 - 12 8W-15 GROUND DISTRIBUTION NS/GS
DIESEL
DRIVER
DOOR
LOCK
LOW DRIVER
SWITCH
WASHER DOOR (8W-61-2)
FLUID ARM/ 3
(8W-61-6)
SWITCH DISARM
A (8W-53-3) 1 SWITCH
(8W-39-3)
RKE OTHER
Z2 OVERHEAD
Z2 Z2
20 20 20
CONSOLE
BK/LG BK/LG BK/LG (8W-49-2)
Z2 UNIVERSAL
20 GARAGE Z2
BK/LG DOOR 18
OPENER BK/LG
HIGH (PART OF
3
PASSENGER NOTE FRONT
POWER HORN READING
Z2
SEAT (8W-41-2)
3 D01D 18 LAMPS/
SWITCH B B02 BK/LG SWITCH)
1 (8W-63-3) (8W-49-3)
14 5 1 3 6
G301
J988W-3 GS001512
NS/GS 8W-15 GROUND DISTRIBUTION 8W - 15 - 13
2
RIGHT FUEL
COMBINATION TANK
RELAY MODULE
(8W-54-3) (8W-30-6)
(8W-30-20)
1 (8W-45-9)
3.8L OTHERS
LEFT REAR
Z1
REAR 16
BLOWER
DOOR BK REAR
AJAR CONTROL
1 SWITCH 4 SWITCH
(8W-44-5) AWS1 Z1 (8W-42-6)
16
Z1 Z1 Z1
RIGHT BK REAR
18 18 16
REAR BK BK BK CIGAR
DOOR 1 AW4 1 AW4 LIGHTER/
AJAR B13 B13 POWER
SWITCH 1 C1 1 C2 Z1 Z1 OUTLET
1 14 14 3
(8W-44-5) ALL BK BK Z1 Z1
(8W-41-3)
Z1 Z1 WHEEL 20 20 Z1 Z1
18 18 DRIVE BK BK 18 16
BK BK 3.8L OTHER BK BK
SOLENOID
(3.8L)
8 14 (8W-31-3) 5 9 3 12 11
G302
10
Z1
12
BK
C * BUILT-UP-EXPORT
TO
B17
(8W-15-14)
GS001513 J988W-3
8W - 15 - 14 8W-15 GROUND DISTRIBUTION NS/GS
FROM
G302
(8W-15-13)
C
Z1
12
BK
LICENSE LEFT REAR
LAMP LIFTGATE WINDOW
(8W-51-2) FLOOD DEFOGGER
B17 LAMP (8W-48-2)
11 (8W-44-4)
LJ01 1 2
Z1
12 CENTER RIGHT
BK HIGH LIFTGATE
MOUNTED FLOOD
STOP LAMP
1 J02A 1 LAMP 2 (8W-44-4)
L15 (8W-51-7)
Z1 Z2 Z1 Z1 Z1 Z1 Z1 Z1 Z1
12 20 20 20 20 20 20 18 12
BK BK/LG BK BK BK BK BK BK BK
1 9 7 2 11 3 8 6 5
G400
J988W-3 GS001514
NS/GS 8W - 20 CHARGING SYSTEM 8W - 20 - 1
POWER FUSIBLE
DISTRIBUTION LINK
CENTER A11
FUSE 10
17 (8W-10-9)
DG
20A
(8W-10-23)
ES09
30
AUTOMATIC
SHUT
DOWN
RELAY
A0 A0 (8W-30-2)
6 6
RD RD 87
FUSED ENGINE 5 C6
B(+) STARTER
MOTOR A142
(8W-21-2) 18
DG/OR
ES12
(8W-10-23)
FROM A11
A142 6
BATTERY ES11 BK/GY
(8W-15-2) 18
DG/OR
1
Z0 GENERATOR
10
BK
2
Z0
6 A142 K20
BK 18 18
DG/OR DG
G103
6 C1 8 C1
AUTOMATIC GENERATOR POWERTRAIN
SHUT FIELD CONTROL
Z0 DOWN DRIVER
8 MODULE
RELAY (8W-30-2)
BK OUTPUT
G100
J988W-3 GS002002
NS/GS 8W-20 CHARGING SYSTEM 8W - 20 - 3
DIESEL
POWER FUSIBLE
DISTRIBUTION LINK
CENTER A11
FUSE 10
ENGINE 17 (8W-10-9)
DG
STARTER 20A
MOTOR (8W-10-25)
(8W-21-3) ES11
30
DIESEL
ES26 POWER
RELAY
(8W-30-28)
FUSIBLE
LINK 87
A54
16
DB 5 C6
A142
18
ES28 DG/OR
A54
10 ES06
RD (8W-10-25)
1 A142 A11
GLOW 18 6
PLUG DG/OR BK/GY
A0
2 RELAY
RD (8W-30-32)
GENERATOR
A0 A0 A142 A142
6 10 18 18
RD RD DG/OR DG/OR
BATTERY FROM
ES01
(8W-15-3)
DF D+
Z0 VOLTAGE +
10 REGULATOR
BK
1 7 E96
Z0 B108
2 A142 A142
BK 18 18
DG/OR DG/OR
G103 BS33
Z0 A142 A142 A142
8 16 16 16
BK DG/OR DG/OR DG/OR
23 45 68
DIESEL DIESEL DIESEL POWERTRAIN
G100 POWER POWER POWER CONTROL
RELAY RELAY RELAY MODULE
OUTPUT OUTPUT OUTPUT (8W-30-28)
GS002003 J988W-3
NS/GS 8W - 21 STARTING SYSTEM 8W - 21 - 1
10 C2
F45
20
YL/RD
MTX EATX
1 1
CLUTCH CLUTCH
INTERLOCK INTERLOCK
SWITCH T141 SWITCH
20 JUMPER
YL/RD
2
T141 2
20 F45
YL/RD 20
YL/RD
3 C2
POWER
DISTRIBUTION
FUSE CENTER
23 (8W-10-8)
40A
(8W-10-16)
86 30
ENGINE
A0
STARTER
6
MOTOR
RELAY RD
85 87
4 C6 3 C7
K90
18 T40
TN 12 A0
BR 6 BATTERY
RD (8W-20-2)
ENGINE
31 C1 STARTER
ENGINE POWERTRAIN
2 1 MOTOR
STARTER CONTROL 1 PULL-IN
MOTOR MODULE 2 HOLD-IN
RELAY (8W-30-6)
CONTROL M
J988W-3 GS002102
NS/GS 8W-21 STARTING SYSTEM 8W - 21 - 3
DIESEL
ST A41 (8W-10-16)
JUNCTION
BLOCK
FUSE (8W-12-2)
10
10A
(8W-12-16)
10 C2
F45
20
YL/RD
1
CLUTCH
INTERLOCK
SWITCH
T141
20
YL/RD
3 C2
POWER
DISTRIBUTION ES26
FUSE CENTER
23 (8W-10-8)
FUSIBLE
40A LINK
(8W-10-16) A0 A54
10 16
86 30 RD DB
ENGINE
STARTER
MOTOR
RELAY A0 ES28
6
RD
85 87
4 C6 3 C7
T40 A0
K90 12 2 BATTERY
18 BR RD (8W-20-3)
TN
ENGINE A54
STARTER 10
E95 RD
6 MOTOR
B107 2 1
1 PULL-IN 1
K90 2 HOLD-IN
20 FUSED GLOW
TN M B(+) PLUG
Z0 Z0
10 2 RELAY
BK BK (8W-30-32)
3
ENGINE POWERTRAIN
STARTER CONTROL G103
MOTOR TO Z0
MODULE
RELAY (8W-30-28)
ES01 6
CONTROL (8W-15-3) BK
G100
GS002103 J988W-3
NS/GS 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1
30 C1
F87
18
WT/BK
BATT A0 (8W-10-8)
6 C2
POWER
DISTRIBUTION
FUSE FUSE CENTER
17 16 (8W-10-9)
20A 20A
(8W-10-23) (8W-10-26)
(8W-12-13)
86 30
AUTOMATIC
SHUT
DOWN
RELAY
85 87
6 C6 8 C6 5 C6 9 C6
GENERATOR
F87 (8W-20-2) A142
18 18
WT/BK DG/OR
ES07 2 ES12
(8W-12-13) (8W-10-23)
F87 K20 K51 A142 A14
18 18 18 18 18
WT/BK DG DB/YL DG/OR RD/WT
20 C1 8 C1 67 C2 6 C1 46 C2
FUSED GENERATOR AUTOMATIC AUTOMATIC FUSED POWERTRAIN
IGNITION FIELD SHUT SHUT B (+) CONTROL
SWITCH DRIVER DOWN DOWN MODULE
OUTPUT RELAY RELAY
(ST-RUN) CONTROL OUTPUT
BATTERY
(8W-20-2)
GROUND GROUND
50 C2 10 C1
Z12 Z12
18 18
BK/TN BK/TN
ES11 Z0 Z0
8 6
(8W-15-2)
BK BK
Z0
10
BK
G100 G103
J988W-3 GS003002
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3
GAS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
28 (8W-10-9)
10A
(8W-10-11)
5 C3
M1
20
PK
M1 20 PK
13 C1 16 C1
JUNCTION FUSED MEMORY
(8W-12-20)
BLOCK B(+) SEAT/
(8W-12-2) MIRROR
MODULE
(8W-63-4)
17 C4
M1 20 PK
M1 7 C1
20
PK FUSED RADIO
B(+) (8W-47-2)
16
DATA
6 7 4 5
LINK
CONNECTOR
D20 D21 Z2 Z11
20 20 20 20
LG PK BK/LG BK/WT
16 17 P18 24 P34
B16 B17 B23 A24 B23
D20 D21 Z11
20 20 20
LG PK 1
BK/WT
3 4 B33 G200
E36 (8W-15-4) 9 B70
D21 E43
18 Z11
PK 18
BK/WT
MTX EATX
ES11 BATTERY
ES24 (8W-15-2) (8W-20-2)
Z0
D20 D21 10
18 D21 18 BK
LG 18 PK
PK
75 C2 65 C2 7
SCI SCI POWERTRAIN SCI TRANSMISSION Z0 Z0
RECEIVE TRANSMIT CONTROL TRANSMIT CONTROL 8 6
MODULE MODULE BK BK
(8W-31-8)
G100 G103
GS003003 J988W-3
8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM NS/GS
GAS
DATA INSTRUMENT AIRBAG
LINK CLUSTER CONTROL
CCD CCD CCD CCD
CONNECTOR (8W-40-2) MODULE
BUS BUS BUS BUS
(-) (+) (-) (+) (8W-43-3)
14 11 3
9 10 4 C2 3 C2
D2 D1 D2 D1 D2 D1
20 TWISTED 20 20 TWISTED 20 20 TWISTED 20
WT/BK PAIR VT/BR WT/BK PAIR VT/BR WT/BK PAIR VT/BR
PS02
D2 PS01
20
WT/BK D2 D1 D2
D6 D1 20 D1 20 20 D2 D1
20 20 WT/BK 20 VT/BR WT/BK 20 20
PK/LB VT/BR VT/BR WT/BK VT/BR
TWISTED 6 5 TWISTED
14 13 12 P18 SENTRY
PAIR CCD CCD PAIR
B14 B13 B12 B23 BUS BUS KEY
(+) (-) IMMOBILIZER
D2 34 C2 3 C2 MODULE 2 C3 1 C3
18 CCD CCD BODY (BUILT-UP CCD CCD RADIO
WT/BK D1 BUS BUS CONTROL BUS BUS (8W-47-2)
18
-EXPORT)
(-) (+) MODULE (-) (+)
VT/BR (8W-39-5)
(8W-45-3)
BS05
BS06
D2 D1
18 18
WT/BK VT/BR
TWISTED
PAIR D2 D1
18 18
WT/BK VT/BR
D6 D2 D1 19 20
20 18 18
PK/LB WT/BK VT/BR CCD CCD CONTROLLER
BUS BUS ANTI-LOCK
6 2 7 B33 (-) (+) 5 6 B75
BRAKE
E36 (8W-35-3)
C20
EATX MTX EATX MTX
D2 D1
18 18
WT/BK VT/BR
TWISTED
ES13 D1 PAIR
ES14 18
D1 VT/BR
D2 D2 18 1 6
D6 D2 D1 18 18 OVERHEAD
VT/BR CCD CCD
18 18 18 WT/BK WT/BK
PK/LB WT/BK VT/BR BUS BUS CONSOLE
(-) (+) (8W-49-2)
46 4 43
SCI CCD CCD TRANSMISSION
RECEIVE BUS BUS CONTROL
(-) (+) 60 C2 59 C2
MODULE
(8W-31-8) CCD CCD POWERTRAIN
BUS BUS CONTROL
(-) (+) MODULE
J988W-3 GS003004
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5
GAS
RIGHT
ST-RUN F87 (8W-10-26) SPEED
CONTROL
POWER
SWITCH
86 DISTRIBUTION
1 RESUME/ACCEL
A/C CENTER
COMPRESSOR (8W-10-10) 2 CANCEL
CLUTCH 3 COAST
RELAY 1 2 3
(8W-42-7)
85
7 C6 V37
22
WT
A/C
HEATER LEFT
CONTROL SPEED
V37 V37 Z2
A/C (8W-42-3) 20 20 CONTROL 22
SWITCH WT WT SWITCH BK
SIGNAL 1 SET
3 C1 2 ON/OFF
1 2
C103
20
DG/LB
Z2
36 P18 20
B36 B23 BK
RADIATOR CLOCKSPRING
RADIATOR FAN
FAN
RELAY RELAY
CONTROL (8W-42-8)
2
C103 4 C2 3 C2
20
DG/LB V37 Z2
20 20
B70 RD/LG BK/LG
1
E43
21 P34
A21 B23
C13 C103 K173 V37
18 18 14 20
DB/OR DG/LB LG/DB RD/LG 3
G200
B70 (8W-15-4)
8
E43
V37
18
RD/LG
64 C2 38 C1 73 C2 41 C2
A/C A/C RADIATOR SPEED POWERTRAIN
COMPRESSOR SWITCH FAN CONTROL CONTROL
CLUTCH SIGNAL RELAY SWITCH MODULE
RELAY CONTROL SIGNAL
CONTROL
GS003005 J988W-3
8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM NS/GS
2.0L/2.4L
ST-RUN A21 (8W-10-16) TRANSMISSION
BACK- RANGE
JUNCTION UP
ST T141 BLOCK LAMP SENSOR
(8W-12-2) FEED (8W-31-3)
(8W-12-16) PTC
1 6 BACK-UP
ST F45 9A BACK- SWITCH
(8W-12-13) UP
(8W-12-16) L1 (8W-51-5)
LAMP
18
FEED
VT/BK
T141 F45 30 C1 2
20 20
YL/BK YL/BK L1
F87
18 18
WT/BK
E36 VT/BK
10
MTX EATX
BATT A0 B33
3 C2 6 C2 (8W-10-8) E36
10
POWER B33
DISTRIBUTION L1 L1
86
ENGINE FUSE CENTER 20 20
(8W-12-13)
STARTER 16 (8W-10-8) VT/BK VT/BK
MOTOR 20A
RELAY (8W-10-26)
(8W-21-2) EATX MTX
85
86 30 BODY
FUEL CONTROL
FUEL
LEVEL
PUMP
SENSOR MODULE
RELAY (8W-45-7)
SIGNAL BS02
46 C1 (8W-70-2)
85 87 G4 L1
18 20
4 C6 3 C6 7 C2 DB VT/BK
A141 B13 2 B13
3
16 AW4 AW4
DG/WT L1
G4
18 20
B13 DB VT/BK
4 AW4
4 3 2
FUEL FUEL BACK-UP FUEL
PUMP LEVEL LAMP TANK
RELAY SENSOR FEED MODULE
OUTPUT SIGNAL
GROUND
1
Z1
K90 K31 16
18 18 BK
TN BR
1 AW4
B13
31 C1 74 C2 Z1
ENGINE FUEL POWERTRAIN 14
STARTER PUMP CONTROL BK
MOTOR RELAY MODULE
RELAY CONTROL
CONTROL 5
G302
(8W-15-13)
J988W-3 GS003006
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7
2.0L/2.4L
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
17 (8W-10-9)
20A
(8W-10-23)
30
AUTOMATIC
SHUT
DOWN
RELAY
(8W-30-2)
87
5 C6
A142
18
DG/OR
ES12
(8W-10-23)
A142
A142 18
18 DG/OR
DG/OR E43
2
B70
4 2 A142
18
UPSTREAM DG/OR
HEATED
OXYGEN 2 4
SENSOR DOWNSTREAM
HEATED
3 1
OXYGEN
SENSOR
K4 Z1 1 3
18 18
BK/LB BK Z12 K4 K141
20 20 20
BK/TN BK/LB TN/WT
ES18
(8W-15-2) 1 B33
3 E36
Z1 G300
(8W-15-5) 10 B70
10
BK
E43
K4
18
G101 BK/LB
(8W-15-2)
ES21
(8W-70-4)
K41 K4 (8W-70-5) K141
18 18 18
BK/DG BK/LB TN/WT
30 C1 43 C2 51 C2
UPSTREAM SENSOR DOWNSTREAM POWERTRAIN
HEATED GROUND HEATED CONTROL
OXYGEN OXYGEN MODULE
SENSOR SENSOR
SIGNAL SIGNAL
GS003007 J988W-3
8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM NS/GS
2.0L
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
17 (8W-10-9)
20A ES17
(8W-10-23)
(8W-70-9)
30
AUTOMATIC K7 K7
SHUT 18 18
DOWN OR OR
RELAY
(8W-30-2)
87
1
5 C6 8V CRANKSHAFT
SUPPLY POSITION
A142 SENSOR
18 CRANCKSHAFT
DG/OR POSITION
SENSOR SENSOR
SIGNAL GROUND
ES12 3 2
(8W-10-23)
K4
18
A142
BK/LB
18
DG/OR
ES02
(8W-70-4)
1
8V CAMSHAFT
2 SUPPLY POSITION
IGNITION SENSOR
COIL CAMSHAFT
PACK POSITION
SENSOR SENSOR
GROUND SIGNAL
2 3
1 3
K4 K4
18 18
BK/LB BK/LB
ES21
(8W-70-4)
K17 K19 K7 K24 K4 K44
18 18 18 18 18 18
DB/TN GY/RD OR GY/BK BK/LB TN/YL
3 C1 11 C1 44 C2 32 C1 43 C2 33 C1
IGNITION IGNITION 8V CRANKSHAFT SENSOR CAMSHAFT POWERTRAIN
COIL COIL SUPPLY POSITION GROUND POSITION CONTROL
NO.2 NO.1 SENSOR SENSOR MODULE
DRIVER DRIVER SIGNAL SIGNAL
J988W-3 GS003008
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9
2.0L
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
17 (8W-10-9)
20A
(8W-10-23)
30
AUTOMATIC
SHUT
DOWN
RELAY
(8W-30-2)
87
5 C6
A142
18
DG/OR
ES12
(8W-10-23)
A142
18
DG/OR
ES99
2 2 2 2
FUEL FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR INJECTOR
NO. 1 NO. 2 NO. 3 NO. 4
1 1 1 1
13 C1 17 C1 7 C1 16 C1
INJECTOR INJECTOR INJECTOR INJECTOR POWERTRAIN
NO. 1 NO. 2 NO. 3 NO. 4 CONTROL
DRIVER DRIVER DRIVER DRIVER MODULE
GS003009 J988W-3
8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM NS/GS
2.0L
ES03
(8W-70-7)
K6 K6
18 18
VT/WT VT/WT
C 2
5V INTAKE 5V A/C
INTAKE SUPPLY AIR SUPPLY PRESSURE
AIR TEMPERATURE/ TRANSDUCER
TEMPERATURE MAP MANIFOLD A/C
SENSOR SENSOR SENSOR SENSOR PRESSURE
SIGNAL SIGNAL GROUND ABSOLUTE GROUND SIGNAL
B D A
PRESSURE 1 3
SENSOR
K4 K4
18 18
BK/LB BK/LB
ES02
(8W-70-4)
K4 K4 K4
18 18 18
BK/LB BK/LB BK/LB
1
ENGINE
COOLANT
TEMPERATURE
SENSOR
ES21 2
(8W-70-4)
2
KNOCK
SENSOR
61 C2 37 C1 36 C1 43 C2 25 C1 26 C1 42 C2
5V INTAKE MANIFOLD SENSOR KNOCK ENGINE A/C POWERTRAIN
SUPPLY AIR ABSOLUTE GROUND SENSOR COOLANT PRESSURE CONTROL
TEMPERATURE PRESSURE SIGNAL TEMPERATURE SIGNAL MODULE
SENSOR SENSOR SENSOR
SIGNAL SIGNAL SIGNAL
J988W-3 GS003010
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11
2.0L
VEHICLE
K6 SPEED
18 VEHICLE SENSOR
VT/WT SPEED
ES03 SENSOR 8V SENSOR
(8W-70-7) GROUND SUPPLY SIGNAL
2 1 3
3
THROTTLE K4 K7
POSITION 18 18
SENSOR BK/LB OR
2 1
K4
18
BK/LB
ES02
(8W-70-4)
K4
18
BK/LB
ES21 ES17
(8W-70-4) (8W-70-9)
K6 K22 K4 K7 G7
18 18 18 18 18
VT/WT OR/DB BK/LB OR WT/OR
61 C2 35 C1 43 C2 44 C2 66 C2
5V THROTTLE SENSOR 8V VEHICLE POWERTRAIN
SUPPLY POSITION GROUND SUPPLY SPEED CONTROL
SENSOR SENSOR MODULE
SIGNAL SIGNAL
GS003011 J988W-3
8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM NS/GS
2.0L
2
EVAP/
PURGE
SOLENOID K70
18
VT/RD
1
K52
18
PK/BK
K39 K60 K40 K59
18 18 18 18
GY/RD YL/BK BR/WT VT/BK
68 C2 70 C2 57 C2 49 C2 48 C2 58 C2
EVAP/PURGE PULSE IDLE IDLE IDLE IDLE
POWERTRAIN
SOLENOID WIDTH AIR AIR AIR AIR CONTROL
CONTROL MODULATED CONTROL CONTROL CONTROL CONTROL MODULE
PURGE MOTOR MOTOR MOTOR MOTOR
CURRENT NO.1 NO.2 NO.3 NO.4
SENSE DRIVER DRIVER DRIVER DRIVER
J988W-3 GS003012
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13
2.0L
ST-RUN V23 (8W-12-9)
MESSAGE
SERVICE
ENGINE CENTER
SOON (8W-46-3)
LAMP
7
*13
G3 GENERATOR
20 (8W-20-2)
BK/PK GENERATOR
FIELD
2 P34 DRIVER
A2 B23 2
G3
20
BK/PK
5 B70 K20
E43 18
G3
DG
18
BK/PK
22 C1 8 C1
SEVICE GENERATOR POWERTRAIN
ENGINE FIELD CONTROL
SOON INDICATOR DRIVER MODULE
LAMP DRIVER
SPEED SPEED
SPEED CONTROL CONTROL
STOP LAMP CONTROL VENT VACUUM
SWITCH ON/OFF SOLENOID SOLENOID
SENSE SWITCH SENSE CONTROL CONTROL
62 C2 5 C1 80 C2 56 C2
K29 V32 V35 V36
18 18 18 18
WT/PK YL/RD LG/RD TN/RD
E43
7 3
B70
K29 V32
20 20
WT/PK YL/RD
1 3
STOP
LAMP
SWITCH
(8W-33-3)
2 4
V30
LHD RHD 20
DB/RD
6 B70
Z1 Z1 E43
20 20
V30
BK BK
18
DB/RD
6 3 2 1
G300 VEHICLE
(8W-15-7) VENT VACUUM
TO SPEED
JUNCTION SOLENOID SOLENOID
CONTROL * RHD
BLOCK SERVO
(8W-12-19) (8W-33-3)
GS003013 J988W-3
8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM NS/GS
2.4L
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
17 (8W-10-9)
20A
(8W-10-23)
30
AUTOMATIC
SHUT
DOWN
RELAY ES17
(8W-30-2) (8W-70-9)
87
K7
5 C6 18
OR
A142
18
DG/OR 1
8V CRANKSHAFT
SUPPLY POSITION
ES12 SENSOR
(8W-10-23) CRANKSHAFT K7
POSITION 18
SENSOR SENSOR OR
A142 SIGNAL GROUND
18 1
DG/OR 3 2
8V CAMSHAFT
SUPPLY POSITION
CAMSHAFT SENSOR
K24 POSITION
18 SENSOR SENSOR
GY/BK GROUND SIGNAL
2 3
2 K4 K4
IGNITION 18 18
COIL BK/LB BK/LB
PACK
ES02
MTX EATX (8W-70-5)
ES21
1 3
(8W-70-5)
ES05
(8W-70-8)
3 C1 11 C1 44 C2 32 C1 43 C2 33 C1
IGNITION IGNITION 8V CRANKSHAFT SENSOR CAMSHAFT POWERTRAIN
COIL COIL SUPPLY POSITION GROUND POSITION CONTROL
NO. 2 NO. 1 SENSOR SENSOR MODULE
DRIVER DRIVER SIGNAL SIGNAL
J988W-3 GS003014
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15
2.4L
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
17 (8W-10-9)
20A
(8W-10-23)
30
AUTOMATIC
SHUT
DOWN
RELAY
(8W-30-2)
87
5 C6
A142
18
DG/OR
ES12
(8W-10-23)
A142
18
DG/OR
10 E69
F09
FS03
2 2 2 2
FUEL FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR INJECTOR
NO. 1 NO. 2 NO. 3 NO. 4
1 1 1 1
F09
1 2 3 4
E69
K11 K12 K13 K14
18 18 18 18
WT/DB TN/WT YL/WT LB/BR
13 C1 17 C1 7 C1 16 C1
INJECTOR INJECTOR INJECTOR INJECTOR POWERTRAIN
NO. 1 NO. 2 NO. 3 NO. 4 CONTROL
DRIVER DRIVER DRIVER DRIVER MODULE
GS003015 J988W-3
8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM NS/GS
2.4L
FS02
(8W-70-7)
K6 K6 K6
18 18 18
VT/WT VT/WT VT/WT
B 2
MANIFOLD 5V A/C
ABSOLUTE SUPPLY PRESSURE
PRESSURE A/C TRANSDUCER
SENSOR PRESSURE
SENSOR SWITCH
C A GROUND SIGNAL
1 3
K1 K4 K4 C18
18 18 18 18
DG/RD BK/LB BK/LB DB
FS01
(8W-70-5)
F09 K4
18
8 11 5 E69 BK/LB
K6 K4 1
18 18 ENGINE
VT/WT BK/LB COOLANT
TEMPERATURE
ES03 SENSOR
(8W-70-7) 2
ES02
(8W-70-5)
K4 K4 K2
18 18 18
BK/LB BK/LB TN/BK
2
KNOCK
SENSOR ES21
(8W-70-5)
F09
12 9 E69
1
K6 K1 K42 K4 K2 C18
18 18 18 18 18 18
VT/WT DG/RD DB/LG BK/LB TN/BK DB
61 C2 36 C1 25 C1 43 C2 26 C1 42 C2
5V MANIFOLD KNOCK SENSOR ENGINE A/C POWERTRAIN
SUPPLY ABSOLUTE SENSOR GROUND COOLANT PRESSURE CONTROL
PRESSURE SIGNAL TEMPERATURE SWITCH MODULE
SENSOR SENSOR SIGNAL
SIGNAL SIGNAL
J988W-3 GS003016
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 17
2.4L
VEHICLE
K6 SPEED
18 SENSOR
VT/WT
ES03 SENSOR 8V VSS
(8W-70-7) GROUND SUPPLY SIGNAL
2 1 3
3
THROTTLE K4 K7 G7
POSITION 18 18 18
SENSOR BK/LB OR WT/OR
2 1
K22 K4
18 18
OR/DB BK/LB
VEHICLE
TRANSMISSION
SPEED CONTROL
SENSOR MODULE
SIGNAL (8W-31-4)
58
ES08 ES02
(EATX) (8W-70-5)
(8W-70-8)
K4 K4 G7
18 18 18
BK/LB BK/LB WT/OR
1
INTAKE
AIR
TEMPERATURE MTX EATX
SENSOR
2 ES21 ES17
(8W-70-5) (8W-70-9)
K6 K22 K21 K4 K7 G7
18 18 18 18 18 18
VT/WT OR/DB BK/RD BK/LB OR WT/OR
61 C2 35 C1 37 C1 43 C2 44 C2 66 C2
5V THROTTLE INTAKE SENSOR 8V VEHICLE POWERTRAIN
SUPPLY POSITION AIR GROUND SUPPLY SPEED CONTROL
SENSOR TEMPERATURE SENSOR MODULE
SIGNAL SENSOR SIGNAL
SIGNAL
GS003017 J988W-3
8W - 30 - 18 8W-30 FUEL/IGNITION SYSTEM NS/GS
2.4L
ST-RUN A21 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
PTC
1
9A
(8W-12-13)
30 C1
F87
18
WT/BK
IDLE IDLE IDLE IDLE IDLE
6 C2 AIR AIR AIR AIR AIR
POWER CONTROL CONTROL CONTROL CONTROL CONTROL
DISTRIBUTION MOTOR MOTOR MOTOR MOTOR MOTOR
CENTER NO. 1 NO. 2 NO. 3 NO. 4
DRIVER DRIVER DRIVER DRIVER
(8W-10-29)
6 C6 4 3 2 1
F87
18
WT/BK
ES07
(8W-12-13)
F87 F87
18 18
WT/BK WT/BK
2
EGR
SOLENOID
K70 (MTX)
18
VT/RD
1
2
EVAP/ 3
PURGE FUSE EVAP
SOLENOID IGN. LEAK
(ST-RUN) DETECTION
1 PUMP
LEAK LEAK
DETECTION DETECTION (EXCEPT
K52
18 PUMP PUMP BUILT-UP
PK/BK SWITCH SOLENOID -EXPORT)
SENSE CONTROL
F09
1 2
6 7 E69
K70 K52 K35 K107 K106 K39 K60 K40 K59
18 18 18 18 18 18 18 18 18
VT/RD PK/BK GY/YL YL/BK WT/DG GY/RD YL/BK BR/WT VT/BK
70 C2 68 C2 40 C1 72 C2 77 C2 57 C2 49 C2 48 C2 58 C2
PULSE EVAP/ EGR LEAK LEAK IDLE IDLE IDLE IDLE POWERTRAIN
WIDTH PURGE SOLENOID DETECTION DETECTION AIR AIR AIR AIR CONTROL
MODULATED SOLENOID CONTROL PUMP PUMP CONTROL CONTROL CONTROL CONTROL MODULE
PURGE CONTROL SWITCH SOLENOID MOTOR MOTOR MOTOR MOTOR
CURRENT SENSE CONTROL NO. 1 NO. 2 NO. 3 NO. 4
SENSE DRIVER DRIVER DRIVER DRIVER
J988W-3 GS003018
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 19
2.4L
TRANSMISSION ST-RUN V23 (8W-12-9)
CONTROL
MESSAGE
CRANKSHAFT THROTTLE TORQUE MODULE SERVICE
POSITION POSITION MANAGEMENT (8W-31-4) ENGINE CENTER
SENSOR SENSOR REQUEST (8W-31-8) SOON (8W-46-3)
SIGNAL SIGNAL SENSE LAMP
6 12 10
7
K24 K22 *13 G3
18 18 GENERATOR
20
GY/BK OR/DB (8W-20-2)
GENERATOR BK/PK
FIELD
2 P34
DRIVER A2 B23
2
ES05 ES08 G3
(8W-70-8) (8W-70-8) 20
BK/PK
32 C1 35 C1 63 C2 8 C1 22 C1
CRANKSHAFT THROTTLE TORQUE GENERATOR SERVICE ENGINE SOON POWERTRAIN
POSITION POSITION MANAGEMENT FIELD DRIVER INDICATOR CONTROL
SENSOR SENSOR REQUIREMENT LAMP DRIVER MODULE
SIGNAL SIGNAL SENSE
SPEED SPEED TRANSMISSION
SPEED CONTROL CONTROL RANGE
STOP LAMP CONTROL VENT VACUUM SWITCH
SWITCH ON/OFF SOLENOID SOLENOID T41
SENSE SWITCH SENSE CONTROL CONTROL SENSE
62 C2 5 C1 80 C2 56 C2 76 C2
K29 V32 V35 V36
18 18 18 18
WT/PK YL/RD LG/RD TN/RD
E43
7 3
B70
K29 V32
20 20
WT/PK YL/RD
1 3 T41
18
STOP BK/YL
LAMP
SWITCH
(8W-33-3)
2 4
V30 10
20 TRANSMISSION
LHD RHD DB/RD RANGE
P/N SENSOR
6 B70 (8W-31-5)
E43
Z1 TO V30
20 JUNCTION 18
BK BLOCK DB/RD
6 (8W-12-19) 3 2 1
G300 VEHICLE
(8W-15-7) VENT VACUUM SPEED
SOLENOID SOLENOID
CONTROL
* RHD
SERVO
(8W-33-3)
GS003019 J988W-3
8W - 30 - 20 8W-30 FUEL/IGNITION SYSTEM NS/GS
3.3L/3.8L
TRANSMISSION
ST-RUN A21 (8W-10-16) BACK- RANGE
UP
JUNCTION LAMP SENSOR
BLOCK FEED (8W-31-3)
(8W-12-2) 6 BACK-UP
PTC
1 BACK- SWITCH
9A UP
L1 (8W-51-5)
(8W-12-13) LAMP
18
FEED
VT/BK
2
30 C1
F87 L1
18 18
WT/BK E36 VT/BK
ST F45 BATT A0 10
(8W-12-16)
6 C2
(8W-10-8) B33
POWER E36
10
B33
DISTRIBUTION
86 L1 L1
ENGINE FUSE CENTER
(8W-10-8) 20 20
STARTER 16 VT/BK VT/BK
MOTOR 20A (8W-10-9)
RELAY (8W-10-26)
(8W-21-2)
EATX MTX
85
86 30
FUEL BODY L1
PUMP FUEL CONTROL 20
RELAY LEVEL VT/BK
SENSOR MODULE
SIGNAL (8W-45-7)
BS02
85 87 46 C1 (8W-70-2)
4 C6 6 C6 3 C6 7 C2 B13
2
A141 G4 AW4
F87 16 18
18 DG/WT DB AWS2
WT/BK 4 3 B13 (8W-31-3)
AW4
4 3 2
ES07 FUEL
FUEL FUEL BACK-UP
(8W-12-13)
PUMP LEVEL SWITCH TANK
RELAY SENSOR SENSE MODULE
OUTPUT SIGNAL
F87 GROUND
18 1
WT/BK ALL
2 GROUND GROUND WHEEL
EGR 3.3L 3.8L DRIVE
SOLENOID
1 C1 1 C2
SOLENOID
Z1 Z1 Z1 Z1 (8W-31-3)
16 16 18 18
BK BK BK BK
1
AWS1
K90 K35 K31 Z1
18 18 18 16
TN GY/YL BR BK
31 C1 40 C1 74 C2 AW4
1
ENGINE EGR FUEL POWERTRAIN B13
STARTER SOLENOID PUMP CONTROL Z1 14BK
MOTOR CONTROL RELAY MODULE 5
RELAY CONTROL
CONTROL G302
(8W-15-13)
J988W-3 GS003020
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 21
3.3L/3.8L
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
17 (8W-10-9)
20A
(8W-10-23)
30
AUTOMATIC
SHUT
DOWN
RELAY
(8W-30-2)
87
5 C6
A142
18
DG/OR
ES12
(8W-10-23)
A142 A142
18 18
DG/OR DG/OR
E43
2
B70
4 2
A142
UPSTREAM 18
HEATED DG/OR
OXYGEN 2 4
SENSOR DOWNSTREAM
3 1 HEATED
OXYGEN
SENSOR
K4 Z1
18 18 1 3
BK/LB BK K141
Z12 K4 20
20 20 TN/WT
ES18 BK/TN BK/LB
(8W-15-2) 3 1 B33
G300 E36
Z1 (8W-15-5) B70
10 10
BK K4 E43
18
G101 BK/LB
(8W-15-2)
ES02
(8W-70-6)
K41 K4 K141
18 18 18
BK/DG BK/LB TN/WT
30 C1 43 C2 51 C2
HEATED SENSOR HEATED POWERTRAIN
OXYGEN GROUND OXYGEN CONTROL
SENSOR SENSOR MODULE
SIGNAL SIGNAL
GS003021 J988W-3
8W - 30 - 22 8W-30 FUEL/IGNITION SYSTEM NS/GS
3.3L/3.8L
BATT A0 (8W-10-8)
ES17 POWER
DISTRIBUTION
FUSE CENTER
K7 K7 K7 17 (8W-10-9)
18 18 18 20A
OR OR OR (8W-10-23)
1
8V CRANKSHAFT 30
SUPPLY POSITION 7 E78 AUTOMATIC
F02 SHUT
SENSOR DOWN
CRANKSHAFT
POSITION RELAY
SENSOR SENSOR (8W-30-2)
SIGNAL GROUND K7
18 87
3 2 OR
1 5 C6
8V FLEXIBLE
K24
18
SUPPLY FUEL
GY/BK SENSOR
A142
FLEXIBLE (3.3L/ 18
FUEL ETHANOL) DG/OR
SENSOR SENSOR
GROUND SIGNAL 1
2 3 8V CAMSHAFT
SUPPLY POSITION
K4
18 SENSOR
CRANKSHAFT ES12
BK/LB POSITION (8W-10-23)
SENSOR SENSOR
GROUND SIGNAL
2 3
K50 K4 K44 A142
18 18 18 18
YL/WT BK/LB TN/YL DG/OR
FS02
(8W-70-6) 3
F02 IGNITION
14 COIL
E78
K4 F02 PACK
K4 8
18 E78
BK/LB 18
BK/LB
2 4 1
ES02
(8W-70-6)
ES05
(8W-70-8)
K19 K17 K18
18 18 18
GY/RD DB/TN RD/YL
K7 K24 K4 K44
18 18 18 18
OR GY/BK BK/LB TN/YL
44 C2 32 C1 54 C2 43 C2 33 C1 11 C1 3 C1 2 C1
8V CRANKSHAFT FLEXIBLE SENSOR CAMSHAFT IGNITION IGNITION IGNITION POWERTRAIN
SUPPLY POSITION FUEL GROUND POSITION COIL COIL COIL CONTROL
SENSOR SENSOR SENSOR NO. 1 NO. 2 NO. 3 MODULE
SIGNAL SIGNAL SIGNAL DRIVER DRIVER DRIVER
J988W-3 GS003022
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 23
3.3L/3.8L
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
17 (8W-10-9)
20A
(8W-10-23)
30
AUTOMATIC
SHUT
DOWN
RELAY
(8W-30-2)
87
5 C6
A142
18
DG/OR
ES12
(8W-10-23)
A142
18
DG/OR
1 E78
F02
A142
18
DG/OR
FS01
(8W-10-24)
A142 A142 A142 A142 A142 A142
18 18 18 18 18 18
DG/OR DG/OR DG/OR DG/OR DG/OR DG/OR
1 1 1
FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR
NO. 2 NO. 4 NO. 6
1 2 1 2 1 2
FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR
NO. 1 NO. 3 NO. 5
2 2 2
F02
3 4 5 6 12 13
E78
K11 K12 K13 K14 K38 K58
18 18 18 18 18 18
WT/DB TN/WT YL/WT LB/BR GY BR/DB
13 C1 17 C1 7 C1 16 C1 15 C1 14 C1
INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR POWERTRAIN
NO. 1 NO. 2 NO. 3 NO. 4 NO. 5 NO. 6 CONTROL
DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER MODULE
GS003023 J988W-3
8W - 30 - 24 8W-30 FUEL/IGNITION SYSTEM NS/GS
3.3L/3.8L
ES03
(8W-70-7)
2 E78 K6
F02 18
VT/WT
K6
18
VT/WT
B 2
MANIFOLD 5V A/C
ABSOLUTE SUPPLY PRESSURE
PRESSURE TRANSDUCER
SENSOR A/C
SENSOR PRESSURE
C A GROUND SIGNAL
1 3
K1 K4
18 18
K4
DG/RD BK/LB
18
BK/LB
FS02
K4
F02 18 F02
10 E78 BK/LB 14 E78 ES21
2 (8W-70-6)
SENSOR
CAMSHAFT K4 K4
GROUND POSITION 18 18
SENSOR BK/LB BK/LB
K4 (8W-30-22)
18
BK/LB
ES02
(8W-70-6)
1
ENGINE
COOLANT K4
TEMPERATURE 18
BK/LB
SENSOR
2
2
KNOCK
K2
18
SENSOR
TN/BK (3.8L)
1
F02
11
E78
K6 K1 K2 K42 K4 C18
18 18 18 18 18 18
VT/WT DG/RD TN/BK DB/LG BK/LB DB
61 C2 36 C1 26 C1 25 C1 43 C2 42 C2
5V MANIFOLD ENGINE KNOCK SENSOR A/C POWERTRAIN
SUPPLY ABSOLUTE COOLANT SENSOR GROUND PRESSURE CONTROL
PRESSURE TEMPERATURE SIGNAL SIGNAL MODULE
SENSOR SENSOR
SIGNAL SIGNAL
J988W-3 GS003024
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 25
3.3L/3.8L
TRANSMISSION
CONTROL
K6 THROTTLE VEHICLE CRANKSHAFT MODULE
18 POSITION SPEED POSITION (8W-31-4)
VT/WT SENSOR SENSOR SENSOR
SIGNAL SIGNAL SIGNAL
12 58 6
3
THROTTLE
POSITION
K22 K24
SENSOR 18 18
OR/DB GY/BK
1 2
K4 K22
18 18
BK/LB OR/DB
ES08
K6 K4 K22 G7 K24
18 18 18 18 18
VT/WT BK/LB OR/DB WT/OR GY/BK
61 C2 43 C2 35 C1 66 C2 32 C1
5V SENSOR THROTTLE VEHICLE CRANKSHAFT POWERTRAIN
SUPPLY GROUND POSITION SPEED POSITION CONTROL
SENSOR SENSOR SENSOR MODULE
SIGNAL SIGNAL SIGNAL
GS003025 J988W-3
8W - 30 - 26 8W-30 FUEL/IGNITION SYSTEM NS/GS
3.3L/3.8L
ST-RUN A21 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
PTC
1
9A
(8W-12-13)
30 C1
F87
18
WT/BK
6 C2
POWER
DISTRIBUTION
CENTER
(8W-10-29)
6 C6
F87
18 IDLE IDLE IDLE IDLE IDLE
WT/BK AIR AIR AIR AIR AIR
CONTROL CONTROL CONTROL CONTROL CONTROL
MOTOR MOTOR MOTOR MOTOR MOTOR
ES07 NO. 1 NO. 2 NO. 3 NO. 4
(8W-12-13) DRIVER DRIVER DRIVER DRIVER
F87 4 3 2 1
18
WT/BK
2 3
EVAP/ FUSE EVAP
PURGE IGN. LEAK
SOLENOID (ST-RUN) DETECTION
PUMP
1 LEAK LEAK (EXCEPT
DETECTION DETECTION BUILT-UP
PUMP PUMP
SWITCH SOLENOID -EXPORT)
SENSE CONTROL
1 2
68 C2 70 C2 72 C2 77 C2 57 C2 49 C2 48 C2 58 C2
EVAP/ PULSE LEAK LEAK IDLE IDLE IDLE IDLE POWERTRAIN
PURGE WIDTH DETECTION DETECTION AIR AIR AIR AIR CONTROL
SOLENOID MODULATED PUMP PUMP CONTROL CONTROL CONTROL CONTROL MODULE
CONTROL PURGE SWITCH SOLENOID MOTOR MOTOR MOTOR MOTOR
CURRENT SENSE CONTROL NO. 1 NO. 2 NO. 3 NO. 4
SENSE DRIVER DRIVER DRIVER DRIVER
J988W-3 GS003026
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 27
3.3L/3.8L
ST-RUN V23 (8W-12-9) GENERATOR
(8W-20-2)
MESSAGE GENERATOR
SERVICE FIELD
ENGINE CENTER
(8W-46-3) DRIVER
SOON
LAMP 2
7
*13
G3 TRANSMISSION
20 TORQUE
MANAGEMENT CONTROL
BK/PK
REQUIREMENT MODULE K20
2 P34 SENSE (8W-31-8) 18
A2 B23 DG
10
G3
20
BK/PK
B70 T10
5 18
E43 YL/DG
G3
18
BK/PK
22 C1 63 C2 8 C1
SERVICE ENGINE SOON TORQUE GENERATOR POWERTRAIN
INDICATOR LAMP DRIVER MANAGEMENT FIELD CONTROL
REQUIREMENT DRIVER MODULE
SENSE
SPEED SPEED SPEED TRANS
STOP CONTROL CONTROL CONTROL RANGE
LAMP ON/OFF VENT VACUUM SWITCH
SWITCH SWITCH SOLENOID SOLENOID T41
SENSE SENSE CONTROL CONTROL SENSE
62 C2 5 C1 80 C2 56 C2 76 C2
K29 V32 V35 V36
18 18 18 18
WT/PK YL/RD LG/RD TN/RD
E43
7 3
B70
K29 V32
20 20
WT/PK YL/RD
1 3
STOP T41
18
LAMP BR/YL
SWITCH
(8W-33-3) 10
2 4 TRANSMISSION
RANGE
Z1 V30
20 20 P/N SENSOR
BK DB/RD (8W-31-5)
6 B70
LHD RHD E43
V30
18
6 DB/RD
G300 3 2 1
(8W-15-7) TO VEHICLE
JUNCTION VENT VACUUM SPEED
BLOCK SOLENOID SOLENOID
CONTROL
(8W-12-19)
SERVO * RHD
(8W-33-3)
GS003027 J988W-3
8W - 30 - 28 8W-30 FUEL/IGNITION SYSTEM NS/GS
DIESEL
ST-RUN A21 (8W-10-16) BATT A0 (8W-10-8)
JUNCTION POWER
BLOCK DISTRIBUTION
PTC
(8W-12-2)
FUSE CENTER
1 17 (8W-10-9)
9A 20A
(8W-12-13) (8W-10-25)
86 30
DIESEL
30 C1 POWER
RELAY
85 87
8 C6 5 C6
F87 86 K51 ES06
18
WT/BK
ENGINE 20 (8W-10-25)
STARTER DB/YL
A142 A142
MOTOR 18 18
RELAY DG/OR DG/OR
85 (IN PDC)
TO (8W-21-3) 3 1 7 E96
POWER K90 B108
DISTRIBUTION 18 A142 A142
TN 18 18
CENTER
DG/OR DG/OR
(8W-10-27)
E95
6
B107 BS33
38 3 42 23 45 68
FUSED STARTER DIESEL DIESEL DIESEL DIESEL POWERTRAIN
IGN. RELAY POWER POWER POWER POWER CONTROL
(ST-RUN) CONTROL RELAY RELAY RELAY RELAY MODULE
OUTPUT OUTPUT OUTPUT
BS31
(8W-15-3)
Z12
14
BK/TN
7
G300
(8W-15-5)
J988W-3 GS003028
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 29
DIESEL
ST-RUN A21 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
PTC
1
9A
(8W-12-13)
30 C1
F87
F87 18
18 WT/BK
WT/BK BATT A0 (8W-10-8)
6 C2
POWER
DISTRIBUTION
TO CENTER
FUSE FUSE
POWERTRAIN 16 17 (8W-10-9)
CONTROL 20A 20A
MODULE (8W-10-26) (8W-10-25)
(8W-30-36)
86 30 30
FUEL DIESEL
HEATER POWER
RELAY RELAY
(8W-30-28)
85 87 87
3 C6 7 C2 5 C6
Z1 A141
20 16 A142
BK DG/WT 18
B33 DG/OR
4
E120
A141 ES06
18 A142
DG/WT 18
BATTERY DG/OR
(8W-20-3) ES40
1
A141 A141 EGR
18 18 SOLENOID
DG/WT DG/WT
1
1 CRANK 2
FUEL CASE
Z0 Z0 Z0 HEATER HEATER K35
2 6 10 20
BK BK BK GY/YL
2
2
2 E96
Z1 Z1 B108
18 18
G100 BK BK K35
20
ES02 GY/YL
(8W-15-3) 25
Z1 POWERTRAIN
16 EGR
BK SOLENOID CONTROL
G103 CONTROL MODULE
ES01
(8W-15-3)
GS003029 J988W-3
8W - 30 - 30 8W-30 FUEL/IGNITION SYSTEM NS/GS
DIESEL
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
28 (8W-10-9)
10A
(8W-10-11)
5 C3
M1
20
PK M1 20PK
13 C1 16 C1
JUNCTION FUSED MEMORY
(8W-12-20)
BLOCK B(+) SEAT/
(8W-12-2) MIRROR
MODULE
(8W-63-4)
17 C4
M1 20 PK
M1 7 C1
20
PK FUSED RADIO
B(+) (8W-47-2)
16
DATA
7 4 5
LINK
CONNECTOR
D21 Z11
20 20
PK BK/WT
17 P18 24 P34
B17 B23 A24 B23
D21 Z2 Z11
20 20 20
PK BK/LG BK/WT
61 1 1
SCI POWERTRAIN G200 G301
TRANSMIT CONTROL (8W-15-4) (8W-15-12)
MODULE
J988W-3 GS003030
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 31
DIESEL
OVERHEAD CONTROLLER
COMPASS/ CONSOLE ANTI-LOCK
CCD CCD
MINI-TRIP (8W-49-2)
BUS BUS BRAKE
CCD CCD COMPUTER (8W-35-3)
(+) (-)
BUS BUS (8W-49-2)
(+) (-) 20 19
D1 D2
6 1 18 18
VT/BR WT/BK
D1 D2
18 TWISTED 18 TWISTED
VT/BR PAIR WT/BK PAIR
C20
6 5 B75
BS05
BS06
TWISTED
PAIR
D1 D2
18 18
VT/BR WT/BK
3 11 DATA
B12 B13 B23 LINK
12 13 P18 TWISTED CONNECTOR
PAIR
D1 D2
20 20
VT/BR WT/BK
TWISTED D1 D2
20 20
PAIR VT/BR WT/BK
PS02
PS01
TWISTED TWISTED TWISTED
PAIR PAIR PAIR
D1 D2
20 20
VT/BR WT/BK
D1 D2 10 9 D1 D2
20 20 CCD CCD INSTRUMENT 20 20
VT/BR WT/BK BUS BUS CLUSTER VT/BR WT/BK
(+) (-) (8W-40-2)
3 C2 34 C2 3 C2 4 C2
CCD CCD BODY CCD CCD AIRBAG
BUS BUS CONTROL BUS BUS CONTROL
(+) (-) MODULE (+) (-) MODULE
(8W-45-3) (8W-43-3)
GS003031 J988W-3
8W - 30 - 32 8W-30 FUEL/IGNITION SYSTEM NS/GS
DIESEL
BATT A0 (8W-10-8)
ST-RUN A21 (8W-10-16)
POWER BATTERY
JUNCTION DISTRIBUTION (8W-20-3)
BLOCK CENTER
A0
(8W-12-2) FUSE 10
FUSE 17 (8W-10-9) RD
6 20A
20A (8W-10-25) ES26
(8W-12-9)
30
DIESEL
14 C4 POWER FUSIBLE
RELAY LINK
(8W-30-28) A0
16
V23 V23 87 DB
18 18
BR/PK BR/PK 5 C6
A142
18
10 C1 DG/OR ES28
A/C
HEATER ES06
CONTROL (8W-10-25)
(8W-42-4) A142
18 A54
DG/OR 10
RD
10 ES29
MESSAGE (8W-10-25)
3 1
CENTER
(8W-46-3) GLOW
GLOW PLUG
PLUG RELAY
LAMP
2 4
7
K154
G85 10
20 GY
K152
OR/BK
18
WT/DG
ES37
17 P34
A17 B23 5 E95
B107 K154 K154 K154 K154
12 12 12 12
BK BK BK BK
26 50
FAULT GOW POWERTRAIN
LAMP/ PLUG CONTROL
GLOW RELAY MODULE
PLUG CONTROL
LAMP
J988W-3 GS003032
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 33
DIESEL
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
17 (8W-10-9)
20A
(8W-10-25)
30
DIESEL
POWER
RELAY
(8W-30-28)
87
5 C6
A142
18
DG/OR
ES06
(8W-10-25)
A142 A142
18 18
DG/OR DG/OR
9 10
FUEL
FUEL FUEL FUEL FUEL
PUMP
TEMPERATURE QUANTITY TIMING SHUTDOWN MODULE
SENSOR ACTUATOR SOLENOID SOLENOID
7 4 8 5 6
K4
K156 20 K140 K126 K153
18 BK/LB 18 18 18
GY TN/WT LG OR/DG
ES05
(8W-70-11)
K4 8 E96 1 E97 4 E95
20 B108 B106 B107
BK/LB
6 E97 K140
B106 18
K4 TN/WT
18
9 E96 BK/LB
B108 BS32
BS34
(8W-70-11)
K156 K4 K140 K140 K140 K126 K153
20 20 18 18 18 20 18
GY BK/LB TN/WT TN/WT TN/WT LG OR/DG
63 33 4 5 49 51 53
FUEL SENSOR FUEL QUANTITY ACTUATOR SIGNAL FUEL POWERTRAIN
TEMPERATURE GROUND (TWISTED PAIR) TIMING SHUTDOWN CONTROL
SENSOR SOLENOID SOLENOID MODULE
SIGNAL CONTROL CONTROL
GS003033 J988W-3
8W - 30 - 34 8W-30 FUEL/IGNITION SYSTEM NS/GS
DIESEL
FUEL
CONTROL
SLEEVE PUMP
CONTROL SLEEVE SLEEVE
SLEEVE POSITION POSITION SENSOR MODULE
POSITION SENSOR SENSOR
SENSOR (-) (+)
2 1 3
TURBO
INTAKE BOOST
AIR BOOST PRESSURE
SENSOR 5V TEMPERATURE PRESSURE
GROUND SUPPLY SENSOR SIGNAL SENSOR
1 3 2 4
K4 K9 K21 K1
18 18 18 18
K57 K134 K135
BK/LB LB BK/RD DG/RD
18 18 18
LG/OR LB/BK WT/BK
ES05
(8W-70-11)
K4
20
BK/LB
2 E95 6 E97
B107 B106
K4
18
BK/LB
E120
BS34 8 6 7 B33
(8W-70-11)
5 6 E96
B108
K4
20
BK/LB
K57 K134 K135 K9 K21 K1
20 20 20 20 20 20
LG/OR LB/BK WT/BK LB BK/RD DG/RD
7 29 52 33 41 64 40
CONTROL SLEEVE SLEEVE SENSOR 5V INTAKE BOOST POWERTRAIN
SLEEVE POSITION POSITION GROUND SUPPLY AIR PRESSURE CONTROL
POSITION SENSOR SENSOR TEMPERATURE SIGNAL MODULE
SENSOR (-) (+) SENSOR
J988W-3 GS003034
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 35
DIESEL
NEEDLE ENGINE
NEEDLE NEEDLE MOVEMENT ENGINE ENGINE SPEED
MOVEMENT MOVEMENT SPEED SPEED
SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
(+) (-) SHIELD SHIELD SIGNAL RETURN
1 2 3 1
K67 K68 Z122 Z122 K24 K3
18 18 18 18 20 20
BR/BK LG/YL BK BK GY/BK BK/VT
ES31 ES30
Z122 Z122
18 18
BK BK
3 4 2 7 5 E97 E120
9
B106 B33
Z12 18 BK
6
G301
(8W-15-12)
Z1 Z1 K3
18 18 20
BK BK BK/VT
BS41 BS40
Z1 Z1
18 18
BK BK
7
G300
(8W-15-5) K24
18
GY/BK
12 11 8 21
NEEDLE NEEDLE ENGINE ENGINE POWERTRAIN
MOVEMENT MOVEMENT SPEED SPEED CONTROL
SENSOR SENSOR SENSOR SENSOR MODULE
(+) (-) RETURN
GS003035 J988W-3
8W - 30 - 36 8W-30 FUEL/IGNITION SYSTEM NS/GS
DIESEL
ST-RUN A21 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
PTC
1
9A
(8W-12-13)
30 C1
F87 18 WT/BK
6 C2
POWER
DISTRIBUTION
CENTER
(8W-10-29)
6 C6
F87
18
WT/BK
1
FUSED VEHICLE
VEHICLE IGNITION SPEED
SPEED (ST-RUN)
SENSOR SENSOR SENSOR
SIGNAL GROUND
3 2
G7 ENGINE ENGINE
18 COOLANT COOLANT COOLANT
WT/OR TEMPERATURE TEMPERATURE TEMPERATURE
SENSOR SENSOR SENSOR
SIGNAL SIGNAL GROUND
SENSOR
4 E96
B108 3 1 2
G58 K2 K4 K4
20 20 20 20
BS30 BK/YL TN/BK BK/LB BK/LB
3 E120 ES05
G7 B33 (8W-70-11)
18 G58
20 K4
WT/OR
BK/YL 20
BK/LB
42 C1 60 C1
BODY 8 6 E97
VEHICLE COOLANT
SPEED TEMPERATURE CONTROL B106
SENSOR SENSOR K4
MODULE 18
SIGNAL SIGNAL (8W-45-9) BK/LB
ENGINE
ENGINE SPEED DISABLE
SENSOR SIGNAL SIGNAL BS34
(8W-70-11)
75 C1 72 C1
F87 G7 K159 G55 K2 K4
18 18 20 20 20 20
WT/BK WT/OR VT/RD OR/BK TN/BK BK/LB
38 43 2 59 14 33
FUSED VEHICLE ENGINE ENGINE ENGINE SENSOR POWERTRAIN
IGNITION SPEED SPEED DISABLE COOLANT GROUND CONTROL
(ST-RUN) SENSOR SENSOR SIGNAL TEMPERATURE MODULE
SIGNAL SIGNAL SENSOR
SIGNAL
J988W-3 GS003036
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 37
DIESEL
ST-RUN F87 (8W-10-29)
POWER
86 DISTRIBUTION
A/C CENTER
COMPRESSOR (8W-10-10)
CLUTCH
RELAY
(8W-42-9)
85
7 C6
LOW
RADIATOR HIGH
RADIATOR HIGH
RADIATOR
SPEED FAN SPEED FAN SPEED FAN
RADIATOR RELAY RADIATOR RELAY RADIATOR RELAY
FAN NO. 2 FAN NO. 1 FAN NO. 3
RELAY (8W-42-10) RELAY (8W-42-10) RELAY (8W-42-10)
CONTROL CONTROL CONTROL
6 6 6
ES09
A/C
HEATER
CONTROL
A/C (8W-42-3)
SWITCH
SIGNAL
3 C1
C137 C103
20 20
YL DG/LB
28 6 48 37
A/C LOW SPEED HIGH SPEED A/C POWERTRAIN
COMPRESSOR RADIATOR RADIATOR SWITCH CONTROL
CLUTCH FAN RELAY FAN RELAY SIGNAL MODULE
RELAY NO. 2 NO. 1&3
CONTROL CONTROL CONTROL
GS003037 J988W-3
8W - 30 - 38 8W-30 FUEL/IGNITION SYSTEM NS/GS
DIESEL
ACCELERATOR
PEDAL
LOW ACCELERATOR ACCELERATOR POSITION
IDLE PEDAL PEDAL SENSOR
SENSOR POSITION SENSOR SENSOR 5V
GROUND SWITCH SIGNAL GROUND SUPPLY
3 5 7 8 10
K4
20
BK/LB
2
A/C
PRESSURE
TRANSDUCER
3 1
K4
20
BK/LB
BS34
(8W-70-11)
19 13 33 65 15 55 57
5V A/C SENSOR LOW ACCELERATOR ACCELERATOR 5V POWERTRAIN
OUTPUT PRESSURE GROUND IDLE PEDAL PEDAL SUPPLY CONTROL
A/D POSITION SENSOR SENSOR MODULE
SWITCH SIGNAL GROUND
J988W-3 GS003038
NS/GS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 39
DIESEL
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
13 (8W-10-10)
20A
(8W-10-29)
8 C3
POWERTRAIN
CONTROL
STOP SPEED SPEED MODULE
LAMP BRAKE CLUTCH CONTROL CONTROL
SWITCH SWITCH SWITCH LAMP SWITCH
SIGNAL SENSE SIGNAL DRIVER SIGNAL
44 20 17 27 36
BS01
(8W-70-2) V38 A21 B23
20
F32 L50 LB/RD
21 P34
18 18
V37
PK/DB WT/TN
20
RD/LG
6 5 3 1
STOP 56 C1 4 C2
LAMP SPEED
BODY
CLOCKSPRING
SWITCH CONTROL CONTROL (8W-33-4)
(8W-33-5) LAMP MODULE
DRIVER (8W-45-9)
4 2
1
CLUTCH
SWITCH V37
FROM 20
LEFT WT
FRONT FROM
LEFT 2
PARK/
TURN HEADLAMP RIGHT
SIGNAL LEVELING SPEED
LAMP MOTOR CONTROL
(8W-50-11) (8W-50-8) SWITCH
(8W-33-4)
Z1 Z1 Z1 V37
18 20 20 Z1 20
BK BK BK 20 WT
BK
6 1
G300 LEFT
(8W-15-7) SPEED
(8W-15-8) CONTROL
SWITCH
(8W-33-4)
GS003039 J988W-3
NS/GS 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-9)
15
20A
(8W-10-28)
86 30
TRANSMISSION
CONTROL
RELAY
85 87
10 C8 3 C8 4 C8 2 C8
Z16
18 T16
BK 18
RD
ES01
(8W-10-28)
56 15 17 16
FUSED 12V TRANSMISSION TRANSMISSION TRANSMISSION
B(+) SUPPLY RELAY RELAY CONTROL
OUTPUT OUTPUT MODULE
EATX EATX
GROUND GROUND
57 53
Z0 Z0
8 6
BK BK
G100 G103
J988W-3 GS003102
NS/GS 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 3
18 C2
F20
OUTPUT TURBINE 20
SHAFT SPEED WT
SPEED SENSOR F20
5 B33 18
SENSOR E36 WT
F20
18
WT
2 1 1 2 1
TRANSMISSION
RANGE
R
SENSOR
6
L1
18
VT/BK
23
T13 E36 CONTROLLER
10 FUSED
18 B33 IGNITION ANTI-LOCK
DB/BK L1 (RUN)
20 BRAKE
VT/BK (8W-35-2)
T13
18
DB/BK BS02
(8W-70-2)
L1
20
ES10 VT/BK
(8W-70-8)
2 B13
AW4
L1
18
VT/BK
AWS2
2 C1 2 C2
ALL
WHEEL
DRIVE
SOLENOID
Z1
T14 T13 T52 1 C1 1 C2 (3.8L) 16
18 18 18
Z1 Z1 BK
LG/WT DB/BK RD/BK
18 18
BK BK AW4
1
B13
AWS1 Z1
14 13 52 (8W-15-13) 14
OUTPUT SPEED INPUT TRANSMISSION BK
SHAFT SENSOR SPEED CONTROL
SPEED GROUND SENSOR 5
MODULE
SENSOR SIGNAL G302
SIGNAL (8W-15-13)
GS003103 J988W-3
8W - 31 - 4 8W-31 TRANSMISSION CONTROL SYSTEM NS/GS
POWERTRAIN
CONTROL
VEHICLE CRANKSHAFT THROTTLE MODULE
SPEED POSITION POSITION (8W-30-14)
SENSOR SENSOR SENSOR SENSOR (8W-30-17)
SIGNAL SIGNAL SIGNAL GROUND (8W-30-22)
66 C2 32 C1 35 C1 43 C2 (8W-30-25)
G7 K24 K22 K4
18 18 18 18
WT/OR GY/BK OR/DB BK/LB
3.3L/3.8L 2.4L
K24 K22 K4 K4
18 18 18 18
GY/BK OR/DB BK/LB BK/LB
3 2
CRANKSHAFT THROTTLE ES21 ES02
CRANKSHAFT THROTTLE (8W-70-6) (8W-70-5)
POSITION POSITION POSITION POSITION
SENSOR SENSOR SENSOR SENSOR
SIGNAL (8W-30-14) SIGNAL (8W-30-17)
(8W-30-22) (8W-30-25)
K24 K22 K4
18 18 18
GY/BK OR/DB BK/LB
58 6 12 51
VEHICLE CRANKSHAFT THROTTLE SENSOR TRANSMISSION
SPEED POSITION POSITION GROUND CONTROL
SENSOR SENSOR SENSOR MODULE
SIGNAL SIGNAL SIGNAL
J988W-3 GS003104
NS/GS 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 5
T13
18
DB/BK
ES10
T41 T41 T42 T3 T1 T54 (8W-70-8)
18 18 18 18 18 18
BR/YL BK/WT VT/WT VT LG/BK VT/LG T13
18
DB/BK
10 5 9 8 7 4 3
TRANSMISSION
RANGE
PN PRNL P3L NOL TRANSMISSION SENSOR
TEMPERATURE
SENSOR
GS003105 J988W-3
8W - 31 - 6 8W-31 TRANSMISSION CONTROL SYSTEM NS/GS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-9)
15
20A
(8W-10-28)
30
TRANSMISSION
CONTROL
RELAY
(8W-31-2)
87
2 C8
T16
18
RD
ES01
(8W-10-28)
T16
18
RD
4
TRANSMISSION
CONTROL
LOW/ 2-4 OVERDRIVE SOLENOIDS
REVERSE PRESSURE PRESSURE
PRESSURE SWITCH SWITCH
SWITCH
2 1 3
T50 T47 T9
18 18 18
DG YL/BK OR/BK
50 47 9
LOW/ 2-4 OVERDRIVE TRANSMISSION
REVERSE PRESSURE PRESSURE CONTROL
PRESSURE SWITCH SWITCH MODULE
SWITCH SENSE SENSE
SENSE
J988W-3 GS003106
NS/GS 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 7
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-9)
15
20A
(8W-10-28)
30
TRANSMISSION
CONTROL
RELAY
(8W-31-2)
87
2 C8
T16
18
RD
ES01
(8W-10-28)
T16
18
RD
4
TRANSMISSION
CONTROL
LOW/ 2-4 UNDERDRIVE OVERDRIVE SOLENOIDS
REVERSE SOLENOID SOLENOID SOLENOID
SOLENOID
7 8 5 6
20 19 59 60
LOW/ 2-4 UNDERDRIVE OVERDRIVE TRANSMISSION
REVERSE SOLENOID SOLENOID SOLENOID CONTROL
SOLENOID CONTROL CONTROL CONTROL MODULE
CONTROL
GS003107 J988W-3
8W - 31 - 8 8W-31 TRANSMISSION CONTROL SYSTEM NS/GS
POWERTRAIN
CONTROL
TORQUE MODULE
MANAGEMENT (8W-30-3)
REQUIREMENT SCI (8W-30-19)
SENSE TRANSMIT (8W-30-27)
63 C2 65 C2
D21
18
PK
ES24
(8W-30-3)
D21
18
PK
E36
4
B33
D21
20
PK
B17 B23
17 P18
7
DATA
11 3 14
LINK
CONNECTOR
D2 D1 D6 (8W-30-3)
20 TWISTED 20 20 (8W-30-4)
WT/BK PAIR VT/BR PK/LB
PS02 PS01
(8W-30-4) (8W-30-4)
D2 D1
20 20
WT/BK VT/BR
13 12 14 P18
B13 B12 B14 B23
D2 D1 D6
18 18 20
WT/BK VT/BR PK/LB
BS06 BS05
(8W-30-4) (8W-30-4)
2 7 6 B33
E36
ES14 ES13
(8W-30-4) (8W-30-4)
D21 D2 D1 D6
T10 18 18 TWISTED 18 18
18 PK WT/BK VT/BR PK/LB
YL/DG PAIR
10 7 4 43 46
TORQUE SCI CCD CCD SCI TRANSMISSION
MANAGEMENT TRANSMIT BUS BUS RECEIVE CONTROL
REQUEST (-) (+) MODULE
SENSE
J988W-3 GS003108
NS/GS 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1
V37 V37
20 20
WT WT
V37 22 WT
RIGHT LEFT
SPEED SPEED
CONTROL CONTROL
SWITCH SWITCH
1 RESUME/ACCEL 1 SET
2 CANCEL 2 ON/OFF
3 COAST
1 2 3 1 2
Z2 22 BK
Z2
20
BK
CLOCKSPRING
3 C2
Z2
20
BK/LG
3
G200
(8W-15-4)
J988W-3 GS003302
NS/GS 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3
GAS
POWERTRAIN
SPEED SPEED SPEED CONTROL
STOP CONTROL CONTROL CONTROL MODULE
LAMP ON/OFF VENT VACUUM (8W-30-13)
SWITCH SWITCH SOLENOID SOLENOID (8W-30-19)
SENSE SENSE CONTROL CONTROL (8W-30-27)
62 C2 5 C1 80 C2 56 C2
E43
7 3 B70
K29 V32
20 20
WT/PK YL/RD
1 5 3
STOP
LAMP
SWITCH
2 6 4
Z1 V30
20 20
BK DB/RD
6 B70
E43
V30
18
DB/RD
3 2 1
VEHICLE
SPEED
VENT VACUUM CONTROL
LHD RHD SOLENOID SOLENOID
SERVO
DUMP
TO SOLENOID
JUNCTION
BLOCK
6 (8W-12-19) 4
G300
(8W-15-7) Z1
18
BK
ES18
(8W-15-2)
Z1
10
BK
G101
(8W-15-2)
GS003303 J988W-3
8W - 33 - 4 8W-33 VEHICLE SPEED CONTROL NS/GS
DIESEL
POWERTRAIN
CONTROL
SPEED SPEED VEHICLE MODULE
CONTROL CONTROL SPEED (8W-30-36)
SWITCH LAMP SENSOR (8W-30-39)
SIGNAL DRIVER SIGNAL
36 27 43
V37 G7
20 18
RD/LG WT/OR
A21 V38
B23 20 BS30
21 P34 LB/RD
V37 G7 G7
20 18 18
RD/LG WT/OR WT/OR
4 56 C1 42 C1
C2 BODY
SPEED VEHICLE
CLOCKSPRING CONTROL SPEED CONTROL
LAMP SENSOR MODULE
DRIVER SIGNAL
B108
(8W-45-9) 4
E96
V37 V37 G7
20 22 18
WT WT WT/OR
3
LEFT RIGHT VEHICLE VEHICLE
SPEED SPEED SPEED SPEED
CONTROL CONTROL SENSOR SENSOR
SIGNAL
SWITCH SWITCH (8W-30-36)
1 SET 1 RESUME/ACCEL
2 ON/OFF 2 CANCEL
3 COAST
1 2 1 2 3
Z2
Z2 22
20 BK
BK
CLOCKSPRING
3 C2
Z2
20
BK/LG
3
G200
(8W-15-4)
J988W-3 GS003304
NS/GS 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 5
DIESEL
BATT A0 (8W-10-8)
POWER ACCELERATOR
DISTRIBUTION ACCELERATOR ACCELERATOR PEDAL
PEDAL PEDAL
FUSE CENTER 5V SENSOR SENSOR
POSITION
13 (8W-10-10) SUPPLY SIGNAL GROUND SENSOR
20A (8W-30-38)
(8W-10-29) 10 7 8
8 C3
K6 K22 K167
20 20 20
VT/WT OR/DB BR/YL
57 15 55
5V ACCELERATOR ACCELERATOR POWERTRAIN
SUPPLY PEDAL PEDAL CONTROL
STOP SENSOR SENSOR MODULE
LAMP BRAKE CLUTCH SIGNAL GROUND (8W-30-33)
SWITCH SWITCH SWITCH (8W-30-38)
SIGNAL SENSE SIGNAL FUEL QUANTITY ACTUATOR SIGNAL (8W-30-39)
44 20 17 4 5 49
F32 L50 K29 K119 K140 K140 K140
18 18 20 20 18 18 18
PK/DB WT/TN WT/PK LG/BK TN/WT TN/WT TN/WT
TWISTED TWISTED
PAIR PAIR
BS01
(8W-70-2)
L50
18 BS32
WT/TN
6 5 3 1 1
STOP CLUTCH
LAMP SWITCH K140
SWITCH 18
TN/WT
4 2 2
LEFT
HEADLAMP B108
8
E96
LEVELING
GROUND MOTOR
1 (8W-50-8)
K140
Z1 Z1 Z1 18
20 20 20 TN/WT
BK BK BK
8
FUEL
FUEL
QUANTITY PUMP
6 1 ACCUATOR MODULE
G300 SIGNAL (8W-30-33)
(8W-15-7)
(8W-15-8)
GS003305 J988W-3
NS/GS 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1
35 C4
JUNCTION
(8W-12-19) BLOCK
(8W-12-2)
2 C2
Z1
14
BK
8
G300
(8W-15-6)
G104
J988W-3 GS003502
NS/GS 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3
6 10
STOP MESSAGE PS02 PS01
LAMP ABS
CENTER (8W-30-4) (8W-30-4)
SWITCH WARNING (8W-46-2) (8W-30-31) (8W-30-31)
(8W-33-5) LAMP
(8W-51-7) D2 D1
5 20 20
BODY 5 WT/BK VT/BR
L50 CONTROL *2
18 ABS MODULE
WT/TN WARNING (8W-45-6)
LAMP 13 12 P18
DRIVER
B13 B12 B23
BS01 17 C2
(8W-70-2)
G19 G19 D2 D1
20 20 18 18
LG/OR LG/OR WT/BK VT/BR
L50
18 3 P34 BS06 BS05
WT/TN A3 B23 (8W-30-4) (8W-30-4)
(8W-30-31) (8W-30-31)
G19 D2 D1
18 18 18
LG/OR WT/BK VT/BR
TWISTED
PAIR
12 16 19 20
STOP ABS CCD CCD CONTROLLER
LAMP WARNING BUS BUS ANTI-LOCK
SWITCH LAMP (-) (+) BRAKE
SENSE DRIVER
* RHD
GS003503 J988W-3
8W - 35 - 4 8W-35 ANTI-LOCK BRAKES NS/GS
LEFT LEFT
FRONT REAR
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR
1 2 2 1
RIGHT RIGHT
FRONT REAR
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR
2 1 2 1
B8 B9 B7 B6 B4 B3 B2 B1
18 18 18 18 18 18 18 18
RD/DB RD WT WT/DB LG LG/DB YL YL/DB
11 4 3 18 10 2 17 1
LEFT LEFT RIGHT RIGHT LEFT LEFT RIGHT RIGHT CONTROLLER
FRONT FRONT FRONT FRONT REAR REAR REAR REAR ANTI-LOCK
WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL BRAKE
SPEED SPEED SPEED SPEED SPEED SPEED SPEED SPEED
SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
(-) (+) (+) (-) (+) (-) (+) (-)
J988W-3 GS003504
NS/GS 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-9)
9 28 (8W-10-10)
20A 10A
(8W-10-30) (8W-10-11)
86 30
HORN
RELAY MEMORY
SEAT/
FUSED MIRROR
85 87 B (+) MODULE
(8W-62-3)
16 C1 (8W-63-4)
4 C2 8 C2 5 C3
X4 X2 M1 M1
20 18 20 20
GY/OR DG/RD PK PK
4 C2 13 C1
JUNCTION
(8W-12-20)
BLOCK
18 9 (8W-12-2)
HORN FUSED BODY
RELAY PASSENGER DRIVER B (+) CONTROL
CONTROL DOOR DOOR MODULE
HORN AJAR AJAR VTSS (8W-45-3)
RELAY SWITCH SWITCH LAMP (8W-45-7)
CONTROL SENSE SENSE DRIVER 6 C4
20 C2 48 C1 79 C1 16 C2 NOT
USED
X3 7 P50
20 G74 G75 G69 M1 M1
BK/RD 18 18 22 20 20
BS19 TN/RD TN BK/OR M1
PK PK
22
1 C2 PK
X2 X2 DRIVER
18 18 CLOCKSPRING
DG/RD DG/RD DOOR 3
AJAR REMOTE
A A SWITCH KEYLESS
LOW HIGH
NOTE NOTE ENTRY
PASSENGER MODULE
HORN HORN
(8W-41-2) (8W-41-2) DOOR *8
(8W-61-5)
X3
AJAR 12
B B 20 SWITCH MESSAGE
Z1 Z1 BK/RD CENTER
18 18 VTSS (8W-46-2)
BK BK LAMP
13 1
G301
(8W-15-10) HORN
(8W-15-11) SWITCH 13
*7
* RHD
J988W-3 GS003902
NS/GS 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 3
BODY
CONTROL
DRIVER PASSANGER MODULE
DOOR DOOR LIFTGATE (8W-45-6)
SWITCH SWITCH MUX (8W-45-8)
MUX MUX SIGNAL
45 C1 55 C1 44 C1
P97 P96 P98
18 20 20
WT/DG WT/LG WT/RD
B17
B02 B03 6
LJ01
11 4
D01D D01P
6 J03A
P97 P96 L16
20 20 P98
WT/DG WT/LG 20
WT/RD
2 2 2
DRIVER
DRIVER PASSANGER
PASSENGER LIFTGATE
DOOR DOOR DOOR DOOR ARM/
SWITCH LOCK SWITCH LOCK DISARM
MUX SWITCH MUX SWITCH SWITCH
GROUND (8W-61-6) 3 (8W-61-6) 1 UNLOCK
3 2 LOCK
P97 P96 1 2
20 20
WT/DG WT/LG
2 2 1
DRIVER PASSENGER
DOOR DOOR
ARM/ ARM/
DISARM DISARM
SWITCH SWITCH
1 UNLOCK 1 UNLOCK
2 LOCK 2 LOCK
1 2 1 2
1 1
Z2 Z2 Z2
20 20 20
BK/LG BK/LG BK/LG
Z2 Z2
20 20
BK/LG BK/LG
3 D01D 3 D01P
B02 B03
Z2 Z2
20 20
BK/LG BK/LG
3 2 9
G301 G400
(8W-15-10) (8W-15-14)
(8W-15-11)
GS003903 J988W-3
8W - 39 - 4 8W-39 VEHICLE THEFT SECURITY SYSTEM NS/GS
4 B17
LJ01
G77 G76 G70 G78
18 18 18 18
TN/OR TN/YL BR/TN TN/BK
4 J03A
L16
G78
18
TN/BK
2 2 1 3
LEFT RIGHT HOOD LIFTGATE
REAR REAR AJAR AJAR
DOOR DOOR SWITCH SWITCH
AJAR AJAR
SWITCH SWITCH 2 1
1 1
Z1 Z1 Z1 Z1
18 18 18 20
BK BK BK BK
8 14 12 11
G302 G301 G400
(8W-15-13) (8W-15-10) (8W-15-14)
J988W-3 GS003904
NS/GS 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 5
BUILT-UP-EXPORT
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-9)
18
15A
(8W-10-20)
2 C2
F41
20
PK/VT
20 C3 19 C4
F41 F87
20 20
PK/VT WT/BK
1 3
FUSED FUSED SENTRY
B(+) IGNITION KEY
(ST-RUN) IMMOBILIZER
MODULE
CCD CCD
BUS BUS
(+) (-) GROUND
6 5 2
D1 D2
20 20
Z2
VT/BR WT/BK
20
BK
12
G200
TO TO (8W-15-4)
PS01 PS02
(8W-30-4) (8W-30-4)
GS003905 J988W-3
NS/GS 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1
13 C1
JUNCTION M1
(8W-12-20)
BLOCK 20 F11
FUEL (8W-12-2) PK 20
FUEL TANK RD/WT
LEVEL
SENSOR MODULE
SIGNAL (8W-30-6) 13 C4 16 C1
(8W-30-20) FUSED MEMORY
3 (8W-45-9) B (+) SEAT/ 4 P50
G4 M1 NOT
20 MIRROR
18 USED
PK MODULE
DB
(8W-62-3)
(8W-63-4)
AW4 M1 TO F11
3
B13 20 IGNITION 20
PK RD/WT
SWITCH
(8W-10-14)
2 11
INSTRUMENT
FUSED LOW FUSED CLUSTER
B (+) FUEL IGNITION
CCD CCD FUEL WARNING (ST-RUN-OFF)
BUS BUS GAUGE LAMP
(+) (-) CONTROL CONTROL GROUND
LOW
FUEL FUEL
GAUGE WARNING
INDICATOR
LAMP
10 9 7
TWISTED
PAIR
G4 D1 D2
20 20 Z2
18 20
DB VT/BR WT/BK
BK/LG
PS01 PS02
(8W-30-4) (8W-30-4)
(8W-30-31) (8W-30-31)
46 C1 3 C2 34 C2
BODY 2
FUEL CCD CCD
LEVEL BUS BUS CONTROL G200
SENSOR (+) (-) (8W-15-4)
MODULE
SIGNAL
(8W-45-3)
(8W-45-9)
J988W-3 GS004002
NS/GS 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3
DOOR LIFTGATE
AJAR AJAR
INDICATOR INDICATOR
LAMP LAMP
10 9
D1 D2
20 TWISTED 20
VT/BR PAIR WT/BK
G78
18
PS01 PS02 TN/BK 4 B17
(8W-30-4) (8W-30-4) LJ01
3 C2 34 C2 59 C1
BODY G78
CCD CCD LEFT LIFTGATE RIGHT 18
DRIVER BUS PASSENGER BUS REAR AJAR REAR CONTROL TN/BK
DOOR (+) DOOR (-) DOOR SWITCH DOOR MODULE
AJAR AJAR AJAR SENSE AJAR (8W-45-3)
SWITCH SWITCH SWITCH SWITCH J03A
4
SENSE SENSE SENSE SENSE L16
79 C1 48 C1 47 C1 77 C1
G74
G75 18 G77 G76 G78
18 TN/RD 18 18 18
TN TN/OR TN/YL TN/BK
PASSENGER
2 2 3
DOOR
LEFT RIGHT LIFTGATE
AJAR
REAR REAR AJAR
SWITCH
DOOR DOOR SWITCH
AJAR AJAR
1 SWITCH 1 SWITCH 1
Z1 Z1 Z1
18 18 20
DRIVER BK BK BK
DOOR 8 14 11
AJAR G302 G400
SWITCH (8W-15-13) (8W-15-14)
GS004003 J988W-3
8W - 40 - 4 8W-40 INSTRUMENT CLUSTER NS/GS
10 C4
F11
20
RD/WT
11
INSTRUMENT
FUSED CLUSTER
IGNITION
(ST-RUN-OFF) SEAT CLUSTER
BELT ILLUMINATION
CCD CCD INDICATOR LAMPS
BUS BUS LAMP
(+) (-) CONTROL
SEAT
BELT
INDICATOR
LAMP
10 9 6 13
D1 D2
FROM
IGNITION
20 20 SWITCH
VT/BR WT/BK A/C
(8W-10-14)
TWISTED HEATER
CONTROL GROUND
PAIR
(8W-42-3) 2 C2
PS01 PS02 E2 Z1 Z1
E2 20 20 20
(8W-30-4) (8W-30-4) 20 OR BK BK
D1 (8W-30-31) D2 (8W-30-31) OR
20 20
VT/BR WT/BK
8 C4 28 C4
JUNCTION
(8W-12-23)
3 C2 34 C2 2 BLOCK
BODY (8W-12-2)
CCD CCD PANEL
BUS BUS SEAT LAMPS CONTROL (8W-12-19)
(+) (-) BELT DRIVER MODULE
SWITCH (8W-45-3)
SENSE (8W-45-5)
(8W-45-7)
78 C1
2 C2
G10
18
Z1 Z1
LG/RD
20 14
BK BK
1 2
SEAT 1 8
BELT G300
(8W-15-6)
SWITCH (8W-15-8)
J988W-3 GS004004
NS/GS 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5
10 C4
F11
20
RD/WT
11
INSTRUMENT
FUSED CLUSTER
IGNITION
CCD CCD ELECTRONIC (ST-RUN-OFF) TRIP
BUS BUS PRNDL ODOMETER ODOMETER
(+) (-) CONTROL CONTROL CONTROL
D1 D2 TWISTED
20 20 PAIR
VT/BR WT/BR
12 13 P18
B12 B13 B23
D1 D2 D1 D2
18 18 18 18
VT/BR WT/BK VT/BR WT/BK
BS05 BS06
(8W-30-4) (8W-30-4)
(8W-30-31) (8W-30-31)
7 2 B33
E36
ES13
(EATX)
D1 D2 ES14
20 20
VT/BR WT/BK (EATX)
D1 D2
3 C2 34 C2 18 18
BODY VT/BR WT/BK
CCD CCD
BUS BUS CONTROL 59 C2 60 C2
(+) (-) MODULE CCD CCD POWERTRAIN
(8W-45-3) BUS BUS CONTROL
(+) (-) MODULE
(8W-30-4)
GS004005 J988W-3
8W - 40 - 6 8W-40 INSTRUMENT CLUSTER NS/GS
GAS
ST-RUN-OFF A81 (8W-10-16)
JUNCTION
D1
BLOCK
(8W-12-2)
FUSE
2
10A
(8W-12-9)
10 C4
F11
20
RD/WT
11
INSTRUMENT
FUSED CLUSTER
IGNITION
CCD CCD (ST-RUN-OFF)
BUS BUS SPEEDOMETER TACHOMETER
(+) (-) CONTROL CONTROL
SPEEDOMETER TACHOMETER
10 9
D1 D2
20 20
VT/BR WT/BK
PS01
(8W-30-4) TRANSMISSION
PS02 VEHICLE CONTROL
(8W-30-4) SPEED
SENSOR MODULE
D1 D2 SIGNAL (8W-31-4)
20 TWISTED 20
VT/BR PAIR WT/BK 58
VEHICLE
TWISTED VEHICLE SPEED
12 13 P18 G7 SPEED
PAIR B12 B13 B23 18 SENSOR SENSOR
D1 D2 WT/OR SIGNAL (8W-30-11)
18 18 (8W-30-17)
3
VT/BR WT/BK
BS05 BS06 G7
(8W-30-4) (8W-30-4) 18
7 2 B33 WT/OR
E36
ES13 ES14
EATX MTX
D1 D2 (EATX) (EATX)
20 20 D1 (8W-30-4) D2 (8W-30-4) G7
VT/BR WT/BK 18 18 18
VT/BR WT/BK WT/OR
3 C2 34 C2 59 C2 60 C2 66 C2
CCD CCD BODY CCD CCD VEHICLE POWERTRAIN
BUS BUS CONTROL BUS BUS SPEED CONTROL
(+) (-) MODULE (+) (-) SENSOR MODULE
SIGNAL (8W-30-4)
(8W-45-3)
J988W-3 GS004006
NS/GS 8W-40 INSTRUMENT CLUSTER 8W - 40 - 7
DIESEL
BATT M1 (8W-10-11) ST-RUN-OFF F11 (8W-12-9)
INSTRUMENT
CLUSTER
FUSED FUSED
B(+) IGN.
(ST-RUN-OFF)
CCD CCD
BUS BUS SPEEDOMETER TACHOMETER
(+) (-) CONTROL CONTROL
SPEEDOMETER TACHOMETER
10 9
D1 D2
20 20
VT/BR WT/BK ENGINE VEHICLE
ENGINE SPEED VEHICLE SPEED
TWISTED SPEED SPEED
PAIR SENSOR
SENSOR SENSOR SENSOR
SHIELD SIGNAL (8W-30-35) SIGNAL (8W-30-36)
3 3
PS01 PS02
(8W-30-31) (8W-30-31) Z122 G7
18 18
FROM BK WT/OR
BS40
(8W-15-3) 4 E96
B108
ES30 K24 G7
(8W-15-3) 20 18
Z1 Z122 GY/BK WT/OR
18 18
TWISTED BK BK
PAIR 5 E97
7 BS30
B106
K24 G7
18 18
GY/BK WT/OR
8 43
ENGINE VEHICLE POWERTRAIN
Z12
ENGINE
SPEED SPEED CONTROL
18 SENSOR SENSOR MODULE
BK SPEED SIGNAL SIGNAL
SENSOR (8W-30-35)
SIGNAL (8W-30-36)
6 2
G301
(8W-15-12)
D1 D2 K159 G7
20 20 20 18
VT/BR WT/BK VT/RD WT/OR
3 C2 34 C2 75 C1 42 C1
CCD CCD ENGINE VEHICLE BODY
BUS BUS SPEED SPEED CONTROL
(+) (-) SENSOR SENSOR MODULE
SIGNAL SIGNAL
(8W-45-3)
(8W-45-9)
GS004007 J988W-3
8W - 40 - 8 8W-40 INSTRUMENT CLUSTER NS/GS
GAS
ST-RUN-OFF A81 (8W-10-16)
JUNCTION
D1
BLOCK
(8W-12-2)
FUSE
2
10A
(8W-12-9)
10 C4
F11
20
RD/WT
11
INSTRUMENT
FUSED CLUSTER
IGNITON
(ST-RUN-OFF) ENGINE
COOLANT CHARGING
CCD CCD TEMPERATURE SYSTEM
BUS BUS GAUGE INDICATOR
(+) (-) CONTROL CONTROL
ENGINE VOLTS
COOLANT INDICATOR
TEMPERATURE LAMP
GAUGE
10 9
D1 D2 ENGINE
20 20 COOLANT
VT/BR WT/BK TEMPERATURE
PS01 SENSOR
2 (8W-30-10)
(8W-30-4)
PS02 (8W-30-16)
(8W-30-4) K2 (8W-30-24)
18
D1 D2 TN/BK
20 TWISTED 20
VT/BR PAIR WT/BK
12 13 P18
B12 B13 B23 2.0L OTHERS
TWISTED
D1 D2
PAIR 18 18 2.4L 3.3L/3.8L
VT/BR WT/BK
F09 F02
BS05 BS06 12
E69 11
E78
(8W-30-4) (8W-30-4)
7 2 B33
E36
D1 D2 ES13 ES14
20 20 (EATX) (EATX) K2
VT/BR WT/BK 18
D1 (8W-30-4) D2 (8W-30-4)
TN/BK
18 18
3 C2 34 C2 VT/BR WT/BK
CCD CCD BODY 59 C2 60 C2 26 C1
BUS BUS CONTROL CCD CCD ENGINE POWERTRAIN
(+) (-) MODULE BUS BUS COOLANT CONTROL
(8W-45-3) (+) (-) TEMPERATURE MODULE
SENSOR (8W-30-4)
SIGNAL
J988W-3 GS004008
NS/GS 8W-40 INSTRUMENT CLUSTER 8W - 40 - 9
DIESEL
BATT M1 (8W-10-11) ST-RUN-OFF F11 (8W-12-9)
INSTRUMENT
CLUSTER
FUSED FUSED
B(+) IGNITION
ENGINE (ST-RUN-OFF)
COOLANT CHARGING
CCD CCD TEMPERATURE SYSTEM
BUS BUS GAUGE INDICATOR
(+) (-) CONTROL CONTROL
ENGINE VOLTS
COOLANT INDICATOR
TEMPERATURE LAMP
GAUGE
10 9
D1 D2 ENGINE
20 20 POWERTRAIN ENGINE
VT/BR WT/BK CONTROL COOLANT COOLANT
TEMPERATURE TEMPERATURE
SCI MODULE SENSOR
TRANSMIT (8W-30-30) SIGNAL
SENSOR
(8W-30-36)
61 3
D21
20
PK
TWISTED B17 B23
PAIR 17 P18
D21
20 G58
PK 20
BK/YL
7
DATA
LINK
CONNECTOR
(8W-30-30)
(8W-30-31)
3 11
D1 D2
20 20 3 E120
VT/BR WT/BK B33
TWISTED
PAIR
PS01
(8W-30-31)
TWISTED
PAIR PS02
(8W-30-31)
D1 D2 G58
20 20 20
VT/BR WT/BK BK/YL
3 C2 34 C2 60 C1
CCD CCD ENGINE BODY
BUS BUS COOLANT CONTROL
(+) (-) TEMPERATURE MODULE
SENSOR
(8W-45-3)
SIGNAL
(8W-45-9)
GS004009 J988W-3
8W - 40 - 10 8W-40 INSTRUMENT CLUSTER NS/GS
GAS
ST-RUN-OFF A81 (8W-10-16)
JUNCTION
D1
BLOCK
(8W-12-2)
FUSE
2
10A
(8W-12-9)
10 C4
F11
20
RD/WT
11
INSTRUMENT
FUSED CLUSTER
IGNITION LOW
(ST-RUN-OFF) WASHER
CRUISE FLUID
CCD CCD INDICATOR LEVEL
BUS BUS LAMP INDICATOR
(+) (-) CONTROL CONTROL
LEFT RIGHT
LOW
CRUISE WASHER SPEED SPEED
INDICATOR FLUID CONTROL CONTROL
LAMP LEVEL SWITCH SWITCH
INDICATOR (8W-33-2) (8W-33-2)
LAMP
V37 V37
10 9 20 20
D1 D2 WT WT
20 20
VT/BR WT/BK
PS01
(8W-30-4)
PS02 CLOCKSPRING
(8W-30-4)
TWISTED D1 D2
PAIR 20 TWISTED 20
VT/BR PAIR WT/BK
LOW
WASHER WASHER
4 C2
FLUID
12 13 P18
FLUID B12 B13 B23 V37
SWITCH 20
SENSE SWITCH D1 D2
RD/LG
B (8W-53-3) 18 18
VT/BR WT/BK 21 P34
A21 B23
BS05 BS06
(8W-30-4) (8W-30-4) V37
20
D1 D2 G29 7 2 B33 RD/LG
20 20 20 E36
VT/BR WT/BK BK/TN B70
ES13 ES14 8
(EATX) (EATX) E43
3 C2 34 C2 58 C1 V37
D1 (8W-30-4) D2 (8W-30-4) 18
CCD CCD WASHER BODY 18 18 RD/LG
BUS BUS FLUID CONTROL VT/BR WT/BK
(+) (-) SWITCH MODULE
SENSE
59 C2 60 C2 41 C2
(8W-45-3) CCD CCD SPEED POWERTRAIN
BUS BUS CONTROL CONTROL
(+) (-) SWITCH MODULE
SIGNAL (8W-30-4)
J988W-3 (8W-30-5) GS004010
NS/GS 8W-40 INSTRUMENT CLUSTER 8W - 40 - 11
DIESEL
BATT M1 (8W-10-11) ST-RUN-OFF F11 (8W-12-9)
INSTRUMENT
CLUSTER
FUSED FUSED
B(+) IGNITION LOW
(ST-RUN-OFF) WASHER
CRUISE FLUID
CCD CCD INDICATOR LEVEL
BUS BUS LAMP INDICATOR
(+) (-) CONTROL CONTROL
LOW
CRUISE WASHER
INDICATOR FLUID
LAMP LEVEL
INDICATOR
LAMP
10 9
D1 D2
20 20
VT/BR WT/BK
TWISTED
PAIR
LEFT RIGHT
SPEED SPEED
CONTROL CONTROL
SWITCH SWITCH
(8W-33-4) (8W-33-4)
PS01 PS02
(8W-30-31) (8W-30-31) V37 V37
20 22
WT WT
LOW CLOCKSPRING
WASHER WASHER
FLUID FLUID
SWITCH
SENSE SWITCH
B (8W-53-3)
4 C2
V37
TWISTED 20
PAIR RD/LG
21 P34
A21 B23
3 C2 34 C2 58 C1 56 C1 27 36
CCD CCD WASHER SPEED BODY SPEED SPEED POWERTRAIN
BUS BUS FLUID CONTROL CONTROL CONTROL CONTROL CONTROL
(+) (-) SWITCH LAMP MODULE LAMP SWITCH MODULE
SENSE DRIVER DRIVER SIGNAL
(8W-45-3) (8W-30-39)
(8W-45-9)
GS004011 J988W-3
NS/GS 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
(8W-10-10)
FUSE
9
20A
(8W-10-30)
86 30
HORN
RELAY
85 87
4 C2 8 C2
X4 X2
20 18
GY/OR DG/RD
4 C2
JUNCTION
18
BLOCK
HORN BODY (8W-12-2)
RELAY CONTROL
CONTROL MODULE
(8W-45-3)
HORN
RELAY
CONTROL
20 C2
BS19
X3
20
BK/RD
X2 X2
18 18
DG/RD DG/RD
1 C2
A A
LOW HIGH
CLOCKSPRING NOTE NOTE
HORN HORN
B B
Z1 Z1
18 18
BK BK
13 1
HORN G301
SWITCH (8W-15-10)
(8W-15-11)
J988W-3 GS004102
NS/GS 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3
16 C2
F1
20
DB
BATT A0 (8W-10-8)
9 C2
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-10)
8
20A
(8W-10-31)
86 30
CIGAR/
ACCESSORY
RELAY
85 87
2 C4 10 C2
F30
16
A/C RD
PANEL
HEATER
LAMPS CONTROL
FEED (8W-42-3)
11 C1 A22 B23
22 P34
E2
Z1 20 F30 F30
18 OR 16 16
BK RD RD
*2 1
FRONT 1
CIGAR REAR
LIGHTER/ CIGAR
POWER LIGHTER/
OUTLET POWER
OUTLET
3 3
Z1 Z1
16 16
BK BK
10 10 11
G300 G200 G302
(8W-15-7) (8W-15-4) (8W-15-13)
* BUILT-UP-EXPORT
GS004103 J988W-3
NS/GS 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1
85 87
2 C4 3 C1
C71
12
B23 DB
B32 B34 B33 B30 B31 B35
P18 Z1 B23
32 34 33 30 31 35 P18
18 1
BK FRONT
BLOWER
C4 C5 C6 C104 C107 M MOTOR
16 16 14 12 12 10
TN LG LB RD/WT TN/BK G300 REAR
2 BLOWER
(8W-15-7)
C7 FRONT
12 GROUND CONTROL
BK/TN
7 C2 4 C2 2 C2 3 C2 8 C2 10 C2 7 SWITCH
(8W-42-6)
A/C
2 3 HEATER
1 4 CONTROL
0 OFF
1 LOW
0 5 2 M1
3 M2
GROUND FRONT HVAC 4 M3
BLOWER CONTROL 5 HIGH
OFF
6 C2
Z1 Z1
12 12
BK BK
G201
(8W-15-4)
J988W-3 GS004202
NS/GS 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3
REAR MODE LEFT TEMP. GROUND RIGHT A/C ON-OFF ELECTRIC HVAC
WIPE/ SELECT CONTROL TEMP. SWITCH WIPER DE-ICE CONTROL
WASH REAR SENSE CONTROL SIGNAL DRIVER
WASHER WIPER ON SENSE DELAY ON DELAY
SWITCH INDICATOR WIPER ON INDICATOR SWITCH
GROUND SENSE DRIVER SWITCH DRIVER SENSE
REAR REAR
ILLUMINATION WIPER WIPER
LAMP ON DELAY
INDICATOR ON
INDICATOR
6 C2 21 C1
Z1 REAR Z2
12 BLOWER 18
BK FRONT BK/LG
TO CONTROL
GROUND
FRONT SWITCH 5
7
CIGAR (8W-42-6) G200
Z1 (8W-15-4)
LIGHTER/ 12
POWER BK
OUTLET
(8W-41-3) G201
(8W-15-4)
GS004203 J988W-3
8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER NS/GS
14 C4 32 C4
V23 C14
18 22
BR/PK WT/RD
10 C1 1 C1
A/C
HEATER
REAR CONTROL
DEFOGGER
ON
INDICATOR
A/C RECIRCULATE
SWITCH MODE
SWITCH
REAR
WINDOW
DEFOGGER
RECIRCULATE A/C
SWITCH
MODE ON
INDICATOR INDICATOR
21 C1
Z2
18
BK/LG
5
G200
(8W-15-4)
J988W-3 GS004204
NS/GS 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5
A/C BLEND
ZONE DOOR
DOOR ACTUATOR
M ACTUATOR M
(DUAL
ZONE A/C)
1 5 2 3 4 1 5 2 3 4
C61 C62 C57 C102 C26 C33 C34 C26 C36 C57
20 20 20 20 20 20 20 20 20 20
DB DB/PK DB/GY LG PK/DB DB/RD DB/WT PK/DB RD/WT DB/GY
JS01B
(8W-70-10)
JS02B
(8W-70-10)
JS03
(8W-70-9)
C26 C57 C34
20 20 20 C34
C61 PK/DB DB/GY DB/WT 20
20 DB/WT
DB
B J01D
9 10 11 1 2 4 5 7 P30
TO
A C61 C62 C102 C26 C57 C33 C34 P34 C36
22 22 22 22 22 22 22 (8W-42-6) 22
TO DB DB/PK LG PK/DB DB/GY DB/RD DB/WT RD/WT
P34
(8W-42-6)
13 C1 15 C1 4 C1 9 C1 20 C1 17 C1 12 C1 5 C1
A/C
HEATER
CONTROL
ZONE ZONE ZONE 5V SENSOR BLEND DOOR BLEND DOOR HVAC
DOOR DOOR DOOR SUPPLY GROUND DOOR COMMON FEEDBACK CONTROL
COMMON DRIVER FEEDBACK DRIVER SIGNAL EVAP.
RECIRC. SIGNAL MODE MODE DOOR TEMP.
DOOR DOOR DOOR 5V FEEDBACK SENSOR SENSOR
DRIVER COMMON DRIVER SUPPLY SIGNAL GROUND SIGNAL
19 C1 12 C1 18 C1 9 C1 6 C1 20 C1 8 C1
C32 C34 C35 C26 C37 C57 C21
22 22 22 22 22 22 22
GY/DB DB/WT DG/YL PK/DB YL DB/GY DB/OR
3 5 6 1 8 2 12 P30
J01D
C32 C34 C26 C37 C57
20 20 20 20 20
GY/DB DB/WT PK/DB YL DB/GY
JS03 JS01B
(8W-70-9) JS02B C57
(8W-70-10)
C34 C34 C35 (8W-70-10) C57 C21
20 20 20 20 20 20
DB/WT DB/WT DG/YL DB/GY DB/GY DB/OR
5 1 1 5 2 3 4 2 1
RECIRCULATION MODE EVAPORATOR
DOOR DOOR TEMPERATURE
M ACTUATOR M ACTUATOR SENSOR
(A/C) (A/C)
GS004205 J988W-3
8W - 42 - 6 8W-42 AIR CONDITIONING-HEATER NS/GS
1 C1 30 C4 12 C2
E2 E2 C40
20 20 12
OR OR BR/WT
8 8
REAR REAR
BLOWER BLOWER
REAR FRONT
CONTROL CONTROL
SWITCH SWITCH
0 OFF 0 OFF
1 LOW 1 REAR
2 MEDIUM 2 LOW
0 3 3 HIGH 0 3 3 HIGH
1 2 1 2
1 2 3 5 4 5 3 1 7
C60 C65 C70 C50 Z1 C50 C60 C70 Z1
16 14 12 12 18 12 16 12 12
BK/LB BK/OR DG BK/LG BK BK/LG BK/LB DG BK
12 G201
G302 (8W-15-4)
(8W-15-13) 35 P34
31 33 A35 B23
A31 A33 P34
B23
BS17
(8W-70-3)
FROM FROM
A/C HEATER A/C HEATER
CONTROL CONTROL
(8W-42-5) (8W-42-5)
B A
C34 C61
20 20
DB/WT DB
34 36 P34
A34 A36 B23
C34 C61 C60 C70
20 20 16 12
DB/WT DB BK/LB DG
1 2 5 4 6 3
REAR
A/C
M M HEATER
UNIT
J988W-3 GS004206
NS/GS 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 7
GAS
ST-RUN A21 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
PTC
1
9A
(8W-12-13)
30 C1
ES07
(8W-12-13)
F87
18 F87 F87
WT/BK 18 18
WT/BK BK/WT
BATT A0 (8W-10-8)
6 C2 6 C6 1 C6
POWER
DISTRIBUTION
FUSE CENTER
(8W-12-13)
11 (8W-10-10)
15A
(8W-10-29)
86 30
A/C
COMPRESSOR
CLUTCH
RELAY
85 87
7 C6 2 C6
A/C
PRESSURE
C3 TRANSDUCER
18
DB/BK
2 3 1
1 2.0L 2.4L 3.3L/3.8L
K6 C18
A/C 18 18
COMPRESSOR VT/WT DB K4 K4 K4
C13 CLUTCH 18 18 18
18 ES03 BK/LB BK/LB BK/LB
DB/OR (8W-70-7)
2
Z1 ES02 FS01 ES21
18 (8W-70-4) (8W-70-5) (8W-70-6)
BK
F09
5
ES23 E69
(8W-15-2) ES21 ES02
Z1 K6 (8W-70-4) ES02 (8W-70-6)
12 18 (8W-70-5)
BK VT/WT
ES21
G102 (8W-70-5)
(8W-15-2)
64 C2 61 C2 42 C2 43 C2
A/C 5V A/C SENSOR POWERTRAIN
COMPRESSOR SUPPLY PRESSURE GROUND CONTROL
CLUTCH RELAY SWITCH MODULE
CONTROL SIGNAL (8W-30-5)
GS004207 J988W-3
8W - 42 - 8 8W-42 AIR CONDITIONING-HEATER NS/GS
GAS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-8)
24
40A
(8W-10-15)
6 C7
A16
12
GY
4
FUSED RADIATOR
B (+) FAN
RADIATOR RADIATOR RELAY
FAN FAN
RELAY RELAY
OUTPUT GROUND CONTROL
3 1 2
C23 Z1
12 14
DG BK
1 E40
RF3
C23 K173
12 14
DG LG/DB
RFS1
C23 C23
12 12
DG DG
1 1
RADIATOR RADIATOR
FAN FAN
M NO. 1 M NO. 2
2 2
Z1 Z1
12 12
BK BK
RFS2
Z1
12
BK
2 RF3
E40
Z1
12
BK
ES23 73 C2
(8W-15-2)
Z1 RADIATOR POWERTRAIN
12 FAN CONTROL
BK RELAY MODULE
CONTROL (8W-30-5)
G102
(8W-15-2)
J988W-3 GS004208
NS/GS 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 9
DIESEL
ES06
(8W-10-25)
A142
18
DG/OR
A142
18
ES29 DG/OR
(8W-10-25)
A142
18
DG/OR
BATT A0 (8W-10-8) BATT A0 (8W-10-8)
1 C6 5 C6
POWER
DISTRIBUTION
FUSE FUSE CENTER
11 17 (8W-10-9)
15A 20A
(8W-10-29) (8W-10-25)
86 30 30
A/C DIESEL
COMPRESSOR POWER
CLUTCH RELAY
RELAY (8W-30-28)
85 87 87
7 C6 2 C6
C3
C13 18
20 DB/BK
DB/OR 1
A/C
COMPRESSOR
CLUTCH
Z2
18
BK
BATTERY
9 E97 ES02 (8W-20-3) A/C
B106 (8W-15-3) PRESSURE
Z1 TRANSDUCER
16
BK
2 3 1
C13
20
DB/OR
ES01
(8W-15-3) Z0 Z0 K7 C18 K4
6 2 20 20 20
Z0 BK OR DB BK/LB
BK
10
BK BS34
G103 (8W-70-11)
28 G100 19 13 33
A/C 5V A/C SENSOR POWERTRAIN
COMPRESSOR SUPPLY PRESSURE GROUND CONTROL
CLUTCH RELAY SWITCH MODULE
CONTROL SIGNAL (8W-30-38)
GS004209 J988W-3
8W - 42 - 10 8W-42 AIR CONDITIONING-HEATER NS/GS
DIESEL
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-8)
24
40A
(8W-10-15)
6 C7
A16
12
BATT A17
GY (8W-10-19)
ES29
(8W-10-25) A17
A142 C116 A142 A142 12
18 12 18 18 RD/BK
DG/OR LG/WT DG/OR DG/OR
4 8 4 8 4 8
RADIATOR RADIATOR RADIATOR
FAN FAN FAN
RELAY RELAY RELAY
NO. 1 NO. 2 NO. 3
6 2 5 6 2 6 2
C137 Z1 C27 C24 C25 C137 C27
20 12 12 20 12 20 12
YL BK DB/PK DB/PK YL YL DB/PK
ES07
ES09
C27
12
DB/PK
4 2
RADIATOR
DRIVER’S PASSENGER’S FAN
M SIDE M SIDE DISCONNECT
RADIATOR RADIATOR
FAN FAN
3 1
Z1
12
BK
ES12
1 E95 10 E97 (8W-15-3)
B107 B106
C137 C24 Z1
20 20 12
YL DB/PK BK
48 6
HIGH LOW POWERTRAIN
SPEED SPEED CONTROL
RADIATOR RADIATOR MODULE G102
NO.1 & NO.3 RELAY NO. 2 (8W-30-37) (8W-15-3)
CONTROL CONTROL
J988W-3 GS004210
NS/GS 8W - 43 AIRBAG SYSTEM 8W - 43 - 1
R43 R45
18 18
BUILT-UP EXCEPT BUILT- BK/LB DG/LB
-EXPORT UP-EXPORT
F14 F14
18 20 BUILT-UP EXCEPT BUILT-
LG/YL LG/YL -EXPORT UP-EXPORT
CLOCKSPRING
F23 F23
18 20
DB/YL DB/YL
1 C1 2 C1
TWISTED
B24 PAIR
B23 B23
23 24 P18
1 C2 2 C2 3 C1 4 C1
FUSED FUSED DRIVER DRIVER AIRBAG
IGNITION IGNITION AIRBAG AIRBAG CONTROL
(ST-RUN) (RUN) LINE 1 LINE 2 MODULE
GROUND
11 C2
Z2
18
BK/LG
G204
(8W-15-4)
J988W-3 GS004302
NS/GS 8W-43 AIRBAG SYSTEM 8W - 43 - 3
V23
18
BR/PK
DATA
LINK
CONNECTOR
(8W-30-4) R42 R44
10 (8W-30-31) 18 18
MESSAGE BK/YL DG/YL
CENTER 3 11
AIRBAG (8W-46-2)
INDICATOR
LAMP
D1 D2
20 20
VT/BR WT/BK TWISTED
11 PAIR
*9
TWISTED
PAIR
R41
18
BK/TN
PS01 PS02
(8W-30-4) (8W-30-4)
(8W-30-31) (8W-30-31)
D1 D2
20 20
VT/BR WT/BK
7 C2 3 C2 4 C2 1 C1 2 C1
AIRBAG CCD CCD PASSENGER PASSENGER AIRBAG
WARNING BUS BUS AIRBAG AIRBAG CONTROL
LAMP (+) (-) LINE 1 LINE 2 MODULE
DRIVER
* RHD
GS004303 J988W-3
NS/GS 8W - 44 INTERIOR LIGHTING 8W - 44 - 1
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
18 (8W-10-9)
15A
(8W-10-20)
2 C2
F41
20
PK/VT
15 C2
JUNCTION
BLOCK
86 30 (8W-12-2)
COURTESY
LAMP
RELAY
85 87
D4
20 C3 34 C3 28 C3 19 C2
F41 M111 M113
20 22 20
F41
PK/VT BR/WT LB/PK
20
1 9 C1 11 C1 PK/VT
GLOVE FRONT HEADLAMP
BOX
INTERIOR
READING SWITCH 2 B75
LAMPS C20
LAMP LAMP (8W-50-9)
ON
DEFEAT (8W-50-10)
SWITCH F41
SWITCH
20
3 C1 10 C1 PK/VT
M13 OVERHEAD
20 CONSOLE OTHERS
M112 BK/YL
2 22
BR/LG
22 P18
B22 B23 CS02
(8W-10-20)
M20 3 B75
20
10 C3 C20 4 3
BR 1
JUNCTION
17
BLOCK FRONT
COURTESY BODY READING
5 P18 CONTROL (8W-12-2)
LAMP LAMPS/
B5 B23 RELAY MODULE
(8W-45-4) SWITCH
DRIVER
(8W-45-8)
READING
LAMP
GROUND
80 C1
M20 M20
20 20 6 2
BR BR
OVERHEAD OTHERS
CONSOLE
1 B75 CS03
C20 (8W-70-3)
M20 20BR
J988W-3 GS004402
NS/GS 8W-44 INTERIOR LIGHTING 8W - 44 - 3
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
18 (8W-10-9)
15A
(8W-10-20)
2 C2
F41
20
PK/VT
15 C2
JUNCTION
BLOCK
86 30
(8W-12-2)
COURTESY
LAMP
RELAY
(8W-44-2)
85 87
19 C2 29 C3 29 C2
F41 M11 M11
20 20 20 M11
PK/VT PK/LB PK/LB 20
B75 B01 PK/LB
2 3
C20 D02
CS02 M1 B03
20 6
(OVERHEAD PK/LB
D01P
CONSOLE) M11
2 1 20
(8W-10-20)
B B KEY-IN DRIVER PK/LB
LEFT RIGHT HALO DOOR
VISOR/ VISOR/ LAMP COURTESY
VANITY VANITY LAMP 1
MIRROR MIRROR PASSENGER
LAMPS LAMPS DOOR
1 2
Z1 Z1 COURTESY
20 20 LAMP
BK BK
A A 36 C4 2
JUNCTION DS01
M20 M20 (8W-15-7) Z1
20 20 (8W-12-19) BLOCK 20
(8W-12-2) Z1
BR BR BK
12
BK D01P
CS03 5
(8W-70-3)
2 C2 D01D B03 TO
1 C20 10
B75 B02 PASSENGER
M20 20BR Z1 Z1 POWER
Z1
5 B23 14 12 18 WINDOW
P18 BK BK BK
SWITCH
2 80 C1 8 5 11 (8W-60-3)
COURTESY GLOVE COURTESY BODY G300
LAMP BOX LAMP CONTROL (8W-15-6)
GROUND LAMP GROUND MODULE (8W-15-7)
(8W-44-2) (8W-45-8)
GS004403 J988W-3
8W - 44 - 4 8W-44 INTERIOR LIGHTING NS/GS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
18 (8W-10-9)
15A
(8W-10-20)
2 C2
F41
20
PK/VT
15 C2
JUNCTION
86 30 BLOCK
COURTESY (8W-12-2)
LAMP
RELAY
(8W-44-2)
85 87
D4
19 C2 22 C2 6 C2
F41 M113 M11
20 20 20
PK/VT LB/PK PK/LB
2 B75 B75 B17
4 3
C20 C20 LJ01
F41
20 CS1 J02A
3
PK/VT L15
CS01 2
CS02 REAR
1 3 (OVERHEAD DOME
3 1
LEFT CONSOLE) LAMP
LEFT 3
MID REAR (8W-10-20) M11
READING 20
READING 2 PK/LB
LAMP 3 1
LAMP CENTER
1 3
RIGHT RIGHT DOME 1
MID REAR 3 LAMP LEFT
READING READING LIFTGATE
LAMP LAMP FLOOD
2 M11
2 LAMP 20
M2 M2
PK/LB
M20 M20 20 20
20 20 BR BR 2
BR BR 1
2 2 RIGHT
CS03 LIFTGATE
FLOOD
1 C20 LAMP
B75
M2 20BR
5 B23 2
P18 Z1 Z1
20 20
80 C1 2
BK BK
COURTESY BODY COURTESY GLOVE
3 8
LAMP CONTROL LAMP BOX
GROUND GROUND G400
MODULE LAMP (8W-15-14)
(8W-45-8) (8W-44-2)
J988W-3 GS004404
NS/GS 8W-44 INTERIOR LIGHTING 8W - 44 - 5
4 B17
LJ01
G78
PASSENGER 18
TN/BK
DOOR
AJAR J03A
SWITCH 4
L16
G78
18
TN/BK
2 3
LEFT LIFTGATE
REAR AJAR
DOOR SWITCH
AJAR
SWITCH 1
1 Z1
20
BK
11
DRIVER G400
DOOR (8W-15-14)
AJAR
SWITCH
1 2
HOOD RIGHT
AJAR REAR
SWITCH DOOR
AJAR
2 SWITCH
1
Z1
18 Z1 Z1
BK 18 18
BK BK
12
G301 8 14
(8W-15-10) G302
(8W-15-13)
GS004405 J988W-3
8W - 44 - 6 8W-44 INTERIOR LIGHTING NS/GS
14 C1 18 C2
L24 V23 F20
20 18 20
WT/LG BR/PK WT
Z1 L1 L1
P112 P114 20 18
20 20 20
VT/BK L1 VT/BK
YL/WT YL/BK BK
18
VT/BK
EC1
4 5 2 3 C19 DIESEL GAS
10 E120 10 E36
B33 B33
C20 Z1 L1 E36
19 20 B75 20 20 10
B33
BK VT/BK
EATX MTX
A20 A18 B23
20 18 P34 C20 L1
12 13 B75 20
P112 P114 L1 VT/BK
20 20 20
Z1
YL/WT YL/BK VT/BK
20 BS02
BK (8W-70-2)
6 C1 4 C2
POWER POWER DRIVER 14
MIRROR MIRROR POWER G300
B(-) B(-) MIRROR (8W-15-5)
(8W-62-6)
J988W-3 GS004406
NS/GS 8W-44 INTERIOR LIGHTING 8W - 44 - 7
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
22 (8W-10-8)
40A
(8W-10-17)
86 30
PARK
LAMP
RELAY
85 87
10 C3 4 C1
L97 L7
18 12
PK/DB BK/YL
9 C2 2 C1
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
3 1
15A 10A
(8W-12-8) (8W-12-8)
16 1
PARK FUSED BODY
LAMP PARK CONTROL
RELAY LAMP COURTESY STEP MODULE
PANEL CONTROL RELAY LAMP DIMMER DIMMER (8W-45-4)
LAMPS OUTPUT SWITCH SWITCH SWITCH (8W-45-5)
DRIVER GROUND GROUND SENSE SENSE SIGNAL
2 14 C2 10 C2 2 C2 11 C2 8 C2
23 C4
E17 E92
E2 M32 20 22
18 E2
22 YL/BK OR/BK
20
*1 OR BK/LB E17 20 YL/BK
OR
2
ASH 1 C2 4 C1 5 C1 12 C1 4 C1
RECEIVER HEADLAMP STEP RADIO
LAMP SWITCH DIMMER (8W-47-2)
(8W-50-9) SWITCH
(8W-50-10) SIGNAL
1
*3 FROM
MESSAGE 2 C2 6 C1
Z1 CENTER Z2 Z2
(8W-46-4) Z1 Z1
18 20 20 18 20
BK BK/LG BK/LG Z1
BK BK
14
BK
OTHER OVERHEAD
8
22 C4 29 C4 21 C4 2 C2 G300
JUNCTION (8W-15-6)
(8W-12-19)
BLOCK
(8W-12-2)
* RHD
GS004407 J988W-3
8W - 44 - 8 8W-44 INTERIOR LIGHTING NS/GS
JUNCTION
BODY
BLOCK
CONTROL (8W-12-2)
MODULE
PANEL (8W-45-5)
LAMPS
DRIVER
2
1 C4 30 C4 8 C4 1 C1
E2 20OR
2
E2 E2 E2 UNIVERSAL
E2
20 20 E2 20 20 GARAGE
OR 20 OR OR DOOR
OR OR
5 11 C1 OPENER
POWER A/C (PART OF
MIRROR HEATER 3
FRONT
SWITCH CONTROL READING
2 Z2
(8W-62-2) (8W-42-3) 18 LAMPS/ E2
(8W-62-4) FRONT BK/LG SWITCH) 20
CIGAR (8W-49-3) OR
LIGHTER/ 6 C2 CS06
POWER (8W-49-3) 8
11 OUTLET REAR
3 (8W-41-3) Z1 C20 BLOWER
3 9
TRACTION 12 B75 REAR
Z1 BK Z2 CONTROL
CONTROL 16 18
SWITCH BK BK/LG
SWITCH
(8W-35-2) (8W-42-6)
E2 4
20 10 5
OR G200 G301 Z1
1 (8W-15-4) 18
(8W-15-11)
BK
12
8 6 G302
REAR INSTRUMENT (8W-15-13)
BLOWER CLUSTER
(8W-40-4)
FRONT
E2 Z1 Z1 CONTROL
20 20 20 IGNITION
OR BK BK
SWITCH SWITCH
(8W-42-6)
7 (8W-10-14)
13
Z1 Z1 GROUND
12
BK
20 2 C2
BK
Z1 20BK
35 C4 G201 28 C4
JUNCTION
(8W-12-19)
BLOCK
(8W-12-2)
2 C2
Z1
5 C1 14
PANEL RADIO BK
(8W-47-2) 8
LAMPS
DRIVER G300
(8W-15-6)
J988W-3 GS004408
NS/GS 8W-44 INTERIOR LIGHTING 8W - 44 - 9
JUNCTION
BODY
BLOCK
CONTROL (8W-12-2)
MODULE
PANEL (8W-45-5)
LAMPS
DRIVER
2
8 C1
E2 E2
20 20
OR OR
B02 B03
11
4
D01D D01P
E2 E2 E2
20 20 20
OR OR OR
1 6 1
DRIVER E2 PASSENGER PASSENGER
DOOR 20 POWER DOOR
OR
LOCK WINDOW LOCK
SWITCH SWITCH SWITCH
(8W-61-2) (8W-60-3) (8W-61-2)
(8W-61-6) (8W-61-6)
14
3 DRIVER 7 3
POWER
Z2 WINDOW Z1 Z2
20 SWITCH 20 20
BK/LG BK BK/LG
(8W-60-2)
PASSENGER
DOOR
COURTESY
GROUND LAMP
13 2 (8W-44-3)
Z1 Z1
12 20
BK BK
5 3 D01P
DS01 B03
(8W-15-7)
Z1 Z2
3 10 D01D 18 20
B02 BK BK/LG
5 11
G300
Z2 (8W-15-7)
20
BK/LG
3 2
G301
(8W-15-10)
(8W-15-11)
GS004409 J988W-3
NS/GS 8W - 45 BODY CONTROL MODULE 8W - 45 - 1
13 C1 15 C4 31 C3 31 C4
JUNCTION
BLOCK
D1 (8W-12-2)
(8W-12-20) (8W-10-16)
FUSE
6
FUSE 20A
2 (8W-12-9)
10A
(8W-12-9)
9 7 14 11 12 13
FUSED FUSED FUSED FUSED BODY
B (+) IGN. IGN. IGN. CONTROL
(ST-RUN-OFF) (RUN-ACC) (ST-RUN) MODULE
29 C4 21 C4 2 C2
Z2 Z2
20 20
BK/LG BK/LG Z1
14
Z1 Z1 BK
20 18
BK BK
6 C1 2 C2
GROUND GROUND HEADLAMP
SWITCH
(8W-50-9)
(8W-50-10)
8
G300
(8W-15-6)
J988W-3 GS004502
NS/GS 8W-45 BODY CONTROL MODULE 8W - 45 - 3
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
22 (8W-10-9)
40A
(8W-10-17)
86 86 30
HORN PARK
RELAY LAMP
(8W-41-2) RELAY
(8W-50-11)
(8W-50-12)
85 85 87
4 C2 10 C3 4 C1
X4 L97 L7
20 18 12
GY/OR PK/DB BK/YL
4 C2 9 C2 2 C1
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
3 1
15A 10A
(8W-12-8) (8W-12-8)
18 16 1
HORN PARK FUSED BODY
RELAY LAMP PARK CONTROL
CONTROL RELAY LAMP MODULE
CONTROL RELAY
OUTPUT
WIPER WASHER
DIMMER PARK HORN FLUID CCD CCD
SWITCH SWITCH RELAY SWITCH BUS BUS
SIGNAL SENSE CONTROL SENSE (+) (-)
8 C2 41 C1 41 C1 58 C1 3 C2 34 C2
G29
20
BK/TN
D1 D2
E92 V7 X3 20 TWISTED 20
22 20 20 VT/BR PAIR WT/BK
OR/BK DG/WT BK/RD
B
2 LOW PS01 PS02
WASHER (8W-30-4) (8W-30-4)
WIPER
WIPER FLUID WASHER (8W-30-31) (8W-30-31)
PARK MODULE SWITCH FLUID
SWITCH (8W-53-2) SENSE SWITCH D1 D2
SENSE 20 TWISTED 20
(8W-53-3)
1 C2 VT/BR PAIR WT/BK
12 C1
3 11
DIMMER HEADLAMP HORN CLOCKSPRING DATA
SWITCH SWITCH RELAY (8W-41-2) LINK
SIGNAL (8W-50-9) CONTROL CONNECTOR
(8W-50-10) (8W-30-4)
(8W-30-31)
GS004503 J988W-3
8W - 45 - 4 8W-45 BODY CONTROL MODULE NS/GS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
19 (8W-10-8)
30A
(8W-10-19)
86 87 87A
WIPER
ON REAR
RELAY REAR
WIPER
WIPER
(8W-53-2)
(8W-53-3) MOTOR MOTOR
CONTROL (8W-53-4)
85 30
3
7 C5 V13
18 FRONT
BR/LG FRONT WIPER
WIPER WASHER
L16 MUX MOTOR SWITCH
2
REAR J03A SIGNAL CONTROL (PART OF
REAR V13 MULTI-
WASHER
WASHER 18 6 11
MOTOR MOTOR BR/LG FUNCTION
V14 CONTROL (8W-53-4) V52 V10 SWITCH)
18 LJ01 20 20 (8W-53-2)
7
RD/VT B B17 DG/YL BR (8W-53-3)
V20 V13
20 18 18 C3
BK/WT BR/LG JUNCTION
(8W-53-5) BLOCK
73 C1 50 C1 49 C1 7 C2 20
(8W-12-2)
WIPER REAR REAR WIPER FRONT BODY
ON/OFF WASHER WIPER MUX WASHER CONTROL
RELAY MOTOR MOTOR SIGNAL MOTOR MODULE
CONTROL CONTROL CONTROL CONTROL
10 C3 21 C4
RADIO
STEP (8W-47-2)
DIMMER
SWITCH
SENSE
L307 L308 L110 M32 E17 M112 Z1 Z1
20 20 22 22 20 4 C1 22 18 20
LG/OR LG/WT BK/YL BK/LB YL/BK BR/LG BK BK
E17
20
YL/BK
3 C2 8 C2 7 C2 4 C1 5 C1 3 C1 2 C2 6 C1
HEADLAMP
SWITCH
(8W-50-9)
(8W-50-10)
J988W-3 GS004504
NS/GS 8W-45 BODY CONTROL MODULE 8W - 45 - 5
HEADLAMP
HIGH/LOW DIMMER
BEAM SWITCH
86
RELAY
LOW CONTROL (PART OF
BEAM 9 MULTI-
RELAY FUNCTION
(IN PDC) SWITCH)
(8W-50-2) L93 (8W-50-2)
85 22
PK
MESSAGE
L193 VTSS CENTER
20 INDICATOR (8W-46-2)
OR/WT LAMP
DRIVER
13
*7 33 C3
JUNCTION
G69 COMBINATION BLOCK
22 HIGH/LOW LEFT RIGHT FLASHER/ (8W-12-2)
BK/OR BEAM REAR REAR DRL
RELAY TURN TURN MODULE
CONTROL SIGNAL SIGNAL (8W-50-2)
12 4 5 (8W-50-12)
(8W-51-3)
76 C1 16 C2 15 19 21
LOW VTSS LOW LEFT RIGHT BODY
BEAM INDICATOR BEAM REAR REAR CONTROL
RELAY LAMP RELAY TURN TURN MODULE
CONTROL DRIVER CONTROL SIGNAL SIGNAL
KEY-IN
IGNITION PANEL
SWITCH LAMPS
SENSE FEED
4 C2 2
8 C4 30 C4 23 C4 1 C4
E2 E2
E2 E2 20 20
20 20 E2 E2 E2 E2
OR OR
OR OR 20 20 18 20
OR OR OR OR
6
INSTRUMENT
PANEL 3
LAMPS CLUSTER 5
(8W-40-4) TRACTION POWER
FEED PANEL PANEL
LAMPS CONTROL MIRROR
SWITCH LAMPS
FEED FEED SWITCH
(8W-35-2) (8W-62-2)
TO (8W-62-4)
G26 FRONT E2 8
20 20 REAR *1 5 C1
LB CIGAR OR PANEL 2
BLOWER RADIO
LIGHTER/ LAMPS ASH PANEL (8W-47-2)
POWER FEED FRONT PANEL LAMPS
RECEIVER
OUTLET CONTROL LAMPS FEED
FEED LAMP
(8W-41-3) SWITCH (8W-44-7)
1 C2 (8W-42-6)
IGNITION 11 C1 1 C2
KEY-IN A/C HEADLAMP
IGNITION SWITCH PANEL PANEL
SWITCH (8W-10-14) LAMPS HEATER LAMPS SWITCH
SENSE FEED CONTROL FEED (8W-50-9)
(8W-42-3) (8W-50-10)
* RHD
GS004505 J988W-3
8W - 45 - 6 8W-45 BODY CONTROL MODULE NS/GS
1 C1 8 C1
MESSAGE E2
ABS 20
WARNING CENTER
G19 E2 E2
OR
20 (8W-46-2) 20 20
LAMP 8
LG/OR OR OR
DRIVER
E2 PANEL REAR
5 LAMPS BLOWER B02 B03
20 4 11
*2 FEED D01D D01P
OR REAR
G19 CONTROL E2 E2
20
LG/OR
SWITCH 20 20
(8W-42-6) OR OR
TO 1
3 P34 1 PASSENGER
A3 B23 UNIVERSAL PANEL
GARAGE PANEL DRIVER LAMPS DOOR
LAMPS DOOR FEED LOCK
G19 DOOR E2
FEED LOCK SWITCH
18 OPENER E2 20
LG/OR (PART OF 20 SWITCH OR (8W-61-2)
OR (8W-61-2) (8W-61-6)
FRONT READING (8W-61-6)
16 LAMPS/SWITCH) 14 6
ABS CONTROLLER (8W-49-3) PANEL DRIVER PANEL PASSENGER
WARNING ANTI-LOCK LAMPS POWER LAMPS POWER
LAMP BRAKE FEED WINDOW FEED WINDOW
DRIVER (8W-35-3) SWITCH SWITCH
* RHD (8W-60-2) (8W-60-3)
J988W-3 GS004506
NS/GS 8W-45 BODY CONTROL MODULE 8W - 45 - 7
BATT A2 (8W-10-13)
JUNCTION
BLOCK
(8W-12-2)
PTC
3
9A
(8W-12-14)
(8W-12-15)
86 86 86
DOOR DOOR DRIVER
LOCK UNLOCK DOOR
RELAY RELAY UNLOCK
(8W-61-3) (8W-61-3) RELAY
(8W-61-4) (8W-61-4) (8W-61-7)
(8W-61-7) (8W-61-7) (8W-61-8)
85 85 85
(8W-61-8) (8W-61-8)
8 6 5
DOOR LOCK DOOR UNLOCK DRIVER BODY
RELAY RELAY UNLOCK CONTROL
CONTROL CONTROL RELAY MODULE
CONTROL
ENGINE DRIVER PASSENGER
OIL SEAT DOOR DOOR FUEL LIFTGATE HOOD
PRESSURE BELT AJAR AJAR LEVEL AJAR AJAR
SWITCH SWITCH SWITCH SWITCH SENSOR SWITCH SWITCH
SENSE SENSE SENSE SENSE SIGNAL SENSE SENSE
52 C1 78 C1 79 C1 48 C1 46 C1 59 C1 43 C1
3 B13
G6 G10 G75 G74 AW4 G78 G70
20 18 18 18 18 18
GY LG/RD TN TN/RD G4 TN/BK BR/TN
18
DB B17
4
LJ01
3
FUEL 1
FUEL HOOD
LEVEL TANK G78 HOOD
9 B33 18 AJAR AJAR
SENSOR MODULE
E36 SIGNAL TN/BK SWITCH SWITCH
(GAS)
SENSE (8W-44-5)
(8W-30-6)
1 (8W-30-20) J03A
4
SEAT
SEAT PASSENGER L16
BELT BELT DOOR
G6 G78
16
SWITCH SWITCH AJAR 18
SENSE (8W-40-4) SWITCH
GY TN/BK
1 3
ENGINE ENGINE DRIVER LIFTGATE
LIFTGATE
OIL OIL DOOR AJAR AJAR
PRESSURE PRESSURE AJAR SWITCH SWITCH
SWITCH SENSE (8W-44-5)
SENSE
SWITCH SWITCH
(8W-46-2)
GS004507 J988W-3
8W - 45 - 8 8W-45 BODY CONTROL MODULE NS/GS
CS03
(8W-70-3)
GLOVE DRIVER
M20 DRIVER DOOR PASSENGER
BOX 20 DRIVER DOOR PASSENGER PASSENGER DOOR
COURTESY DRIVER DOOR ARM/ PASSENGER DOOR DOOR
LAMP BR SWITCH
LAMP DOOR
LOCK MUX DISARM DOOR
LOCK SWITCH ARM/
GROUND (8W-44-2) SWITCH SWITCH MUX DISARM
MUX SWITCH 2 SWITCH MUX SWITCH
2
C20 (8W-61-2) (8W-39-3) (8W-61-2) 2 SWITCH
1 2 P97 2 (8W-39-3)
M20 B75 (8W-61-6) 20 (8W-61-6) P96
20 OTHER RKE WT/DG OTHER RKE 20
BR WT/LG
P18 M20
5
20
B5 B23 BR
M20 P96
20 20
BR WT/LG
11 D01D
B02 4 D01P
BS10 B03
80 C1 45 C1 55 C1
COURTESY DRIVER PASSENGER BODY
LEFT RIGHT
REAR
LAMP DOOR
REAR
DOOR CONTROL
GROUND SWITCH SWITCH MODULE
DOOR AJAR DOOR AJAR AUTOMATIC
MUX MUX
SWITCH SWITCH HEADLAMP
SENSE SENSE SIGNAL
47 C1 77 C1 51 C1
18 B75
C20
G77 G76
18 18 C19
TN/OR TN/YL 6
EC1
L24
2 2 20
LEFT RIGHT WT/LG
LEFT RIGHT
REAR REAR REAR REAR 7
DOOR AJAR DOOR DOOR AJAR DOOR AUTOMATIC AUTOMATIC
SWITCH SWITCH DAY/NIGHT
SENSE
AJAR SENSE
AJAR HEADLAMP
SWITCH SWITCH SIGNAL MIRROR
(8W-44-5) (8W-44-5) (8W-44-6)
J988W-3 GS004508
NS/GS 8W-45 BODY CONTROL MODULE 8W - 45 - 9
BODY
ENGINE CONTROL
SPEED ENGINE VEHICLE FUEL COOLANT COOLANT
CONTROL SPEED ENGINE SPEED LEVEL LEVEL TEMPERATURE
MODULE
LAMP SENSOR DISABLE SENSOR SENSOR SWITCH SENSOR
DRIVER SIGNAL SIGNAL SIGNAL SIGNAL SENSE SIGNAL
56 C1 75 C1 72 C1 42 C1 46 C1 57 C1 60 C1
G7
18
WT/OR G58
V38 K159 G55 G18 20
20 20 20 BS30 BK/YL
20
LB/RD VT/RD OR/BK (8W-30-36)
PK/BK
G7
18
WT/OR 2 3 B33
27 2 59 43 G4 E120
18
SPEED ENGINE ENGINE VEHICLE POWERTRAIN DB
CONTROL SPEED DISABLE SPEED CONTROL
LAMP SENSOR SENSOR 3
SIGNAL MODULE G18
DRIVER SIGNAL SIGNAL ENGINE
ENGINE
(DIESEL) 20
COOLANT
(8W-30-36) PK/BK COOLANT
TEMPERATURE TEMPERATURE
SIGNAL SENSOR
SIGNAL (DIESEL)
1
(8W-30-36)
LOW
COOLANT
LEVEL
SWITCH
BACK-UP (DIESEL)
2
BACK-UP
SWITCH
(8W-51-5) Z1
LAMP
20
FEED
BK
2
ES02
(8W-15-3)
Z1
L1 16
18 BK
VT/BK
E120 ES01
10
B33 (8W-15-3)
BATTERY
L1 (8W-20-3)
20
VT/BK
Z1
10
B13 BK
3
BS02 AW4
L1
(8W-70-2) B13
1 Z0 Z0
20 AW4
6 2
VT/BK BK BK
G4 Z1 Z1
B13 18 16 14
2
AW4 DB BK BK G100 G103
2 3 1 5
FUEL G302
BACK-UP FUEL GROUND
(8W-15-13)
LAMP LEVEL TANK
FEED SENSOR MODULE
SIGNAL (DIESEL)
GS004509 J988W-3
8W - 45 - 10 8W-45 BODY CONTROL MODULE NS/GS
BUILT-UP-EXPORT
JUNCTION
BLOCK
(8W-12-2)
86 87 87A 87A 87 86
POWER POWER
MIRROR MIRROR
FOLD UNFOLD
RELAY RELAY
(8W-62-8) (8W-62-8)
(8W-12-19)
85 30 30 85
30 C2 11 C3 11 C4 36 C1 36 C4 2 C2
2
POWER
FOLDING
MIRROR
1 2 SWITCH
1 1 UNFOLD
2 FOLD
(8W-62-8)
P174 P136 8
20 20 G300
YL/RD YL (8W-15-6)
71 C1 74 C1 39 C2
POWER POWER POWER BODY
MIRROR MIRROR FOLDING CONTROL
FOLD UNFOLD MIRROR MODULE
RELAY RELAY SWITCH
SIGNAL
J988W-3 GS004510
NS/GS 8W - 46 MESSAGE CENTER 8W - 46 - 1
M1 M1
14 C4 6 C4 20
22
M1 20PK PK
PK
V23 V23 M1
18 18 20 16 C1
BR/PK BR/PK PK 3 FUSED MEMORY
REMOTE B (+) SEAT/
10 C1 FUSED
B (+) KEYLESS MIRROR
FUSED A/C
ENTRY MODULE
IGNITION HEATER (8W-62-3)
(ST-RUN) CONTROL MODULE
(8W-63-4)
(8W-42-4) (8W-61-5)
10 *8 12
MESSAGE
CENTER
ABS ENGINE LOW AIRBAG VTSS
WARNING COOLANT OIL WARNING LAMP
LAMP TEMPERATURE PRESSURE LAMP
LAMP LAMP
5 6 8 11 13
*2 *1 *12 *9 *7
G19 R41 G69
20 18 22
LG/OR G2 G6 BK/TN BK/OR
22 22 7 C2
3 P34 VT GY AIRBAG
AIRBAG
A3 B23 G19 WARNING CONTROL
20 LAMP MODULE
LG/OR DRIVER (8W-43-3)
17 C2 6 C2 33 C2 16 C2
ABS ENGINE ENGINE ENGINE VTSS BODY
WARNING TEMPERATURE OIL OIL LAMP CONTROL
LAMP WARNING PRESSURE PRESSURE DRIVER MODULE
DRIVER LAMP SWITCH SWITCH (8W-45-5)
DRIVER SENSE SENSE (8W-45-6)
52 C1
G6 20GY
G19
18 GAS DIESEL
LG/OR
9 B33 1 B33
E36 E36
G6
16
16 GY
ABS CONTROLLER 1
WARNING ANTI-LOCK ENGINE
LAMP BRAKE OIL
DRIVER (8W-35-3) PRESSURE
SWITCH
* RHD
J988W-3 GS004602
NS/GS 8W-46 MESSAGE CENTER 8W - 46 - 3
14 C4
V23
18 V23
BR/PK 18
10 BR/PK
MESSAGE 10 C1
GAS DIESEL
CENTER FUSED A/C
IGNITION HEATER
(ST-RUN) CONTROL
SERVICE GLOW BRAKE
ENGINE PLUG WARNING (8W-42-4)
SOON LAMP LAMP
LAMP
7 7 9
*13 G85 *11
20 G9
G3 OR/BK 20
20 GY/BK
BK/PK
8 C3
JUNCTION
10 BLOCK
17
2 P34 COMBINATION (8W-12-2)
BRAKE
A2 A17 B23 LAMP FLASHER/
SENSE DRL
MODULE
G3 G85 (8W-50-13)
EATX MTX
20 20
BK/PK OR/BK
G9
9 C3 8 C2 1 C2 20
GY/BK
B70 26 G9
5 2 C1
E43 GLOW POWERTRAIN 20
PLUG CONTROL GY/BK IGNITION
G3 LAMP MODULE A SWITCH
18 DRIVER (8W-30-32) BRAKE 1 START
BK/PK 1 4 2 RUN
PRESSURE 0 OFF
2 0 3
SWITCH 3 LOCK
4 ACC
22 C1 (8W-10-14)
B 1 C1
SERVICE POWERTRAIN G9
ENGINE CONTROL 20
SOON GY/BK Z1
MODULE Z1
INDICATOR 20
LAMP (8W-30-13) 20
(8W-30-19) BK BK
DRIVER
(8W-30-27) PARK
BRAKE 9 14
SWITCH G300 G200
(8W-15-8) (8W-15-4)
* RHD
GS004603 J988W-3
8W - 46 - 4 8W-46 MESSAGE CENTER NS/GS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
86 30
HIGH CENTER
FUSE (8W-10-10)
BEAM 5
RELAY 10A
(8W-50-2) (8W-10-33)
(8W-10-34)
85 87
2 C3 6 C5
L324 L34
20 20
WT/LG RD/OR
33 C3 22 C4
JUNCTION
12 15 BLOCK
COMBINATION BODY (8W-12-2)
HIGH/ HIGH/
LOW FLASHER/ LOW CONTROL (8W-12-19)
BEAM DRL BEAM MODULE
RELAY MODULE RELAY (8W-45-5)
CONTROL (8W-50-2) CONTROL
2 C2
Z1 Z1
18 14
BK BK
13 8
G200 G300
(8W-15-4) (8W-15-6)
* RHD
J988W-3 GS004604
NS/GS 8W-46 MESSAGE CENTER 8W - 46 - 5
JUNCTION
BODY
BLOCK
CONTROL (8W-12-2)
LEFT RIGHT MODULE
REAR REAR (8W-45-5)
TURN TURN
SIGNAL SIGNAL
19 21
COMBINATION
FLASHER/
COMBO LEFT RIGHT LEFT RIGHT DRL
FLASHER TURN TURN REAR REAR MODULE
SWITCHED SIGNAL SIGNAL TURN TURN (8W-51-3)
GROUND SENSE SENSE SIGNAL SIGNAL
(8W-52-2)
9 7 8 4 5
26 C3 4 C3 22 C3 21 C3 14 C3 28 C2 36 C2
L63 L62
L91 L305 L302 18 18 L63 L62
22 22 22 DG/RD BR/RD 18 18
DB/PK LB/WT LB/YL DG/RD BR/RD
L91 *3 *5
20 2 4
DB/PK MESSAGE
L62
LEFT RIGHT
CENTER L63
18
5 P50 TURN TURN
18
BR/RD
NOT DG/RD
INDICATOR INDICATOR
USED
3
1 4 3 *4
TURN 1
SIGNAL/ RIGHT
1 2 3 RIGHT
HAZARD REAR REPEATER
SWITCH TURN LAMP
(PART OF SIGNAL (BUILT-UP
8
MULTI- -EXPORT)
Z1 **1
FUNCTION 20 (8W-52-3)
5
SWITCH) BK RIGHT
1 HAZARD RIGHT
2 LEFT REAR REAR
3 RIGHT 22 C4 TURN LAMP
JUNCTION SIGNAL ASSEMBLY
(8W-12-19) BLOCK 1 (8W-51-4)
(8W-12-2) LEFT (8W-51-5)
LEFT
REAR REPEATER
TURN LAMP
2 C2 SIGNAL (BUILT-UP
**1 -EXPORT)
Z1 Z1 (8W-52-2)
18 14 5
BK BK LEFT
LEFT
REAR REAR
13 8 TURN LAMP
G200 G300 SIGNAL ASSEMBLY
(8W-15-4) (8W-15-6) (8W-51-4)
(8W-51-5)
* RHD
GS004605 ** EXCEPT BUILT-UP-EXPORT J988W-3
NS/GS 8W - 47 AUDIO SYSTEM 8W - 47 - 1
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-9)
MEMORY 28
SEAT/ 10A
MIRROR (8W-10-11)
FUSED
B (+) MODULE
(8W-62-3)
16 C1 5 C3
M1 M1
20 20
PK PK
RUN-ACC A31 (8W-10-16)
13 C1
JUNCTION
BODY BLOCK
CONTROL (8W-12-2)
PANEL MODULE
LAMPS FUSED (8W-45-2)
FUSE
FEED B (+) (8W-45-4)
8
2 9 (8W-45-5)
10A
(8W-12-11)
(8W-12-23)
STEP
DIM
24 C3 1 C4 SWITCH 17 C4
SIGNAL
X12 E2 E2
11 C2 M1 M1
18 20 20 20 20
RD/WT OR OR PK PK
E17
20
X12 DATA
YL/BK 16
20 5
RD/WT LINK
POWER
PANEL CONNECTOR
LAMP MIRROR (8W-30-3)
FEED SWITCH (8W-30-30)
6 P50 (8W-62-2)
NOT (8W-62-4)
USED
HEADLAMP TO TO
STEP SWITCH
DIMMER (8W-50-9) PS01 PS02
SWITCH (8W-50-10) (8W-30-4) (8W-30-4)
SENSE
5 C1
E17 D1 D2
20 20 20
YL/BK VT/BR WT/BK
6 C1 5 C1 4 C1 7 C1 1 C3 2 C3
FUSED PANEL STEP FUSED CCD CCD RADIO
IGNITION LAMPS DIMMER B (+) BUS BUS
(RUN-ACC) FEED SWITCH (+) (-)
SIGNAL
GROUND
X15 16BK/DG
G202
(8W-15-5)
J988W-3 GS004702
NS/GS 8W-47 AUDIO SYSTEM 8W - 47 - 3
BASE
2 3 3 3
LEFT LEFT RIGHT RIGHT
FRONT REAR REAR FRONT
SPEAKER SPEAKER SPEAKER SPEAKER
3 6 6 2
A9 A7 A10 A8 B23
9 7 10 8 P34
2 C1 4 C2 2 C2 6 C2 3 C2 7 C2 5 C2 3 C1
LEFT LEFT LEFT LEFT RIGHT RIGHT RIGHT RIGHT RADIO
FRONT FRONT REAR REAR REAR REAR FRONT FRONT
SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER
(-) (+) (+) (-) (+) (-) (+) (-)
GS004703 J988W-3
8W - 47 - 4 8W-47 AUDIO SYSTEM NS/GS
PREMIUM
RUN-ACC A31 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
FUSE
8
10A
(8W-12-11)
86 30
NAME
BRAND
SPEAKER
RELAY
85 87
(8W-12-19)
13 C3 2 C2 22 C1
X60 Z1 X1
20 14 16
RD/DG BK DG/RD
8 1
G300 RADIO
(8W-15-6) CHOKE
X13
16
RD/DG
BS03
X13 X13
16 16
RD/DG RD/DG
J988W-3 GS004704
NS/GS 8W-47 AUDIO SYSTEM 8W - 47 - 5
PREMIUM
RADIO
RADIO
CHOKE
2 CHOKE (8W-47-4) 1
LEFT OUTPUT RIGHT
REAR 2 REAR
PILLAR PILLAR
SPEAKER X13 SPEAKER
1 16
RD/DG 2
BS03
(8W-47-4)
X151 X157 X158 X152
20 20 20 20
X13 X13
BR/YL BR/LB DB/OR DB/WT
16 16
RD/DG RD/DG
1 4 5 5 4 1
LEFT RIGHT
REAR REAR
SPEAKER SPEAKER
6 3 2 3 6 2
BS08
(8W-15-5)
X15
16
BK/DG
G202
(8W-15-5)
6 C2 2 C2 3 C2 7 C2
LEFT LEFT RIGHT RIGHT RADIO
REAR REAR REAR REAR
SPEAKER SPEAKER SPEAKER SPEAKER
(-) (+) (+) (-)
GS004705 J988W-3
8W - 47 - 6 8W-47 AUDIO SYSTEM NS/GS
PREMIUM LHD
4 RADIO 4
LEFT CHOKE RIGHT
RADIO
FRONT CHOKE (8W-47-4) FRONT
PANEL OUTPUT PANEL
SPEAKER 2 SPEAKER
1 1
X13
16
X153 X155 RD/DG X154 X156
20 20 20 20
WT/BR BR/WT WT/VT VT/WT
BS03
(8W-47-4)
2 25 6 26
P18 P18
B2 B25 B23 B6 B26 B23
X13 X13
16 16
5 B01 RD/DG RD/DG B120
10 3 7
D02 D02
B01 B03
2 14
D02 D01P
X153 X155 X154 X156
20 20 X13 X13 20 20
WT/BR BR/WT 16 16 WT/VT VT/WT
RD/DG RD/DG
1 4 5 5 1 4
LEFT RIGHT
DOOR DOOR
SPEAKER SPEAKER
6 3 2 3 6 2
8 9 1 D02 8 7 1 D01P
B01 B03
2 C1 4 C2 5 C2 3 C1
LEFT LEFT RIGHT RIGHT RADIO
DOOR DOOR DOOR DOOR
G202
SPEAKER SPEAKER SPEAKER SPEAKER (8W-15-5)
(-) (+) (+) (-)
J988W-3 GS004706
NS/GS 8W-47 AUDIO SYSTEM 8W - 47 - 7
PREMIUM RHD
4 RADIO 4
LEFT CHOKE RIGHT
RADIO
FRONT CHOKE (8W-47-4) FRONT
PANEL OUTPUT PANEL
SPEAKER 2 SPEAKER
1 1
X13
16
X154 X156 RD/DG X153 X155
20 20 20 20
WT/VT VT/WT WT/BR BR/WT
BS03
(8W-47-4)
6 26 2 25
P18 P18
B6 B26 B23 B2 B25 B23
X13 X13
16 16
5 B01 RD/DG RD/DG B120
10 3 7
D02 D02
B03 B01
14 2
D01P D02
X154 X156 X153 X155
20 20 X13 X13 20 20
WT/VT VT/WT 16 16 WT/BR BR/WT
RD/DG RD/DG
1 4 5 5 1 4
LEFT RIGHT
DOOR DOOR
SPEAKER SPEAKER
6 3 2 3 6 2
8 9 1 D02 8 7 1 D01P
B01 B03
3 C1 5 C2 4 C2 2 C1
LEFT LEFT RIGHT RIGHT RADIO
DOOR DOOR DOOR DOOR
G202
SPEAKER SPEAKER SPEAKER SPEAKER (8W-15-5)
(-) (+) (+) (-)
GS004707 J988W-3
NS/GS 8W - 48 WINDOW DEFOGGERS 8W - 48 - 1
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
27 (8W-10-8)
40A
ST-RUN A21 (8W-10-16) RUN A22 (8W-10-14) (8W-10-11)
JUNCTION
BLOCK
6 C1
(8W-12-2) A4
12
BK/RD
FUSE FUSE
6 12
35 C1
20A 10A
(8W-12-9) (8W-12-12)
86 30
REAR
WINDOW
DEFOGGER
RELAY
85 87
FUSE
7
10A
(8W-12-10)
14 C4 32 C4 20 C4 6 C1
C14
V23 22
18 C16 C16 C15
WT/RD
BR/PK 20 20 12
10 C1 1 C1 LB/YL LB/YL BK/WT
A/C
HEATER 4 C1 12 B17
PASSENGER LJ01
CONTROL
(8W-42-4) POWER
FUSED REAR HVAC
1 J03A
CONTROL MIRROR
IGNITION REAR WINDOW (8W-62-2)
L16
(RUN) DEFOGGER (8W-42-4)
WINDOW (8W-62-5)
DEFOGGER RELAY 5 C1
CONTROL REAR
SWITCH SENSE Z1
20
WINDOW
BK DEFOGGER
REAR
WINDOW 4 C1
DEFOGGER
SWITCH
DRIVER Z1
POWER 12
MIRROR BK
(8W-62-2) 5
V23
21 C1 (8W-62-4) G400
18 5 C1 (8W-15-14)
Z2 Z1
BR/PK
18 20
10
BK/LG BK
FUSED MESSAGE 5 6 7
IGNITION CENTER G200
(ST-RUN) (8W-46-3) (8W-15-4)
J988W-3 GS004802
NS/GS 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 3
15 C3
V20
18
RD
1 C1
ELECTRIC
WIPER
DE-ICER
1 C2
C66
18
BK/WT
7 C1
A/C
HEATER
CONTROL
ELECTRIC HVAC (8W-42-3)
WIPER CONTROL
DE-ICER (8W-42-3)
DRIVER
GS004803 J988W-3
NS/GS 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1
B75
11 10 8 C20
CS04
(8W-12-9)
V23 G31 G32
18 20 20
BR/PK VT/LG BK/LB
4 5 2
OVERHEAD
FUSED AMBIENT SENSOR COMPASS/ CONSOLE
IGN. TEMPERATURE GROUND MINI-TRIP
(RUN) SENSOR COMPUTER
CCD SIGNAL CCD
BUS BUS
GROUND (+) (-)
3 6 1
Z2
18 D1 D2
BK/LG 18 18
VT/BR WT/BK
CS06 C20
(8W-49-3) 6 5 B75
Z2 D1 D2
18 18 18
BK/LG VT/BR WT/BK
C20
9
B75
Z2 TO TO
18 BS05 BS06
BK/LG (8W-30-4) (8W-30-4)
(8W-30-31) (8W-30-31)
*3
5
G301
(8W-15-11)
*DIESEL
J988W-3 GS004902
NS/GS 8W-49 OVERHEAD CONSOLE 8W - 49 - 3
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-9)
18
15A
(8W-10-20)
2 C2 JUNCTION
BODY BLOCK
F41 CONTROL (8W-12-2)
20 MODULE
PK/VT (8W-45-6)
15 C2
2
JUNCTION
BLOCK
(8W-12-2)
1 C1
19 C2
E2
F41 20
20 OR
PK/VT
2 B75 B75
C20 17 OVERHEAD
C20 COMPASS/ CONSOLE
CS02 MINI-TRIP
(8W-10-20) COMPUTER
E2
F41 18 GROUND
20 OR
PK/VT
3
4 2
FUSED PANEL UNIVERSAL
B(+) LAMPS GARAGE
FEED DOOR
OPENER Z2
18
GROUND (PART OF BK/LG
3 FRONT
READING
Z2
18 LAMPS/
BK/LG SWITCH)
CS06
Z2
18
BK/LG
C20
9
B75
Z2
18
BK/LG
*3
5
G301
(8W-15-11)
(8W-15-12)
* DIESEL
GS004903 J988W-3
NS/GS 8W - 50 FRONT LIGHTING 8W - 50 - 1
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
(8W-10-10)
86 30 86 30
LOW HIGH
BEAM BEAM
RELAY RELAY
85 87 85 87
L94 L324
20 20
OR/WT WT/LG
B20 B21
B23
20 21 P18
L94 L324
20 22
OR/WT WT/LG
L193
20 10 12
OR/WT HEADLAMP
DIMMER
SWITCH
(PART OF
9 8 MULTI-
FUNCTION
L93
22
SWITCH)
PK
Z1
18
BK
33 C3
JUNCTION
13
BLOCK
(8W-12-2) G200
76 C1 15 12 (8W-15-4)
LOW LOW BODY LOW COMBINATION
BEAM BEAM CONTROL BEAM FLASHER/
RELAY SENSE MODULE RELAY DRL
CONTROL (8W-45-5) CONTROL MODULE
J988W-3 GS005002
NS/GS 8W-50 FRONT LIGHTING 8W - 50 - 3
EXCEPT BUILT-UP-EXPORT
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
(8W-10-10)
86 30 86 30
LOW HIGH
BEAM BEAM
RELAY RELAY
(8W-50-2) (8W-50-2)
85 87 85 87
8 C5 1 C3 1 C5 6 C5
TO TO TO TO 1
BS15 RIGHT LEFT LEFT MESSAGE
(8W-50-6) FUSED
HEADLAMP HEADLAMP HIGH HIGH CENTER
(8W-50-6) (8W-50-6) HEADLAMP BEAM (8W-46-4)
(8W-50-5) RELAY
OUTPUT
TO
RIGHT
DODGE/
LOW PYLMOUTH CHRYSLER
TO HEADLAMP
FOG (8W-50-4)
LAMP L34 L34
RELAY 20 20
(IN JB) RD/OR RD/OR
(8W-50-5)
TO TO
RIGHT RIGHT
HEADLAMP HIGH
(8W-50-6) HEADLAMP
(8W-50-4)
GS005003 J988W-3
8W - 50 - 4 8W-50 FRONT LIGHTING NS/GS
EXCEPT BUILT-UP-EXPORT/CHRYSLER
BATT A0 (8W-10-8)
POWER
30 30 DISTRIBUTION
HIGH LOW CENTER
BEAM BEAM (8W-10-10)
RELAY RELAY
(8W-50-2) (8W-50-2)
87 87
FUSE FUSE
5 7
10A 15A
(8W-10-33) (8W-10-33)
6 C5 1 C3
L34 L44
20 20
RD/OR VT/RD
A A
RIGHT RIGHT
HIGH LOW
B HEADLAMP B HEADLAMP
Z1 Z1
20 20
BK BK
7
G301
(8W-15-10)
J988W-3 GS005004
NS/GS 8W-50 FRONT LIGHTING 8W - 50 - 5
EXCEPT BUILT-UP-EXPORT/CHRYSLER
BATT A0 (8W-10-8)
POWER
30 30 DISTRIBUTION
HIGH LOW CENTER
BEAM BEAM (8W-10-10)
RELAY RELAY
FUSE (8W-50-2) FUSE (8W-50-2)
4 6
10A 20A
(8W-10-33) 87 (8W-10-33) 87
1 C5 8 C5
L43
18
VT
16 C1
JUNCTION
BLOCK
86 30
(8W-12-2)
FOG
LAMP
RELAY
85 87
12 C1 31 C1 25 C1
L39 L39
18 18
LB LB
1
RIGHT
FOG
2 LAMP
1
L33 L43 LEFT
20 18 FOG
RD VT
2 LAMP
A
LEFT L94 Z39 Z39 L39
20 20 20 18
LOW OR/WT BK BK LB
B HEADLAMP
A
LEFT B20 B19 B3 B23
HIGH P18
20 19 3
B HEADLAMP
L94 Z39 L39
20 18 18
OR/WT BK LB
Z1 Z1 10
20 20 LOW HEADLAMP
BK BK BEAM DIMMER
RELAY SWITCH
CONTROL A B
1 9 (PART OF
G300 MULTI- TO TO
(8W-15-8) FUNCTION HEADLAMP HEADLAMP
SWITCH) SWITCH SWITCH
(8W-50-2) (8W-50-6) (8W-50-6)
GS005005 J988W-3
(8W-50-9) (8W-50-9)
8W - 50 - 6 8W-50 FRONT LIGHTING NS/GS
BATT A0 (8W-10-8)
POWER
30 30 DISTRIBUTION
HIGH LOW CENTER
BEAM BEAM (8W-10-10)
RELAY RELAY
(8W-50-2) (8W-50-2)
87 87
L34
20
EXCEPT BUILT- BUILT-UP L33 RD/OR
UP-EXPORT -EXPORT L44 EXCEPT BUILT-
20 20
RD BUILT-UP- UP-
VT/RD EXPORT EXPORT
L43
18
VT L34
BUILT-UP EXCEPT BUILT- 20
-EXPORT UP-EXPORT
BS15 L43 RD/OR
18
L44
L39 L39 L39 VT
20
18 18 18 VT/RD
VT/RD VT/RD LB L43 D
18 L44
VT 20
1 1 C TO
LEFT RIGHT VT/RD
RIGHT
FOG FOG B3 B23 TO HEADLAMP
LAMP LAMP 3 P18 BS16 (8W-50-8)
2 2 (8W-50-8)
*2 *1 L34
Z39 Z39 L39 1 3
20 20 18 20
BK BK LB
LEFT RD/OR
HEADLAMP
2
*3 1 3
B19 B23
19 P18 RIGHT
Z1 HEADLAMP
B
20 2
Z39
TO BK
18
HEADLAMP Z1
BK
20
SWITCH BK
(8W-50-5)
A
(8W-50-9) 9
TO G300
HEADLAMP (8W-15-8)
7
SWITCH
(8W-50-5) G301
(8W-50-9) (8W-15-10)
* BUILT-UP-EXPORT
J988W-3 GS005006
NS/GS 8W-50 FRONT LIGHTING 8W - 50 - 7
BUILT-UP-EXPORT
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
30
PARK CENTER
FUSE (8W-10-8)
22 LAMP
40A RELAY
(8W-10-17) (8W-50-11)
(8W-50-12)
87
4 C1
L7
12
BK/YL
2 C1
JUNCTION
BLOCK
(8W-12-2)
FUSE
4
15A
(8W-12-8)
3 C1
F39 F39
18 18
PK/LG PK/LG
1 1
LEFT RIGHT
FOG FOG
LAMP LAMP
2 2
Z39 Z39
20 20
BK BK
B19 B23
19 P18
Z39
18
Z39 18BK
BK
6 C2
F
GROUND HEADLAMP
SWITCH TO
(8W-50-10) HEADLAMP
SWITCH
(8W-50-10)
GS005007 J988W-3
8W - 50 - 8 8W-50 FRONT LIGHTING NS/GS
BUILT-UP-EXPORT
FROM
FROM POWER
JUNCTION DISTRIBUTION
BLOCK CENTER
(8W-50-6) (8W-50-6)
C D
L44
20
VT/RD L34
20
BS16 RD/OR
2 1
RIGHT
B3 B23 HEADLAMP
3 P18 3
L44 L44
20 20
VT/RD VT/RD
2 C1
HEADLAMP
SWITCH Z1
(8W-50-10) 20
BK
1 C1 8 C1
L13
20
BR/YL
A16 P34
16 B23
L13 L13
20 18
BR/YL BR/YL
3 2 2 3
LEFT RIGHT
HEADLAMP HEADLAMP
M M
LEVELING LEVELING
MOTOR MOTOR
1 1
Z1 Z1 Z1
20 20 20
BK BK BK
1 9 9 7
G300 G200 G301
(8W-15-8) (8W-15-4) (8W-15-10)
J988W-3 GS005008
NS/GS 8W-50 FRONT LIGHTING 8W - 50 - 9
EXCEPT BUILT-UP-EXPORT
BATT F41 (8W-10-20)
JUNCTION
BODY
COURTESY CONTROL BLOCK
PANEL LAMP MODULE (8W-12-2)
LAMPS RELAY (8W-45-3)
DRIVER DRIVER (8W-45-4)
2 17 (8W-45-5)
(8W-12-23) 86 30
COURTESY FROM
LAMP P18
RELAY (8W-50-5)
(8W-44-2) (8W-50-6)
FROM
P18 B
85 87 (8W-50-5)
23 C4 DIMMER (8W-50-6)
SWITCH D4 (8W-12-22)
SIGNAL A
L39
8 C2 10 C3 34 C3 28 C3 18
E2 Z39 LB
20 E92 M112 M111 M113 18
OR 22 22 22 20 BK
OR/BK BR/LG BR/WT LB/PK
1 C2 12 C1 3 C1 9 C1 11 C1 6 C2 5 C2
HEADLAMP
FOG SWITCH
LAMP 0 OFF
ILLUM. 1 PARK
INDIC.
LAMP 2 HEAD
0 4
3 AUTO
4 ON
DOME
LAMP
0 3 0 3
SWITCH
1 2 1 2
4 C1 5 C1 2 C2 6 C1 10 C1 8 C2 3 C2 7 C2
Z1 Z1 M13
18 20 20
M32 BK BK BK/YL
22 E17 L308 L307 L110
BK/LB
B22 P18
20 20 20 22
YL/BK
22 B23 LG/WT LG/OR BK/YL
M13 Z2 Z2
20 20 20
BK/YL BK/LG BK/LG
10 C2 14 C2 40 C2 13 C2 12 C2
GROUND GROUND PARK HEADLAMP AUTO BODY
21 C4 29 C4 LAMP SWITCH HEADLAMP CONTROL
JUNCTION SWITCH SENSE SWITCH MODULE
BLOCK SENSE SENSE
(8W-45-2)
(8W-12-2) (8W-45-4)
3 B75
2 C2 C20
2 C2 11 C2 M13
COURTESY STEP BODY Z1 20
LAMP DIMMER CONTROL 14 BK/YL
SWITCH SWITCH MODULE BK 1
SENSE SENSE (8W-45-4) 8 FRONT
FRONT
G300 READING READING
(8W-15-6) LAMP LAMPS/
FEED
SWITCH
GS005009 (8W-44-2) J988W-3
8W - 50 - 10 8W-50 FRONT LIGHTING NS/GS
BUILT-UP-EXPORT
BODY
COURTESY CONTROL
PANEL LAMP MODULE
LAMPS RELAY (8W-45-3)
DRIVER DRIVER
BATT F41 (8W-10-20)
(8W-45-4)
2 17 (8W-45-5) JUNCTION
BLOCK
86 30 (8W-12-2)
COURTESY
(8W-12-23) LAMP
RELAY FROM FROM
P18 P18
(8W-50-7) (8W-50-11)
85 87 F E
DOME DIMMER (8W-12-22)
LAMP SWITCH D4
23 C4 SWITCH SIGNAL
(8W-12-22) Z39 L77
2 C2 8 C2 10 C3 34 C3 28 C3 18 18
BK BR/YL
E2 M32 E92 M112 M111 M113
20 22 22 22 22 20
OR BK/LB OR/BK BR/LG BR/WT LB/PK
1 C2 4 C1 12 C1 3 C1 9 C1 11 C1 6 C2 5 C2
HEADLAMP
REAR
SWITCH
FOG 0 OFF
ILLUM. FOG LAMP
LAMP 1 PARK
LAMP INDIC. 2 HEAD
DOME INDIC.
0 4 3 REAR
LAMP
4 ON
SWITCH
0 3 0 3 0 3
1 2 1 2 1 2
2 C2 5 C1 6 C1 10 C1 7 C2 8 C2 3 C2
Z1 Z1 M13 L308 L307
18 20 20 20 20
BK BK BK/YL LG/WT LG/OR
E17 20YL/BK
11 C2 40 C2 13 C2
B22 P18 STEP PARK HEADLAMP BODY
22 B23 DIMMER LAMP SWITCH CONTROL
SWITCH SWITCH SENSE MODULE
SENSE SENSE
(8W-45-2)
3 B75 (8W-45-4)
C20 GROUND GROUND
14 C2 10 C2
Z2 20BK/LG
Z2 20BK/LG
21 C4 29 C4
JUNCTION
(8W-12-19) BLOCK
(8W-12-2)
M13 E17
2 C2 20 20
Z1 BK/YL YL/BK
14
BK
1 4 C1
8 FRONT FRONT STEP RADIO
G300 READING READING DIMMER (8W-47-2)
(8W-15-5) LAMP LAMPS/ SWITCH
FEED SIGNAL
SWITCH
(8W-44-2)
J988W-3 GS005010
NS/GS 8W-50 FRONT LIGHTING 8W - 50 - 11
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-8)
22 10 (8W-10-10)
40A 20A
(8W-10-17) (8W-10-29)
86 30
PARK
LAMP
RELAY
85 87
10 C3 4 C1 9 C5
L97 L7 L9
18 12 18
PK/DB BK/YL BK/WT
9 C2 2 C1 27 C2
JUNCTION
16 1
BODY COMBINATION
BLOCK
PARK FUSED (8W-12-2)
LAMP FUSED CONTROL LEFT B(+) RIGHT FLASHER/
RELAY PARK LAMP MODULE FRONT FRONT DRL
CONTROL RELAY (8W-45-3) TURN TURN MODULE
OUTPUT SIGNAL SIGNAL
1 2 3
5 C1 11 C2 23 C1 5 C2
L77 L61 L78 L60
L77 20 18 20 18
18 BR/YL LG DG/YL TN
BR/YL RIGHT
*1 *3 *1 *3 FRONT
B28 B23 LEFT L78 2 1
2 1 20 PARK/
28 P18 FRONT
DG/YL TURN
PARK/
SIGNAL
L77 TURN
3 LAMP
18 3 SIGNAL
BR/YL *2 *2
LAMP *3 BUILT-UP EXCEPT BUILT
4 -EXPORT -UP-EXPORT
Z1 FUSED RIGHT
E
18 B(+) REAR Z1 Z1
BK LAMP 18 20
TO
BK BK
HEADLAMP ASSEMBLY
SWITCH 6 (8W-51-4)
G300 (8W-51-5) 8
(8W-50-10)
(8W-15-7) G301
(8W-15-10)
* BUILT-UP-EXPORT
GS005011 J988W-3
8W - 50 - 12 8W-50 FRONT LIGHTING NS/GS
DRL
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-8)
22 10 (8W-10-10)
40A 20A
(8W-10-17) (8W-10-29)
86 30
PARK
LAMP
RELAY
85 87
10 C3 4 C1 9 C5
L97 L7 L9
18 12 18
PK/DB BK/YL BK/WT
9 C2 2 C1 27 C2
JUNCTION
16 1 BLOCK
PARK BODY FUSED COMBINATION (8W-12-2)
FUSED CONTROL LEFT RIGHT FLASHER/
LAMP B (+)
PARK LAMP MODULE FRONT FRONT DRL
RELAY
RELAY (8W-45-3) TURN TURN MODULE
CONTROL
OUTPUT SIGNAL SIGNAL
1 2 3
5 C1 11 C2 23 C1 5 C2
L77 L61 L78 L60
20 18 20 18
BR/YL LG DG/YL TN
LEFT RIGHT
2 1 2 1
FRONT FRONT
PARK/ PARK/
TURN TURN
3 SIGNAL 3 SIGNAL
LAMP LAMP
Z1
18 Z1
BK 20
BK
6 8
G300 G301
(8W-15-7) (8W-15-10)
J988W-3 GS005012
NS/GS 8W-50 FRONT LIGHTING 8W - 50 - 13
DRL
HEADLAMP
DIMMER
SWITCH
(PART OF
9 MULTI-
FUNCTION
SWITCH)
L93
(8W-50-2)
22
PK
RUN A22 (8W-10-14)
33 C3
JUNCTION
BLOCK
(8W-12-2)
FUSE 2
12 BODY
10A CONTROL
(8W-12-12) MODULE
(8W-45-3)
6 12
FUSED HIGH/LOW COMBINATION
IGNITION BEAM RED BRAKE FLASHER/
(RUN) RELAY WARNING DRL
CONTROL LAMP MODULE
GROUND DRIVER
11 10
(8W-12-17)
2 C2 8 C3 9 C3
G9
G9 20
20 GY/BK
MESSAGE GY/BK
Z1 CENTER
14 (8W-46-3)
BK G9
20
9 GY/BK
6 2 C1
G300 IGNITION
(8W-15-7)
SWITCH
1 1 START
4
2 RUN
2 0 3
0 OFF
3 LOCK
4 ACC
1 C1
(8W-10-14)
Z1
20
BK
PARK
BRAKE
14 SWITCH
G200
(8W-15-4)
GS005013 J988W-3
NS/GS 8W - 51 REAR LIGHTING 8W - 51 - 1
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
22 (8W-10-8)
40A
(8W-10-17)
86 30
PARK
LAMP
RELAY
85 87
10 C3 4 C1
L97 L7
18 12
PK/DB BK/YL
9 C2 2 C1
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE
1 3 5
10A 15A 15A
(8W-12-8) (8W-12-8) (8W-12-8)
16 1
PARK FUSED BODY
LAMP B(+) CONTROL
RELAY MODULE
CONTROL (8W-45-3)
(8W-45-4)
(8W-12-19)
PARK
LAMP
SWITCH
SENSE 21 C4 2 C2 18 C1 23 C1
40 C2
Z1 Z1 L77 L77 L78 L78
L308 18 14 20 20 20 20
20 BK BK BR/LB BR/LB DG/YL DG/YL
LG/WT B17
5 A
LJ01
J02A TO
6
L15 LEFT
L77 REAR
20 LAMP
8 C2 2 C2 BR/LB *1
HEADLAMP ASSEMBLY
(8W-51-4) 2
SWITCH 2
(8W-51-5) FUSED RIGHT
B
1 HEAD LICENSE
2 PARK
B(+) FRONT
0 OFF LAMP TO PARK/
1 2 0 RIGHT
(8W-50-9) 1 TURN
(8W-50-10) Z1 REAR SIGNAL
20 LAMP
BK LAMP
8 7
ASSEMBLY (8W-50-11)
(8W-51-4) (8W-50-12)
G300 G400 (8W-51-5)
(8W-15-6) (8W-15-14)
* BUILT-UP-EXPORT
J988W-3 GS005102
NS/GS 8W-51 REAR LIGHTING 8W - 51 - 3
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
CENTER
FUSE (8W-10-10)
10
20A
(8W-10-29)
9 C5
L9
18
BK/WT
RUN A22 (8W-10-14)
27 C2
JUNCTION
BLOCK
(8W-12-2)
FUSE
12
10A
(8W-12-12)
1 6
FUSED FUSED COMBINATION
B(+) IGNITION FLASHER/
(RUN) DRL
MODULE
LEFT RIGHT
REAR REAR
TURN TURN
SIGNAL SIGNAL
4 5
28 C2 36 C2
L63 L62
18 18
DG/RD L63 BR/RD L62
18 18
DG/RD BR/RD
1 1
LEFT RIGHT
REPEATER REPEATER
2 LAMP 2 LAMP
(BUILT-UP (BUILT-UP
-EXPORT) -EXPORT)
C D
Z1 Z1
18 TO 18 TO
BK LEFT BK RIGHT
REAR REAR
LAMP LAMP
ASSEMBLY ASSEMBLY
14 (8W-51-4) 10 (8W-51-4)
G300 (8W-51-5) G301 (8W-51-5)
(8W-15-5) (8W-15-10)
GS005103 J988W-3
8W - 51 - 4 8W-51 REAR LIGHTING NS/GS
EATX
RUN A22 (8W-10-14) BATT A0 (8W-10-8)
JUNCTION POWER
BLOCK DISTRIBUTION
FUSE
(8W-12-2)
FUSE CENTER
12 13 (8W-10-10)
10A 20A
(8W-12-12) (8W-10-29)
18 C2 8 C3
F20 F32
20 18
WT PK/DB
6
B33 STOP
5
E36 LAMP
F20
18 SWITCH
WT (8W-51-7)
1 5
TRANSMISSION L50
RANGE 18
WT/TN
SENSOR
R
(8W-31-3) BS01
6 (8W-70-2)
FROM FROM FROM FROM
JUNCTION JUNCTION JUNCTION JUNCTION
L1 BLOCK BLOCK BLOCK BLOCK
18 (8W-51-3) (8W-51-2) (8W-51-2) (8W-51-3)
VT/BK
C A B D
BACK-UP BACK-UP
LAMP LAMP
3 6 3 6
*4 *1 *4 *1
L1 L1 Z1 L1 Z1
20 20 20 20 20
VT/BK VT/BK BK VT/BK BK
BS02
(8W-70-2)
9 3
G302
(8W-15-13)
18 C2
F20 8 C3
20
F32
WT
18
GAS DIESEL PK/DB
5 B33 6
E120 STOP
B33 F20
LAMP
5
E36 20
WT SWITCH
F20
1 (8W-51-7)
18
WT BACK-UP 5
1 SWITCH L50
BACK-UP 18
SWITCH WT/TN
2 BS01
(8W-70-2)
FROM FROM FROM FROM
2 JUNCTION
L1 L1
JUNCTION JUNCTION JUNCTION
BLOCK BLOCK BLOCK BLOCK
18 18 (8W-51-2)
VT/BK VT/BK (8W-51-3) (8W-51-2) (8W-51-3)
A
E36 E120 C B D
10
B33 10 B33
L63 L77 L50 L50 L78 L62
18 20 18 18 20 18
DG/RD BR/LB WT/TN WT/TN DG/YL BR/RD
*5 *3 *6 *6 *3 *5
1 4 5 5 4 1
LEFT RIGHT
REAR REAR
TAIL/ TAIL/ LAMP TAIL/ TAIL/ LAMP
TURN STOP ASSEMBLY STOP TURN ASSEMBLY
SIGNAL LAMP LAMP SIGNAL
LAMP LAMP
BACK-UP BACK-UP
LAMP LAMP
3 6 3 6
*4 *1 *4 *1
L1 L1 Z1 L1 Z1
20 20 20 20 20
VT/BK VT/BK BK VT/BK BK
BS02
(8W-70-2)
9 3
G302
(8W-15-13)
2 C2 5 C2 7 C2
HEADLAMP
SWITCH
Z1 REAR 0 OFF
18 3 0 FOG 1 PARK
BK LAMP 2 HEAD
2 1 3 REAR
DIMMER
INDICATOR
SWITCH (8W-50-9)
6 C1
Z1 20BK
21 C4
JUNCTION
BLOCK
(8W-12-2)
3 4
GROUND GROUND BODY
CONTROL
MODULE
(8W-45-4)
J988W-3 GS005106
NS/GS 8W-51 REAR LIGHTING 8W - 51 - 7
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
13 (8W-10-10)
20A
(8W-10-29)
8 C3
F32
18
PK/DB
6
STOP
LAMP
SWITCH
5
L50
18
WT/TN
BS01
(8W-70-2)
L50
18
WT/TN
B17
2
J01A
L50
20
WT/TN
J02A
2
L15
L50
20
WT/TN
3
CENTER
HIGH
MOUNTED
STOP
LAMP
1
Z1
20
BK
2
G400
(8W-15-14)
GS005107 J988W-3
NS/GS 8W - 52 TURN SIGNALS 8W - 52 - 1
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
10 (8W-10-10)
20A
(8W-10-29)
9 C5
L9 18 BK/WT RUN A22 (8W-10-14)
27 C2
JUNCTION
BLOCK
FUSE (8W-12-2)
12
10A
(8W-12-12)
1 6
FUSED FUSED COMBINATION BODY
LEFT LEFT COMBO B (+) IGN. LEFT FLASHER/ LEFT CONTROL
FRONT TURN FLASHER (RUN) REAR DRL REAR MODULE
TURN SIGNAL SWITCHED TURN MODULE TURN (8W-45-5)
SIGNAL SENSE GROUND SIGNAL SIGNAL
2 7 9 4 19
11 C2 4 C3 26 C3 21 C3 28 C2
L61 L305 L63 L63
18 22 18 18
L91
LG LB/WT DG/RD DG/RD
L91 20
22 DB/PK
*3
DB/PK
5 P50 2
NOT
MESSAGE
USED LEFT
CENTER
TURN (8W-46-5)
4 1 L63 **5
INDICATOR
TURN 18 1
SIGNAL/ DG/RD LEFT
2 3 1 HAZARD REAR
3 TAIL/
SWITCH LAMP
*4 TURN
(PART OF ASSEMBLY
SIGNAL
8
MULTI- LAMP
(8W-51-4)
**3 FUNCTION
1 LEFT Z1 SWITCH) Z1
FRONT 18 1 HAZARD 20 6
BK 2 LEFT 1 **1
PARK/ 3 RIGHT
BK
3 TURN LEFT
**2 SIGNAL 36 C4 REPEATER
Z1
18 LAMP JUNCTION 2 LAMP
(8W-12-19) (BUILT-UP
BK (8W-50-11) BLOCK
(8W-50-12) (8W-12-2) Z1 -EXPORT)
13 18
G200 2 C2 BK
(8W-15-4)
Z1 Z1
14 20
BK BK
10 8 14 9
G300 G302
* RHD (8W-15-5) (8W-15-13)
** BUILT-UP-EXPORT (8W-15-6)
J988W-3 (8W-15-7) GS005202
NS/GS 8W-52 TURN SIGNALS 8W - 52 - 3
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
10 (8W-10-10)
20A
(8W-10-29)
9 C5
L9 18 BK/WT RUN A22 (8W-10-14)
27 C2
JUNCTION
BLOCK
FUSE (8W-12-2)
12
10A
(8W-12-12)
1 6
FUSED FUSED COMBINATION BODY
RIGHT RIGHT COMBO B (+) IGN. RIGHT FLASHER/ RIGHT CONTROL
FRONT TURN FLASHER (RUN) REAR DRL REAR MODULE
TURN SIGNAL SWITCHED TURN MODULE TURN (8W-45-5)
SIGNAL SENSE GROUND SIGNAL SIGNAL
3 8 9 5 21
5 C2 22 C3 26 C3 14 C3 36 C2
L60 L302 L62 L62
18 22 18 18
L91
TN LB/YL BR/RD BR/RD
L91 20
22 DB/PK
*5
DB/PK
5 P50 4
NOT
MESSAGE
USED RIGHT
CENTER
TURN (8W-46-5)
3 1 **5
INDICATOR L62
TURN 18 1
SIGNAL/ BR/RD RIGHT
2 3 1 HAZARD REAR
SWITCH 3 TAIL/ LAMP
*4 TURN ASSEMBLY
(PART OF
MULTI- SIGNAL (8W-51-4)
8 LAMP
FUNCTION
SWITCH) Z1
**3 1 HAZARD 6
20
1 RIGHT 2 LEFT 1 **1
BK
3 RIGHT
FRONT Z1 RIGHT
PARK/ 18 36 C4 REPEATER
3 TURN BK JUNCTION 2 LAMP
**2 SIGNAL (8W-12-19) (BUILT-UP
Z1 BLOCK
Z1 -EXPORT)
18 LAMP (8W-12-2)
18
BK (8W-50-11)
2 C2 BK
(8W-50-12)
13 Z1
G200 Z1 10
14 20
8 (8W-15-4) G301
BK BK
G301 (8W-15-10)
(8W-15-10) 8 3
G300 G302
* RHD (8W-15-6) (8W-15-13)
** BUILT-UP-EXPORT
GS005203 J988W-3
NS/GS 8W - 53 WIPERS 8W - 53 - 1
8W-53 WIPERS
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
19 (8W-10-8)
30A
(8W-10-19)
86 30 87 86 30
WIPER WIPER
ON HIGH/
RELAY LOW
RELAY
85 87A 85 87 87A
7 C5 5 C5 2 C4 4 C5 3 C5
V14 V16 Z1 V4 V3
18 20 18 12 12
RD/VT WT BK RD/YL BR/WT
RUN-ACC A31 (8W-10-16)
JUNCTION
3 1
BLOCK
(8W-12-2) WIPER
PTC MODULE
7
9A M
(8W-12-16)
B1 B23
1 P18
5 C3 V16
20
F1
WT
20 2 4
DB
7 5
FRONT
Z1
WIPER 14
0 0
SWITCH BK
1 1
(PART OF
2 MULTI- 10 12
FUNCTION G300
SWITCH) (8W-15-5)
0 OFF (8W-15-7)
1 HIGH
2 LOW
3 3 WASH
6 11 8
V52 V7
20 20
DG/YL DG/WT
73 C1 7 C2 41 C1
WIPER FRONT WIPER BODY
ON/OFF WIPER PARK CONTROL
RELAY SWITCH SWITCH MODULE
CONTROL MUX SENSE
(8W-45-3)
(8W-45-4)
J988W-3 GS005302
NS/GS 8W-53 WIPERS 8W - 53 - 3
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
19 (8W-10-8)
30A
(8W-10-19)
86 30 87 86 30
WIPER WIPER
ON HIGH/
RELAY LOW
RELAY
(8W-53-2)
85 87A 85 87 87A
7 5
FRONT F1 F1
20 20
WIPER DB DB
0 1 0 1
SWITCH A
2 (PART OF
FUSED REAR
MULTI-
IGNITION WASHER
FUNCTION (RUN-ACC) MOTOR
SWITCH) (8W-53-4)
0 OFF
1 HIGH
3 2 LOW
3 WASH
A
6 11 8 FRONT
A
Z1 V10 Z1 WASHER
LOW M
20 20 18 MOTOR
WASHER BK BR BK
FLUID 14 13
SWITCH B
G301 G200
B (8W-15-11) (8W-15-4)
V10
G29 20
20 BR
BK/TN
18 C3 21 C2
JUNCTION
73 C1 58 C1 20 BLOCK
BODY (8W-12-2)
WIPER LOW FRONT
ON/OFF WASHER WASHER CONTROL
MODULE 31
RELAY FLUID MOTOR WASHER
CONTROL SIGNAL CONTROL (8W-45-3)
(8W-45-4) MODULE
(BUILT-
UP-EXPORT)
GS005303 (8W-53-5) J988W-3
8W - 53 - 4 8W-53 WIPERS NS/GS
11 12 13
FUSED BODY
IGN. CONTROL
(ST-RUN) MODULE
(8W-45-2)
REAR (8W-45-4)
WASHER REAR REAR (8W-45-6)
PUMP WIPE/ WIPER
MOTOR WASH MOTOR
3 C2 CONTROL MUX DRIVER 7 C1
50 C1 38 C2 49 C1 V23
V13 18
F1 F1 V20 V26 18 BR/PK
20 20 20 22 BR/LG
DB DB BK/WT YL/WT 8 B17
7
LJ01
A 3 J03A
2
FUSED
FRONT L16
3 2
IGNITION WASHER
REAR
(RUN-ACC) MOTOR
(8W-53-3) WIPER
MOTOR
A M
REAR
WASHER
M MOTOR
1
2 C1
A/C
HVAC
HEATER
REAR CONTROL
REAR REAR REAR WIPER WIPE/ DELAY CONTROL
WASHER WIPER WIPER ON ON (8W-42-3) (8W-42-3)
WASH
SWITCH ON DELAY INDICATOR MUX INDICATOR
SENSE SWITCH SWITCH DRIVER DRIVER
5 6
G200 G400
(8W-15-4) (8W-15-14)
J988W-3 GS005304
NS/GS 8W-53 WIPERS 8W - 53 - 5
BUILT-UP-EXPORT
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
30
PARK CENTER
FUSE (8W-10-8)
22 LAMP
40A RELAY
(8W-10-17) (8W-50-11)
87
4 C1
L7
12
BK/YL
RUN-ACC A31 (8W-10-16) BATT A2 (8W-10-13)
2 C1
JUNCTION
BLOCK
(8W-12-2)
S 56 P
WASHER
MODULE
LOGIC
31 30
BODY
CONTROL
MODULE
(8W-45-4)
20
18 C3 21 C2 34 C1
V10
20 V10 V53
BR 20 18
11 BR RD/YL
FRONT Z1
FRONT 18
WASHER WIPER B B BK
11
MOTOR SWITCH FRONT HEADLAMP G301
CONTROL WASHER
(PART OF (8W-15-10)
PUMP WASHER WASHER
MULTI- CONTROL MOTOR M
FUNCTION SWITCH (8W-53-3)
OUTPUT
SWITCH) A
GS005305 (8W-53-3) J988W-3
NS/GS 8W - 54 TRAILER TOW 8W - 54 - 1
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
22 (8W-10-8)
40A
(8W-10-17)
86 30
PARK
LAMP
RELAY
85 87
10 C3 4 C1
L97 L7
18 12
PK/DB BK/YL
9 C2 2 C1
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE
1 3 5
10A 15A 15A
(8W-12-8) (8W-12-8) (8W-12-8)
16 1
BODY COMBINATION
PARK FUSED FLASHER/
LAMP PARK CONTROL
MODULE DRL
RELAY LAMP MODULE
CONTROL RELAY (8W-45-3) LEFT RIGHT (8W-51-3)
OUTPUT TURN TURN
SIGNAL SIGNAL
4 5
28 C2 18 C1 36 C2 23 C1
STOP
STOP LAMP
LAMP SWITCH
SWITCH (8W-51-7)
OUTPUT
5
L50
18
WT/TN
BS01
(8W-70-2)
L50 L50
18 L50 18
L50 18
WT/TN WT/TN
18 WT/TN
WT/TN
1 3 B99 3 1
5
LEFT T05 RIGHT
COMBINATION COMBINATION
RELAY L50 L50 RELAY
18 18
WT/TN WT/TN
2 4 4 2
4 5 1 1 5 4
LEFT RIGHT
L50 STOP/ STOP/
18 TURN TURN
WT/TN SIGNAL SIGNAL
3 2 RELAY 2 3 RELAY
RIGHT LEFT
STOP REAR STOP REAR
LAMP LAMP
SWITCH
LAMP SWITCH
LAMP
OUTPUT GROUND ASSEMBLY OUTPUT GROUND ASSEMBLY
5 6 (8W-51-4) 5 6 (8W-51-4)
*6 *1 (8W-51-5) *6 *1 (8W-51-5)
Z1 Z1 L50 Z1
20 18 18 20
BK BK WT/TN BK
T08 T05
6 6
B98 B99
Z1 Z1
20 20
BK BK
3 9
G302
L73 Z1 (8W-15-13) L74
18 18 18
YL WT LG TRAILER
TOW
4 3 1 CONNECTOR
* BUILT-UP-EXPORT
GS005403 J988W-3
NS/GS 8W - 60 POWER WINDOWS 8W - 60 - 1
11 9 14
DRIVER
POWER
WINDOW
SWITCH
1 DOWN
2 UP
3 OPEN
4 CLOSE
1 2 1 2 3 4 4 3
EXPRESS
DOWN
MODULE
6 8 7 3 5 1 13
Z1
Q23 Q13 Q14 Q24 12
18 18 18 18 BK
RD/WT DB GY DG
Q21 Q11 DS01
16 16
(8W-15-7)
WT LG
8 1 2 13 10 D01D
B02
*1 LEFT *3 RIGHT
3 2 2 1 Z1
REAR REAR 12
2 1
VENT VENT BK
DRIVER MOTOR MOTOR 5
(LHD) (LHD) G300
WINDOW
MOTOR (8W-15-7)
RIGHT LEFT
M REAR M REAR
VENT VENT
M MOTOR MOTOR
(RHD) * RHD
(RHD)
J988W-3 GS006002
NS/GS 8W-60 POWER WINDOWS 8W - 60 - 3
9
DRIVER
POWER
WINDOW
SWITCH
1 DOWN
2 UP
3 OPEN
4 CLOSE
1 2 1 2 3 4 4 3
EXPRESS
DOWN MODULE
2 4 13
Q26 Q16
14 14
VT/WT BR/WT
PASSENGER
DOOR
6 9 D01D
COURTESY
B02
F55 Q26 Q16 E2 GROUND LAMP
12 12 12 20 2 (8W-44-3)
TN/DG VT/WT BR/WT OR Z1 20BK
B03 Z1 Z1
2 20 12
13 D01P BK BK
2 1 3 6 7
PASSENGER D01P DS01
5 (8W-15-7)
POWER B03
1 2 WINDOW D01D
10
SWITCH B02
1 DOWN Z1 Z1
5 8 2 UP 18 12
Q22 14 VT Q12 14 BR BK BK
2 1
PASSENGER 11 5
WINDOW G300
(8W-15-7)
MOTOR
M
GS006003 J988W-3
NS/GS 8W - 61 POWER DOOR LOCKS 8W - 61 - 1
2 1 1 2
DRIVER PASSENGER
DOOR DOOR
LOCK LOCK
SWITCH SWITCH
E2
20
OR
3 3
Z2 E2 Z2
20 20 6 20
BK/LG OR PASSENGER BK/LG
PANEL
LAMP POWER
FEED WINDOW
SWITCH
(8W-60-3)
14
PANEL DRIVER
LAMP POWER
3 D01D FEED WINDOW 3 D01P
B02 SWITCH B03
(8W-60-2)
Z2 Z2
20 20
BK/LG BK/LG
3 2
G301
(8W-15-10)
(8W-15-11)
(8W-15-12)
J988W-3 GS006102
NS/GS 8W-61 POWER DOOR LOCKS 8W - 61 - 3
STANDARD
BATT A2 (8W-10-13)
JUNCTION
BLOCK
(8W-12-2)
PTC
3
9A
(8W-12-14)
(8W-12-15)
(8W-10-13)
86 87 87A 86 87 87A
DOOR DOOR
UNLOCK LOCK
RELAY RELAY
85 30 85 30
6 8
DOOR DOOR BODY
UNLOCK LOCK CONTROL
RELAY RELAY MODULE
CONTROL CONTROL (8W-45-7)
15 C1 19 C1 9 C1 32 C1 11 C1 2 C2
F136
F136 20 F136 F136 F131 F133 F133 F133
20 VT/WT 20 20 20 20 20 20
VT/WT VT/YL VT/YL BK/PK BR BR BR/RD
TO B17
9
LEFT B02 B03 LJ01
5 10
REAR 12 D01D D01P J02A
4
SLIDING L15
F131 F133 F133
DOOR 20 20 20 F133 Z1
CONTACT BK/PK BR BR 20 14
(8W-61-4) BR/RD BK
2 2 1
TO DRIVER PASSENGER LIFTGATE
10 B17 RIGHT DOOR DOOR LOCK
LJ01 REAR LOCK LOCK M MOTOR
SLIDING MOTOR MOTOR
F136
20 DOOR 3
M M
VT/WT CONTACT
(8W-61-4) F136
20 8
5 J02A 1 1
VT/WT G300
L15 9 D01P
(8W-15-6)
B03
GS006103 J988W-3
8W - 61 - 4 8W-61 POWER DOOR LOCKS NS/GS
STANDARD
BATT A2 (8W-10-13)
JUNCTION
BLOCK
(8W-12-2)
PTC
3
9A
(8W-12-14)
(8W-12-15)
(8W-10-13)
86 87 87A 86 87 87A
DOOR DOOR
UNLOCK LOCK
RELAY RELAY
85 30 85 30
6 8
DOOR DOOR BODY
UNLOCK LOCK CONTROL
RELAY RELAY MODULE
CONTROL CONTROL (8W-45-7)
15 C1 19 C1 26 C1 2 C2
8
G300
TO TO (8W-15-6)
LIFTGATE PASSENGER 15 B75
LOCK DOOR C20
MOTOR LOCK
(8W-61-3) MOTOR
2 2 (8W-61-3) 1 1
LEFT RIGHT RIGHT LEFT
REAR REAR REAR REAR
SLIDING SLIDING SLIDING SLIDING
DOOR DOOR DOOR DOOR
CONTACT CONTACT CONTACT CONTACT
LEFT RIGHT
REAR REAR
M SLIDING M SLIDING
DOOR DOOR
LOCK LOCK
MOTOR MOTOR
J988W-3 GS006104
NS/GS 8W-61 POWER DOOR LOCKS 8W - 61 - 5
RKE
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
28 (8W-10-9)
10A
(8W-10-11)
5 C3
M1
20
PK
13 C1
JUNCTION M1
BLOCK 20
(8W-12-20)
(8W-12-2) PK
9
FUSED BODY
B (+) CONTROL 16 C1
MODULE
(8W-45-6) FUSED MEMORY
B (+) SEAT/
RKE MIRROR
RKE MODULE INTERFACE MODULE
PROGRAM RKE (8W-62-3)
6 C4 ENABLE INTERFACE
19 C1
37 C2 1 C2
NOT G96 G96
USED 20 20
M1 D9 LG/RD LG/RD
7 P50
20 22
PK GY/BK 23 P34
M1 A23 B23
22
PK
G96
20
LG/RD
3 5 6
FUSED RKE MODULE RKE REMOTE
B (+) PROGRAM INTERFACE KEYLESS
ENABLE ENTRY
GROUND MODULE
4
Z2
20
BK/LG
11
G200
(8W-15-4)
GS006105 J988W-3
8W - 61 - 6 8W-61 POWER DOOR LOCKS NS/GS
RKE
JUNCTION
BODY
CONTROL BLOCK
DRIVER MODULE (8W-12-2)
DOOR PANEL (8W-45-8)
SWITCH LAMPS
MUX DRIVER
45 C1 2 PASSENGER
(8W-12-23) DOOR LIFTGATE
SWITCH LOCK/UNLOCK
8 C1 MUX MUX
55 C1 44 C1
P97 E2 E2 P96 P98
20 20 20 20 20
WT/DG OR OR WT/LG WT/RD
B02 B03
11 4 D01D 11 4 D01P
DRIVER E2 P96 2
POWER 20 20 PASSENGER
PANEL OR WT/LG DOOR
WINDOW
LAMPS
FEED SWITCH ARM/
14 (8W-60-2) DISARM
SWITCH
P97 E2 E2 P96
20 20 20 20
(VTSS)
WT/DG OR OR WT/LG
6 B17
LJ01
2 1 1 2 1
P98
DRIVER PASSENGER 20
DOOR DOOR WT/RD
LOCK LOCK
SWITCH SWITCH
6 J03A
L16
P97 E2 Z2 P98
20 20 20 20
WT/DG OR BK/LG WT/RD
3 3
2 Z2 6 Z2 2
DRIVER 20
PANEL PASSENGER 20 LIFTGATE
DOOR BK/LG POWER BK/LG ARM/
LAMPS
ARM/ FEED WINDOW DISARM
DISARM SWITCH SWITCH
SWITCH (8W-60-3) (VTSS)
(VTSS)
3 D01D 3 D01P
B02 B03
Z2
1 20 1
BK/LG
Z2 Z2 Z2
20 20 20
BK/LG BK/LG BK/LG
3 2 9
G301 G400
(8W-15-10) (8W-15-14)
(8W-15-11)
(8W-15-12)
J988W-3 GS006106
NS/GS 8W-61 POWER DOOR LOCKS 8W - 61 - 7
RKE
BATT A2 (8W-10-8)
JUNCTION
BLOCK
(8W-12-2)
PTC
3
9A
(8W-12-14)
(8W-12-15)
(8W-10-13)
85 30 30 85 85 30
6 5 8 (8W-12-19)
DOOR LEFT DOOR BODY
UNLOCK FRONT LOCK CONTROL
RELAY UNLOCK RELAY MODULE
CONTROL CONTROL CONTROL (8W-45-7)
15 C1 19 C1 9 C1 32 C1 11 C1 2 C2
F136
20 F136 F136 F131 F133 F133 F133
VT/WT 20 20 20 20 20 20
F136
VT/YL VT/YL BK/PK BR BR BR/RD
20
VT/WT
TO 9 B17
LEFT B02 B03 LJ01
10
REAR 5 12 D01D D01P J02A
16 B75 4
SLIDING C20 F131 F133 F133 L15
DOOR 20 20 20 F133 Z1
BK/PK BR BR 20 14
CONTACT BR/RD BK
(8W-61-8)
2 2 1
TO DRIVER PASSENGER LIFTGATE
10 B17 RIGHT DOOR DOOR LOCK
LJ01 REAR LOCK LOCK M MOTOR
SLIDING MOTOR MOTOR
F136
20 DOOR 3
M M
VT/WT CONTACT
(8W-61-8) F136
20 8
5 J02A 1 1
VT/WT G300
L15 9 D01P
(8W-15-6)
B03
GS006107 J988W-3
8W - 61 - 8 8W-61 POWER DOOR LOCKS NS/GS
RKE
BATT A2 (8W-10-13)
JUNCTION
BLOCK
PTC (8W-12-2)
3
9A
(8W-12-14)
(8W-12-15)
(8W-10-13)
85 30 30 85 85 30
6 5 8
DOOR LEFT DOOR BODY
CONTROL (8W-12-19)
UNLOCK FRONT LOCK
RELAY UNLOCK RELAY MODULE
CONTROL CONTROL CONTROL (8W-45-7)
15 C1 19 C1 26 C1 2 C2
LEFT RIGHT
REAR REAR
M SLIDING M SLIDING
DOOR DOOR
LOCK LOCK
MOTOR MOTOR
J988W-3 GS006108
NS/GS 8W - 62 POWER MIRRORS 8W - 62 - 1
2 C2
F41
20
PK/VT
15 C2
JUNCTION
BODY
CONTROL BLOCK
PANEL MODULE (8W-12-2)
LAMPS (8W-45-5)
(8W-12-21) FEED
2
(8W-12-23)
16 C3 1 C4
F41 E2
20 20
PK/VT OR
9 5
POWER
MIRROR
SWITCH
2 1 2 1 2 1 3 4 3 4 3 4 1 LEFT
2 RIGHT
3 UP
4 DOWN
5 LEFT MIRROR
6 RIGHT MIRROR
5 6
12 7 6 1 13 8 11
Z1
20
BK
35 C4
JUNCTION
(8W-12-19)
P71 P75 P73 P70 P72 P74 BLOCK
20 20 20 20 20 20 (8W-12-2)
YL DB/WT YL/PK WT YL/BK DB
2 C2
Z1
14
2 C1 1 C1 3 C1 4 C1 4 C1 3 C1 2 C1 1 C1 BK
DRIVER PASSENGER
POWER POWER 8
M M
M M MIRROR MIRROR G300
(8W-15-6)
J988W-3
5 C1 5 C1 GS006202
NS/GS 8W-62 POWER MIRRORS 8W - 62 - 3
MEMORY
BATT A0 (8W-10-8) BATT A2 (8W-10-13)
POWER POWER
DISTRIBUTION SEAT
FUSE CENTER CIRCUIT
28 (8W-10-9) BREAKER
10A 30A
(8W-10-11)
5 C3 F35
14
M1
RD
20
PK S02
3
B09
F35
13 C1 14
FUSED JUNCTION RD
B (+) BLOCK B56
3
(8W-12-2) S02
M1 F35
20 14 F35
PK RD 14
RD
16 C1 8 C2 5
FUSED FUSED MEMORY FUSED PASSENGER
B (+) B (+) SEAT/ B (+) POWER
RKE MEMORY MEMORY MEMORY MIRROR SEAT
INTERFACE SET NO. 1 NO. 2 GROUND MODULE SWITCH
(8W-63-3)
19 C1 8 C1 20 C1 21 C1 7 C2
P22 P23 P24 Z1
20 20 20 14
PK/BK PK/RD PK/WT BK
B01
4 6 7 D02D
G96 P22 P23 P24 MEMORY
20 20 20 20
LG/RD PK/BK PK/RD PK/WT POWER
5 6 4
SEAT
MEMORY GROUND SWITCH
1 (8W-63-5)
SET
1 2 3 SWITCH
1 SET Z1
2 MEM 1 20
3 MEM 2 BK
3
A23 B23
23 P34 Z1
20
BK S02
1
B09
DS01
(8W-15-7)
G96 G96 Z1 Z1
20 20 12 12
LG/RD LG/RD BK BK
6 1 C2 10 D01D
REMOTE BODY B02
RKE RKE
5 2
INTER- KEYLESS INTER- CONTROL
FACE FACE G300
ENTRY MODULE (8W-15-5)
MODULE (8W-45-6) (8W-15-7)
(8W-61-5)
GS006203 J988W-3
8W - 62 - 4 8W-62 POWER MIRRORS NS/GS
MEMORY
BATT A0 (8W-10-8) JUNCTION
BODY
CONTROL BLOCK
POWER (8W-12-2)
PANEL MODULE
DISTRIBUTION LAMPS (8W-45-5)
FUSE CENTER FEED
18 (8W-10-9)
2
15A (8W-12-23)
(8W-10-20)
15 C2 16 C3 1 C4
2 C2
F41 F41 E2
20 20 20
PK/VT PK/VT OR
9 5
POWER
MIRROR
SWITCH
2 1 2 1 2 1 3 4 3 4 3 4 1 LEFT
2 RIGHT
3 UP
4 DOWN
5 LEFT MIRROR
6 RIGHT MIRROR
5 6
12 7 6 1 13 8 11
P75 P73 Z1
20 20 20
DB/WT YL/PK BK
10 P18 35 C4
B10 B23 JUNCTION
(8W-12-19)
BLOCK
(8W-12-2)
P73
20
YL/PK
2 C2
10 C1
P71 MEMORY
20 LEFT
LEFT LEFT LEFT Z1
YL MIRROR SEAT/ 14
COMMON LEFT LEFT MIRROR MIRROR MIRROR
MIRROR MIRROR VERTICAL POSITION HORIZONTAL MIRROR BK
VERTICAL HORIZONTAL POSITION GROUND POSITION MODULE
11 C1 12 C1 2 C1 1 C1 3 C1 8
P73 P71 P75 P64 P69 P65 G300
20 20 20 20 20 20
(8W-15-6)
YL/PK YL DB/WT YL/OR WT/RD DB/YL
B8 B15
B23 A27 A28 A26 B23
8 15 P18 27 28 26 P34
3 C1 2 C1 1 C1 4 C1 1 C2 2 C2 3 C2
DRIVER
POWER
M M MIRROR
J988W-3
5 C1 GS006204
NS/GS 8W-62 POWER MIRRORS 8W - 62 - 5
MEMORY
JUNCTION
BODY
CONTROL BLOCK
PANEL MODULE (8W-12-2)
LAMPS (8W-45-5)
FEED
2
(8W-12-23)
1 C4
E2 20 OR
BATT F41 (8W-10-20)
5
POWER
MIRROR
SWITCH
2 1 2 1 2 1 3 4 3 4 3 4 1 LEFT
2 RIGHT
3 UP
4 DOWN
5 LEFT MIRROR
6 RIGHT MIRROR
5 6
12 7 6 1 13 8 11
Z1
P70 P72 P74 20
20 20 20 BK
WT YL/BK DB 35 C4
JUNCTION
(8W-12-19)
BLOCK
9 11 (8W-12-2)
7 P18
B7 B9 B11 B23
2 C2
P70 P72 P74 Z1
20 20 20 14
WT YL/BK DB BK
23 C1 24 C1 25 C1 8
MEMORY G300
RIGHT RIGHT RIGHT
(8W-15-6)
MIRROR MIRROR MIRROR SEAT/
COMMON VERTICAL HORIZ. MIRROR
MODULE
GS006205
5 C1 J988W-3
8W - 62 - 6 8W-62 POWER MIRRORS NS/GS
MEMORY/EXCEPT BUILT-UP-EXPORT
10 C1
LEFT MEMORY
MIRROR SEAT/
COMMON MIRROR
LEFT LEFT LEFT MODULE
LEFT LEFT MIRROR MIRROR MIRROR
MIRROR MIRROR POSITION POSITION POSITION
VERTICAL HORIZONTAL VERTICAL GROUND HORIZONTAL
11 C1 12 C1 2 C1 1 C1 3 C1
P73
20
P71 P75 P64 P69 P65
YL/PK
20 20 20 20 20
YL DB/WT YL/OR WT/RD DB/YL
3 C1 2 C1 1 C1 1 C2 2 C2 3 C2
DRIVER
POWER
M M
MIRROR
POWER POWER
MIRROR MIRROR
B(-) B(-)
6 C1 4 C2
P112 P114
20 20
YL/WT YL/BK
20 18
P34
A20 A18 B23
19 20 B75
C20
4 5 C19
EC1
P112 P114
20 20
YL/WT YL/BK
4 5
POWER POWER AUTOMATIC
MIRROR MIRROR DAY/NIGHT
B(-) B(-) MIRROR
(8W-44-6)
J988W-3 GS006206
NS/GS 8W-62 POWER MIRRORS 8W - 62 - 7
MEMORY/BUILT-UP-EXPORT
10 C1
LEFT MEMORY
MIRROR SEAT/
COMMON MIRROR
LEFT LEFT LEFT MODULE
LEFT LEFT MIRROR MIRROR MIRROR
MIRROR MIRROR VERTICAL POSITION HORIZONTAL
VERTICAL HORIZONTAL POSITION GROUND POSITION
11 C1 12 C1 2 C1 1 C1 3 C1
P73
20
YL/PK
P71 P75 P64 P69 P65
20 20 20 20 20
YL DB/WT YL/OR WT/RD DB/YL
3 C1 2 C1 1 C1 1 C2 2 C2 3 C2
DRIVER
POWER
MIRROR
M M
GS006207 J988W-3
8W - 62 - 8 8W-62 POWER MIRRORS NS/GS
BUILT-UP-EXPORT
BATT A0 (8W-10-8)
POWER
DISTRIBUTION
FUSE CENTER
18 (8W-10-9)
15A
(8W-10-20)
2 C2
F41
20
PK/VT
15 C2
JUNCTION
BLOCK
(8W-12-2)
86 87 87A 87A 87 86
POWER POWER
MIRROR MIRROR
FOLD UNFOLD
RELAY RELAY
(8W-12-19)
85 30 30 85
30 C2 11 C3 11 C4 36 C1 36 C4 2 C2
6 C2 6 C2
DRIVER PASSENGER
POWER POWER
M MIRROR M MIRROR
5 C2 5 C2
Z1
20
BK
2
POWER
FOLDING
MIRROR
1 2 SWITCH
1 1 UNFOLD
2 FOLD
P174 P136 8
20 20 G300
YL/RD YL (8W-15-6)
71 C1 74 C1 39 C2
POWER POWER POWER BODY
MIRROR MIRROR FOLDING CONTROL
FOLD UNFOLD MIRROR MODULE
RELAY RELAY SWITCH
(8W-45-10)
SIGNAL
J988W-3 GS006208
NS/GS 8W - 63 POWER SEAT 8W - 63 - 1
BATT A2 (8W-10-13)
POWER
SEAT
CIRCUIT
BREAKER
2 30A
HEATED
OTHER SEAT
F35
14
F35
RD
14
RD
S02
3
HS6D 8 C2
F35 FUSED MEMORY
14 B(+) SEAT/
RD HS5D MIRROR
2
B09 FUSIBLE
LINK MODULE
10A (8W-62-3)
F35
14
RD
B09 A
3
S02
TO
DRIVER
HEATED
F35
14 SEAT
RD MODULE
(8W-63-7)
5
DRIVER
POWER
SEAT
SWITCH
4 3 1 2 1 2 3 4 1 UP
2 DOWN
3 FORWARD
4 REARWARD
3 6 8 9 7 10 2 4 1
A B A B
DRIVER DRIVER
SEAT SEAT
REAR RECLINER
VERTICAL MOTOR S02
1
B09
M
MOTOR M
Z1
B A B A 12
DRIVER DRIVER BK
SEAT SEAT
HORIZONTAL FRONT 2
MOTOR VERTICAL G300
(8W-15-5)
M M
MOTOR (8W-15-9)
J988W-3 GS006302
NS/GS 8W-63 POWER SEATS 8W - 63 - 3
BATT A2 (8W-10-13)
POWER
SEAT
CIRCUIT
BREAKER
2 30A
HEATED
OTHER SEATS
F35
14
F35 RD
14
RD 8 C2
S02 FUSED MEMORY
3
HS6P B (+) SEAT/
MIRROR
F35 HS5P FUSIBLE MODULE
2 LINK (8W-62-3)
14 B56
RD 10A
B56
3
S02
B
F35
14 TO
RD PASSENGER
HEATED
SEAT
MODULE
(8W-63-8)
5
PASSENGER
POWER
SEAT
SWITCH
4 3 1 2 1 2 3 4 1 UP
2 DOWN
3 FORWARD
4 REARWARD
3 6 9 8 10 7 2 4 1
B A B A
PASSENGER PASSENGER
SEAT SEAT
REAR RECLINER
VERTICAL MOTOR S02
1
MOTOR B56
M M
A B A B Z1
PASSENGER PASSENGER 12
SEAT SEAT BK
HORIZONTAL FRONT 7
MOTOR VERTICAL G300
M M
MOTOR (8W-15-5)
GS006303 J988W-3
8W - 63 - 4 8W-63 POWER SEATS NS/GS
MEMORY
BATT A0 (8W-10-8) BATT A2 (8W-10-13)
POWER POWER
DISTRIBUTION SEAT
FUSE CENTER CIRCUIT
28 (8W-10-9) BREAKER
10A 2 30A
(8W-10-11) (8W-63-2)
(8W-63-3)
5 C3
M1
20
PK
13 C1
FUSED JUNCTION
B(+) BLOCK
(8W-12-2)
M1 F35
20 14
PK RD
16 C1 8 C2
FUSED FUSED MEMORY
B(+) B(+) SEAT/
RKE MEMORY MEMORY MEMORY MIRROR
INTERFACE SET NO. 1 NO. 2 GROUND MODULE
19 C1 8 C1 20 C1 21 C1 7 C2
P22 P23 P24 Z1
20 20 20 14
PK/BK PK/RD PK/WT BK
B01
4 6 7 D02
G96 P22 P23 P24 MEMORY
20 20 20 20
LG/RD PK/BK PK/RD PK/WT POWER
5 6 4
SEAT
MEMORY GROUND SWITCH
1 (8W-63-5)
SET
1 2 3 SWITCH
1 SET Z1
2 MEM 1 20
3 MEM 2 BK
3
A23 B23
23 P34 Z1
20
BK S02
1
B09
DS01
(8W-15-7)
G96 G96 Z1 Z1
20 20 12 12
LG/RD LG/RD BK BK
6 1 C2 10 D01D
REMOTE BODY B02
RKE RKE
5 2
INTER- KEYLESS INTER- CONTROL
FACE FACE G300
ENTRY MODULE (8W-15-5)
MODULE (8W-45-6)
(8W-61-5)
J988W-3 GS006304
NS/GS 8W-63 POWER SEATS 8W - 63 - 5
MEMORY
MEMORY
POWER
SEAT
SWITCH
4 3 1 2 1 2 3 4 1 UP
2 DOWN
3 FORWARD
4 REARWARD
5 3 6 8 9 7 10 2 4 1
11 C3 3 C3 14 C3 13 C3 2 C3 12 C3 1 C3 15 C3 4 C3
FUSED SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT MEMORY
B(+) RWD FWD REAR REAR FRONT FRONT RECLINE RECLINE SEAT/
UP DOWN UP DOWN FWD RWD MIRROR
REAR REAR FRONT FRONT MODULE
HORIZ. HORIZ. VERTICAL VERTICAL VERTICAL VERTICAL RECLINE RECLINE
FWD RWD UP DOWN UP DOWN FWD RWD GND
2 C2 1 C2 3 C2 6 C2 5 C2 10 C2 4 C2 9 C2 7 C2
S02
A B 1
B09
MEMORY
SEAT
RECLINER
MOTOR
M
B A
MEMORY
SEAT
FRONT
VERTICAL
M
MOTOR
A B
Z1
MEMORY 12
SEAT BK
REAR
VERTICAL
M
MOTOR
A B 2
MEMORY G300
SEAT (8W-15-5)
HORIZONTAL
MOTOR
M
GS006305 J988W-3
8W - 63 - 6 8W-63 POWER SEATS NS/GS
MEMORY
SS02
A C
MEMORY MEMORY
SEAT SEAT
FRONT HORIZONTAL
VERTICAL POSITION
B C POSITION B A SENSOR
SENSOR
C C
MEMORY MEMORY
SEAT SEAT
REAR RECLINE
VERTICAL POSITION
B A POSITION B A SENSOR
SENSOR
SS01
20 C3 8 C3 7 C3 18 C3 17 C3 10 C3
6V SEAT SEAT SEAT SEAT SEAT MEMORY
SUPPLY FRONT REAR HORIZONTAL RECLINER POSITION SEAT/
VERTICAL VERTICAL POSITION POSITION SENSE MIRROR
POSITION POSITION SENSE SENSE COMMON
SENSE SENSE
MODULE
J988W-3 GS006306
NS/GS 8W-63 POWER SEATS 8W - 63 - 7
HEATED
RUN A22 (8W-10-14)
JUNCTION
BLOCK
(8W-12-2)
FUSE
12
10A
(8W-12-12)
MEMORY MEMORY
POWER SEAT/
14 C2 SEAT MIRROR
B09 GROUND SWITCH GROUND MODULE
4 (8W-63-5) (8W-63-5)
HS5D 1 7 C2
F20
20
WT Z1 Z1
20 14
BK BK
HS2
D B
FUSED FUSED DRIVER
IGNITION IGNITION HEATED 1 S02
(RUN) HEATED (RUN) HS6D
DRIVER SEAT
SEAT HEATED SWITCH
TEMPERATURE SEAT
Z1
SENSOR SWITCH GROUND 14
A F E BK
Z1
18
BK
HS1
FROM Z1 Z1
FUSIBLE 18 14
LINK BK BK
(8W-63-2)
D HS5D
1
A GROUND DRIVER B09
HEATED Z1
HEATED HEATED HEATED SEAT 12
SEAT SEAT SEAT BK
DRIVER BACK DRIVER CUSHION
2
A C B Z1 G300
18 (8W-15-5)
P89 P88 BK
20 18
BK/RD RD/WT
F35 P86 P7 Z1 P87 A B
18 20 20 18 18
RD VT WT/BK BK RD/WT HEATED GROUND DRIVER
SEAT HEATED
DRIVER SEAT
BACK
D B C F A E
FUSED HEATED DRIVER GROUND HEATED FEED DRIVER
B(+) SEAT HEATED SEAT BACK HEATED
TEMPERATURE SEAT DRIVER SEAT
SENSOR SWITCH
MODULE
GS006307 J988W-3
8W - 63 - 8 8W-63 POWER SEATS NS/GS
HEATED
RUN A22 (8W-10-14)
JUNCTION
BLOCK
(8W-12-2)
FUSE
12
10A
(8W-12-12)
7 C2
4 B56
HS5P
F20
20
WT
HS4
D B
FUSED FUSED PASSENGER
IGNITION IGNITION HEATED
(RUN) (RUN) SEAT
HEATED PASSENGER
SEAT HEATED SWITCH
TEMPERATURE SEAT
SENSOR SWITCH GROUND
A F E
Z1
18
BK
HS3
Z1 Z1
18 14
FROM
BK BK
FUSIBLE 1 HS5P
D B56
LINK
(8W-63-3) GROUND PASSENGER Z1
HEATED 12
B HEATED HEATED HEATED SEAT BK
SEAT SEAT SEAT
DRIVER BACK DRIVER CUSHION
7
A C B G300
(8W-15-9)
P89 P88 Z1
20 18 18
BK/RD RD/WT BK
A B
F35 P86 P8 Z1 P87 HEATED GROUND PASSENGER
18 20 20 18 18 SEAT HEATED
RD VT WT/BK BK RD/WT DRIVER SEAT
BACK
D B C F A E
FUSED HEATED PASSENGER GROUND HEATED HEATED PASSENGER
B(+) SEAT HEATED SEAT SEAT HEATED
TEMPERATURE SEAT DRIVER BACK SEAT
SENSOR SWITCH
MODULE
J988W-3 GS006308
NS/GS 8W - 70 SPLICE INFORMATION 8W - 70 - 1
LJ01 T08
5 T05 1 3 2
B17 5
B98
B99 LEFT RIGHT
STOP/ COMBINATION
TURN RELAY
L50 L50 L50
SIGNAL (8W-54-3)
18 18
18
WT/TN
RELAY WT/TN WT/TN
(8W-54-3)
BS01
L50 ALL
L50 L50 18
18 18 WT/TN WHEEL
WT/TN WT/TN
44
DRIVE
12 5 POWERTRAIN SOLENOID
CONTROLLER STOP CONTROL 2 C1 2 C2 (3.8L)
ANTI-LOCK LAMP (8W-31-3)
MODULE
BRAKE SWITCH (DIESEL)
(8W-35-3) (8W-33-5)
AWS2
(8W-30-39)
BACK-UP
SWITCH
AUTOMATIC (8W-51-5)
DAY/NIGHT TRANSMISSION
MIRROR 2 L1
RANGE L1 18
(8W-44-6)
SENSOR 18 VT/BK
3 (8W-31-3) VT/BK
6
L1 DIESEL GAS
20
L1 E120 E36 2 AW4
VT/BK 10 10 B13
18 B33 B33
EC1 VT/BK
3
C19 L1
EATX MTX
13 C20 E36 20
B75 10 VT/BK
B33
BS02
L1 L1
20 20
VT/BK VT/BK
*4 *4
3 3
LEFT RIGHT
REAR REAR
LAMP LAMP
ASSEMBLY ASSEMBLY
* BUILT-UP-EXPORT
(8W-51-4) (8W-51-4)
J988W-3 (8W-51-5) (8W-51-5) GS007002
NS/GS 8W-70 SPLICE INFORMATION 8W - 70 - 3
C70
12
DG
M20
20
BR BS17
FRONT FRONT
READING READING
1 B75
LAMPS/ LAMPS/
C20
SWITCH SWITCH
6 (8W-44-2) 2 (8W-44-2)
OVERHEAD OTHERS
CONSOLE
CS03
A A 2 2
LEFT RIGHT RIGHT RIGHT
VISOR/ VISOR/ MID REAR
VANITY VANITY READING READING
MIRROR MIRROR LAMP LAMP
LAMPS LAMPS (8W-44-4) (8W-44-4)
(8W-44-3) (8W-44-3)
GS007003 J988W-3
8W - 70 - 4 8W-70 SPLICE INFORMATION NS/GS
2.0L
VEHICLE INTAKE ENGINE
SPEED AIR COOLANT
SENSOR TEMPERATURE/ TEMPERATURE
(8W-30-11) MANIFOLD SENSOR
2 A ABSOLUTE 1 (8W-30-10)
PRESSURE
K4 K4 SENSOR K4
18 18 (8W-30-10) 18
BK/LB BK/LB BK/LB
ES02
(2.0L)
K4 K4 K4
18 18 18
BK/LB BK/LB BK/LB
2 1 2
CRANKSHAFT A/C KNOCK
POSITION PRESSURE SENSOR
SENSOR TRANSDUCER (8W-30-10)
(8W-30-8) (8W-30-10)
K4 K4 K4 K4
18 18 18 18
BK/LB BK/LB BK/LB BK/LB
ES21
(2.0L)
K4
18
BK/LB
E36
1
B33
K4 K4
18 20
BK/LB BK/LB
2 3
CAMSHAFT DOWNSTREAM
POSITION HEATED
SENSOR OXYGEN
(8W-30-8) SENSOR
(8W-30-7)
J988W-3 GS007004
NS/GS 8W-70 SPLICE INFORMATION 8W - 70 - 5
2.4L
K4 K4 K4 K4 K4 K4
18 18 18 18 18 18
BK/LB BK/LB BK/LB BK/LB BK/LB BK/LB
ES02
K4
18 K4 K4
BK/LB 18 18
BK/LB BK/LB
5 E69
F09 2
KNOCK
SENSOR
K4 (8W-30-16)
18
BK/LB
FS01 ES21
K4 K4 K4 K4 K4 K4
18 18 18 18 18 18
BK/LB BK/LB BK/LB BK/LB BK/LB BK/LB
E36
1
1 B33 43 C2
A/C K4 POWERTRAIN
PRESSURE 20 CONTROL
BK/LB
TRANSDUCER MODULE
(8W-30-16) (8W-30-7)
1 3
ENGINE DOWNSTREAM
COOLANT HEATED
TEMPERATURE OXYGEN
SENSOR SENSOR
(8W-30-16) (8W-30-7)
A 3
MANIFOLD UPSTREAM
ABSOLUTE HEATED
PRESSURE OXYGEN
SENSOR SENSOR
(8W-30-16) (8W-30-7)
GS007005 J988W-3
8W - 70 - 6 8W-70 SPLICE INFORMATION NS/GS
3.3L/3.8L
FLEXIBLE
FUEL
K4 SENSOR
20 (3.3L/ETHANOL)
BK/LB
2 (8W-30-22)
1 B33
E36
K4 K4 K4 K4 K4
18 18 18 18 18
BK/LB BK/LB BK/LB BK/LB BK/LB
ES02
K4 K4 K4 K4
18 18 18 18
BK/LB BK/LB BK/LB BK/LB
14 E78
F02
3 2
K4 UPSTREAM CRANKSHAFT
18 HEATED POSITION
BK/LB OXYGEN SENSOR
SENSOR (8W-30-22)
(8W-30-21)
FS02 ES21
K4 K4 K4 K4 K4
18 18 18 18 18
BK/LB BK/LB BK/LB BK/LB BK/LB
1
ENGINE 1
COOLANT A/C
2
TEMPERATURE PRESSURE
CAMSHAFT
SENSOR TRANSDUCER
POSITION (8W-30-24) (8W-30-24)
SENSOR
(8W-30-22)
A 51
MANIFOLD TRANSMISSION
ABSOLUTE CONTROL
PRESSURE MODULE
SENSOR (8W-31-4)
(8W-30-24)
J988W-3 GS007006
NS/GS 8W-70 SPLICE INFORMATION 8W - 70 - 7
A/C
PRESSURE
THROTTLE POWERTRAIN
TRANSDUCER
(8W-30-10) POSITION CONTROL
(8W-30-16) MANIFOLD SENSOR MODULE
2 (8W-30-11) (8W-30-11)
ABSOLUTE
(8W-30-17) (8W-30-17)
2.0L 2.4L PRESSURE 3 61 C2
SENSOR
B (8W-30-16)
K6
18 INTAKE
VT/WT AIR
K6
18 TEMPERATURE/
VT/WT MANIFOLD
C ABSOLUTE
FS02 PRESSURE
(2.4L) SENSOR
(2.0L)
K6 (8W-30-10) K6 K6
18 18 18
VT/WT VT/WT VT/WT
K6 F09
8 K6
18 E69
VT/WT 18
VT/WT
K6
18
VT/WT
ES03
(2.0L/2.4L)
K6
18
VT/WT
K6 K6 K6
18 18 18
VT/WT VT/WT
F02 VT/WT
2
E78
K6
18
VT/WT
ES03
(3.3L/3.8L)
GS007007 J988W-3
8W - 70 - 8 8W-70 SPLICE INFORMATION NS/GS
EATX
ES05
ES08
ES10
J988W-3 GS007008
NS/GS 8W-70 SPLICE INFORMATION 8W - 70 - 9
K7 K7 K7 K7
18 18 18 18
OR OR OR OR
ES17
(2.0L/2.4L)
K7
18
OR
A/C
HEATER
HVAC CONTROL 1
CONTROL
(8W-42-5) FLEXIBLE
(8W-42-5)
FUEL
SENSOR
(3.3L/ETHANOL)
(8W-30-22)
12 C1
5 P30
J01D
JS03
GS007009 J988W-3
8W - 70 - 10 8W-70 SPLICE INFORMATION NS/GS
JS01B
C57
20
DB/GY
J01D
2
P30
C57
22
DB/GY
20 C1
A/C
HEATER
CONTROL
(8W-42-5)
9 C1
C26
22
PK/DB
1 P30
J01D
C26
20
PK/DB
JS02B
2 2 4
MODE BLEND A/C
DOOR DOOR ZONE
ACTUATOR ACTUATOR DOOR
(8W-42-5) (8W-42-5) ACTUATOR
(DUAL ZONE A/C)
(8W-42-5)
J988W-3 GS007010
NS/GS 8W-70 SPLICE INFORMATION 8W - 70 - 11
DIESEL
K4 K4 K4 K4
20 18 20 20
BK/LB BK/LB BK/LB BK/LB
ES05
(DIESEL)
K4
20
BK/LB
6 E97
B106
K4
18
BK/LB
BS34
(DIESEL)
K4 K4 K4
20 20 20
BK/LB BK/LB BK/LB
33 3 1
POWERTRAIN ACCELERATOR A/C
CONTROL PEDAL PRESSURE
MODULE POSITION TRANSDUCER
(8W-30-38) SENSOR (8W-30-38)
(8W-30-38)
GS007011 J988W-3
NS/GS 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1
BLACK
CAV CIRCUIT FUNCTION
1 - -
2 C6 14LB M2 SPEED BLOWER MOTOR
5 1
3 C104 12RD/WT M3 SPEED BLOWER MOTOR
10 6 4 C5 16LG M1 SPEED BLOWER MOTOR
5 - -
A/C HEATER 6 Z1 12BK GROUND
CONTROL -C2 7 C4 16TN LOW SPEED BLOWER MOTOR
8 C107 12TN/BK HIGH SPEED BLOWER MOTOR
9 - -
10 C7 12BK/TN HIGH SPEED BLOWER MOTOR
BLACK
1 2
A/C
COMPRESSOR
CLUTCH
* BUILT-UP-EXPORT
NSGS8005 J988W-3
8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS NS/GS
GRAY
A/C
PRESSURE
TRANSDUCER
(GAS)
GRAY
CAV CIRCUIT FUNCTION
1 K4 20BK/LB SENSOR GROUND
2 1
2 K7 20OR 5 VOLT SUPPLY
4 3 3 C18 20DB A/C PRESSURE SIGNAL
4 - -
A/C
PRESSURE
TRANSDUCER
(DIESEL)
NATURAL
CAV CIRCUIT FUNCTION
1 C61 20DB DUAL ZONE A/C ACTUATOR (+/-)
5 1 2 C57 20DB/GY SENSOR GROUND
3 C102 20LG ZONE DOOR FEEDBACK SIGNAL
A/C 4 C26 20PK/DB 5 VOLT SUPPLY
ZONE DOOR 5 C62 20DB/PK DUAL ZONE A/C ACTUATOR (+/-)
ACTUATOR
(DUAL ZONE A/C)
YELLOW
CAV CIRCUIT FUNCTION
1 R42 18BK/YL PASSENGER AIRBAG LINE NO. 1
1 4 2 R44 18DG/YL PASSENGER AIRBAG LINE NO. 2
3 R43 18BK/LB DRIVER AIRBAG LINE NO. 1
AIRBAG 4 R45 18DG/LB DRIVER AIRBAG LINE NO. 2
CONTROL
MODULE - C1
J988W-3 NSGS8006
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7
GRAY
ALL WHEEL
DRIVE
SOLENOID - C1
(3.8L ONLY)
GRAY
GRAY
RED
ASH
RECEIVER
LAMP
(LHD)
RED
BLACK
CAV CIRCUIT FUNCTION
7 1 1 V23 18BR/PK FUSED IGNITION (ST-RUN)
2 Z1 20BK GROUND
3 L1 20VT/BK BACK-UP LAMP FEED
4 P112 20YL/WT* POWER MIRROR B(-)
5 P114 20YL/BK* POWER MIRROR B(-)
AUTOMATIC 6 - -
DAY/NIGHT 7 L24 20WT/LG* AUTOMATIC HEADLAMP SIGNAL
MIRROR
* EXCEPT BUILT-UP-EXPORT
J988W-3 NSGS8008
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9
BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
1 2 Z1 14BK
2 1 1 Z1 12BK 1
4 3 Z1 14BK
3 4
F35 14RD
2 F35 14RD 2
B09 HS5D F35 14RD
3 A2 12PK/BK 3 A2 12PK/BK
4 F20 20WT 4 F20 20WT
BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
1 2 Z1 14BK
2 1 1 Z1 12BK 1
4 3 Z1 20BK
3 4
2 A2 12PK/BK 2 A2 12PK/BK
B09 3 F35 14RD S02 3 F35 14RD
4 F20 20WT 4 -
LT. GRAY
LT. GRAY 4 1
CAV CIRCUIT CAV CIRCUIT
4 1
1 Z1 14BK 1 Z1 16BK
2 L1 20VT/BK 2 L1 20VT/BK
3 G4 18DB 3 G4 18DB
4 A141 16DG/WT 4 A141 16DG/WT
B13 AW4
NSGS8009 J988W-3
8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS NS/GS
CAV CIRCUIT CAV CIRCUIT
B1 V16 20WT 1 V16 20WT
B2 X153 20WT/BR 2 X153 20WT/BR
B3 L39 18LB 3 L39 18LB
L44 20VT/RD
B3 3 L44 20VT/RD
L44 20VT/RD
B4 A1 12RD 4 A1 12RD
M20 20BR
B5 5 M20 20BR
M20 20BR
B6 X154 20WT/VT 6 X154 20WT/VT
P70 20WT*
B7 P70 20WT* 7
P70 20WT**
P71 20YL*
B8 P71 20YL* 8
P71 20YL**
BLACK
P72 20YL/BK*
B9 P72 20YL/BK* 9
P72 20YL/BK**
B1 B7
P73 20YL/PK*
B10 P73 20YL/PK* GRAY 10
P73 20YL/PK**
7 1 P74 20DB*
B11 P74 20DB* 14 8 11
B30 B36 18 15 P74 20DB**
A1 A7 B12 D1 18VT/BR 22 19 12 D1 20VT/BR
B13 D2 18WT/BK 29 23 13 D2 20WT/BK
B14 D6 20PK/LB* 36 30 14 D6 20PK/LB*
P75 20DB/WT*
A36 B15 P75 20DB/WT* 15
A30 P18 P75 20DB/WT**
B16 D20 20LG* 16 D20 20LG*
B17 D21 20PK 17 D21 20PK
B23
B18 L34 20RD/OR 18 L34 20RD/OR
Z39 20BK
B19 19 Z39 18BK
Z39 20BK
B20 L94 20OR/WT 20 L94 20OR/WT
B21 L324 20WT/LG 21 L324 22WT/LG
B22 M13 20BK/YL 22 M13 20BK/YL
F14 18LG/YL
B23 23 F14 18LG/YL
F14 20LG/YL
F23 18DB/YL
B24 24 F23 18DB/YL
F23 20DB/YL
B25 X155 20BR/WT 25 X155 20BR/WT
B26 X156 20VT/WT 26 X156 20VT/WT
L36 20LG
B27 27 L36 20LG
L36 20LG
B28 L77 18BR/YL 28 L77 18BR/YL
F39 18PK/LG*
B29 29 -
F39 18PK/LG*
B30 C104 12RD/WT 30 C104 12RD/WT
B31 C107 12TN/BK 31 C107 12TN/BK
B32 C4 16TN 32 C4 16TN
B33 C6 14LB 33 C6 14LB
B34 C5 16LG 34 C5 16LG
B35 C71 12DB 35 C71 12DB
B36 C103 20DG/LB 36 C103 20DG/LB
* GAS
** GAS/MEMORY OPTIONS
GAS, EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT
J988W-3 NSGS8010
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11
CAV CIRCUIT CAV CIRCUIT
A1 B27 20RD/YL
BLACK 1 B27 20RD/YL
A1 B27 18RD/YL GRAY
A2 G3 20BK/PK
B7 B1 7 1 2 G3 20BK/PK
A2 G3 18BK/PK 14 8
18 15 G19 20LG/OR
A3 G19 18LG/OR 22 19 3
G19 20LG/OR
A4 K29 20WT/PK 29 23 4 K29 20WT/PK
B30 B36 - 36 30 5 -
A5
A1 A7 -
A6 6 -
A7 X57 20BR/LB P34 7 X57 20BR/LB
A8 X58 20DB/OR 8 X58 20DB/OR
A9 X51 20BR/YL 9 X51 20BR/YL
A30 A36 A10 X52 20DB/WT 10 X52 20DB/WT
A11 X15 16BK/DG 11 X15 16BK/DG
X53 20DG
B23 A12 X53 20DG 12
X53 20DG*
X54 20VT
A13 X54 20VT 13
X54 20VT*
A14 14 X55 20BR/RD
X55 20BR/RD
X55 20BR/RD*
X56 20DB/RD
A15 X56 20DB/RD 15
X56 20DB/RD*
L13 20BR/YL
A16 16 L13 20BR/YL
L13 18BR/YL
A17 V32 20YL/RD 17 V32 20YL/RD
A17 G85 20OR/BK 17 G85 20OR/BK
A18 V30 20DB/RD 18 V30 20DB/RD
A18 P114 20YL/BK 18 P114 20YL/BK
A19 L50 18WT/TN 19 L50 18WT/TN
A20 F32 18PK/DB 20 F32 18PK/DB
A20 P112 20YL/WT 20 P112 20YL/WT
A21 V37 20RD/LG 21 V37 20RD/LG
F30 16RD
A22 22 F30 16RD
F30 16RD
G96 20LG/RD** G96 20LG/RD
A23
G96 20LG/RD** 23
A23 G96 20LG/RD** G96 20LG/RD
A24 Z11 20BK/WT 24 Z11 20BK/WT
A25 P66 20WT/BK** 25 P66 20WT/BK
A26 P65 20DB/YL** 26 P65 20DB/YL
A27 P64 20YL/OR** 27 P64 20YL/OR
A28 P69 20WT/RD** 28 P69 20WT/RD
A29 P68 20DG/RD** 29 P68 20DG/RD
A30 P67 20YL/RD** 30 P67 20YL/RD
A31 C50 12BK/LG* 31 C50 12BK/LG*
A32 - 32 -
C60 16BK/LB*
* REAR A/C HEATER A33 33 C60 16BK/LB*
** MEMORY SEAT C60 16BK/LB*
EXCEPT BUILT-UP-EXPORT A34 C34 20DB/WT* 34 C34 20DB/WT*
BUILT-UP-EXPORT A34 C63 20LB* 34 C63 22LB
RHD A35 C70 12DG* 35 C70 12DG*
DIESEL A36 36 C61 20DB*
C61 20DB*
GAS
GAS,BUILT-UP-EXPORT
NSGS8011 J988W-3
8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
CAV CIRCUIT BLACK CAV CIRCUIT
1 G6 20GY 1 G6 16GY
2 G18 20PK/BK 2 G18 20BK/PK
1 5
5 1 3 G58 20BK/YL 3 G58 20BK/YL
4 A141 16DG/WT 4 A141 18DG/WT
10 6
5 F20 20WT 6 10 5 F20 20WT
6 K21 20BK/RD 6 K21 18BK/RD
B33 7 K1 20DG/RD E120 7 K1 18DG/RD
(DIESEL) 8 K9 20LB (DIESEL) 8 K9 18LB
9 K3 20BK/VT 9 K3 20BK/VT
10 L1 20VT/BK 10 L1 18VT/BK
BLACK
CAV CIRCUIT BLACK CAV CIRCUIT
1 K4 20BK/LB 1 K4 18BK/LB
2 D2 18WT/BK 2 D2 18WT/BK
1 5
5 1 3 D20 20LG 3 D20 18LG
4 D21 20PK 4 D21 18PK
10 6
5 F20 20WT 6 10 5 F20 18WT
6 D6 20PK/LB 6 D6 18PK/LB
B33 7 D1 18VT/BR E36 7 D1 18VT/BR
(GAS) 8 F11 20RD/WT (GAS) 8 F11 18RD/WT
9 G6 20GY 9 G6 16GY
10 L1 20VT/BK 10 L1 18VT/BK
BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
1 Z1 12BK 1 2 Z1 14BK
2 1 1
4 3 3 4 F35 14RD
2 F35 14RD 2
F35 14RD
B56 3 - HS5P 3 -
4 F20 20WT 4 F20 20WT
BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
1 2 Z1 14BK
2 1 1
1 Z1 12BK
4 3 3 4 Z1 20BK*
2 A2 12PK/BK 2 A2 12PK/BK
B56 3 F35 14RD S02 3 F35 14RD
4 F20 20WT 4 F20 20WT
* MEMORY
J988W-3 NSGS8012
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13
* RHD
** EXCEPT BUILT-UP-EXPORT
NSGS8013 J988W-3
8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
3 1 L62 18BR/RD
1 L62 18BR/RD 1 3 1
L62 18BR/RD
2 - 4 6 2 -
6 4
3 L1 20VT/BK 3 L1 20VT/BK
L78 20DG/YL
B98 4 L78 20DG/YL T08 4
L78 18BR
(TRAILER TOW)
5 L50 18WT/TN 5 L50 18WT/TN
6 Z1 20BK 6 Z1 20BK
Z1 18WT
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
3 1 L63 18DG/RD
1 L63 18DG/RD 1 3 1
L63 18DG/RD
2 - 4 6 2 -
6 4
3 L1 20VT/BK 3 L1 20VT/BK
B99 4 L77 20BR/LB T05 4 L77 20BR/LB
(TRAILER TOW) 5 L50 18WT/TN 5
L50 18WT/TN
L50 18WT/TN
6 Z1 20BK 6 Z1 20BK
Z1 18BK
* DIESEL
J988W-3 NSGS8014
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15
* DIESEL
** GAS
BUILT-UP-EXPORT
NSGS8015 J988W-3
8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
J988W-3 NSGS8016
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17
BLACK
CAMSHAFT
POSITION
SENSOR
BLACK
CAV CIRCUIT FUNCTION
1 - -
3 1 2 CENTER DOME LAMP FEED
M113 20LB/PK
3 M20 20BR CENTER DOME LAMP GROUND
CENTER DOME
LAMP
RED
NSGS8017 J988W-3
8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS NS/GS
YELLOW
BLACK
BLACK
RED
J988W-3 NSGS8018
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19
2 1
BLACK
* LHD
** RHD
J988W-3 NSGS8020
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21
NSGS8021 J988W-3
8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
BLACK
BLACK
1 2
DRIVER DOOR
COURTESY LAMP
J988W-3 NSGS8022
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23
BLACK
DRIVER DOOR
LOCK MOTOR
RED
4 5 6
CAV CIRCUIT FUNCTION
1 P75 20DB/WT DRIVER POWER MIRROR UP
2 P71 20YL DRIVER POWER MIRROR LEFT
3 2 1 3 P73 20YL/PK DRIVER POWER MIRROR RIGHT/DOWN
4 C16 20LB/YL REAR DEFOGGER LAMP DRIVER
DRIVER POWER
5 Z1 20BK GROUND
MIRROR - C1
6 P112 20YL/WT POWER MIRROR B(-)
* BUILT-UP-EXPORT
** EXCEPT BUILT-UP-EXPORT
J988W-3 NSGS8024
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25
BLACK
BLACK
A B
CAV CIRCUIT FUNCTION
A P15 14YL/LB DRIVER POWER SEAT HORIZONTAL FORWARD
DRIVER SEAT B P17 14RD/LB DRIVER POWER SEAT HORIZONTAL REARWARD
HORIZONTAL MOTOR
NSGS8025 J988W-3
8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
BLACK
RED
DRIVER
WINDOW MOTOR
BLACK
BLACK
2 1
E40 RF3
J988W-3 NSGS8026
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
6 4 C137 20YL
3 1 1 C137 20YL 1
2 K57 20LG/OR 3 1 2 K57 20LG/OR
6 4 3 Z1 16BK 3 Z12 14BK/TN
4 K153 18OR/DG 4 K153 18OR/DG
E95 5 K152 20WT/DG B107 5 K152 20WT/DG
(DIESEL) 6 K90 18TN (DIESEL) 6 K90 20OR/VT
NSGS8027 J988W-3
8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS NS/GS
GRAY
EGR SOLENOID
(2.4L MTX/3.3L/3.8L)
BLACK
1 2
CAV CIRCUIT FUNCTION
1 V20 18RD REAR WASHER MOTOR CONTROL
2 - -
ELECTRIC
WIPER DE-ICER-C1
BLACK
1 2
CAV CIRCUIT FUNCTION
1 C66 18BK/WT WIPER DE-ICE SWITCHED GROUND
2 - -
ELECTRIC
WIPER DE-ICER-C2
BLACK
2 1
BLACK
1 2
CAV CIRCUIT FUNCTION
1 K4 18BK/LB SENSOR GROUND
2 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE COOLANT
TEMPERATURE SENSOR
(GAS)
GREEN
BLACK (2.0L)
1 2
CAV CIRCUIT FUNCTION
1 G6 16GY ENGINE OIL PRESSURE SWITCH SENSE
2 - -
ENGINE OIL
PRESSURE SWITCH
NSGS8029 J988W-3
8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS NS/GS
LIGHT
GRAY CAV CIRCUIT FUNCTION
1 K107 18DB/WT* LEAK DETECTION PUMP SWITCH SENSE
4 1 1 K107 18YL/BK** LEAK DETECTION PUMP SWITCH SENSE
2 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
3 F87 18WT/BK FUSED IGNITION SWITCH OUTPUT
EVAP LEAK 4 - -
DETECTION PUMP
(EXCEPT BUILT-UP-EXPORT)
BLACK
1 2
BLACK
1 CIRCUIT FUNCTION
CAV
2
1 C21 20DB/OR A/C SWITCH SENSE
EVAPORATOR 2 C57 20DB/GY SENSOR GROUND
TEMPERATURE SENSOR
LT. GRAY
4 1 CAV CIRCUIT FUNCTION
1 K7 18OR 8V SUPPLY
2 K4 18BK/LB SENSOR GROUND
3 K50 18YL/WT FLEXIBLE FUEL SENSOR SIGNAL
4 - -
FLEXIBLE FUEL
SENSOR
(3.3L/ETHANOL) * 3.3L/3.8L
** 2.4L
J988W-3 NSGS8030
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31
BLACK
FRONT BLOWER
MOTOR
RED/BLUE
2 1
CAV CIRCUIT FUNCTION
1 F30 16RD FUSED B(+)
3 2 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
3 Z1 16BK GROUND
FRONT CIGAR LIGHTER
POWER OUTLET
NSGS8031 J988W-3
8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
BLUE
CAV CIRCUIT FUNCTION
4 1 M13 20BK/YL FRONT READING LAMP FEED
6
2 E2 18OR PANEL LAMPS FEED
3 1 3 Z2 18BK/LG GROUND
4 F41 20PK/VT FUSED (B+)
FRONT 5 - -
READING LAMPS/
6 M20 20BR COURTESY LAMP GROUND
SWITCH
(OVERHEAD CONSOLE)
BLACK
BLACK
1 2
CAV CIRCUIT FUNCTION
1 A141 18DG/WT FUEL PUMP RELAY OUTPUT
2 Z1 18BK GROUND
FUEL HEATER
(DIESEL)
J988W-3 NSGS8032
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33
BLACK
2 1
BLACK
BLACK
2 1
BLACK
BLACK
2 1
NSGS8033 J988W-3
8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
BLACK
2 1
BLACK
FUEL INJECTOR
NO. 4
(3.3L/3.8L)
BLACK
BLACK
FUEL INJECTOR
NO. 6
(3.3L/3.8L)
J988W-3 NSGS8034
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35
BLACK
CAV CIRCUIT FUNCTION
1 K134 18LB/BK SLEEVE POSITION SENSOR (-)
2 K57 18LG/OR CONTROL SLEEVE POSTION SENSOR
5 1 3 K135 18WT/BK SLEEVE POSTION SENSOR (+)
10 6 4 K4 20BK/LB SENSOR GROUND
5 K126 18LG SOLENOID CONTROL
6 K153 18OR/DG SHUT OFF FEED
FUEL PUMP 7 K156 18GY FUEL TEMPERATURE SENSOR SIGNAL
MODULE 8 K140 18TN/WT FUEL QUANTITY ACTUATOR SIGNAL
(DIESEL) 9 A142 18DG/OR AUTO SHUTDOWN RELAY OUTPUT
10 A142 18DG/OR AUTO SHUTDOWN RELAY OUTPUT
LIGHT
GRAY
CAV CIRCUIT FUNCTION
1 Z1 16BK GROUND
4 1 2 L1 20VT/BK BACK-UP LAMP FEED
3 G4 18DB FUEL LEVEL SENSOR SIGNAL
4 A141 16DG/WT* FUEL PUMP RELAY OUTPUT
FUEL
TANK MODULE
* GAS
** RHD
NSGS8035 J988W-3
8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS NS/GS
9 Z1 20BK 9
Z1 20BK
10 Z1 18BK 10
11 Z1 18BK 11
12 Z1 14BK 12
13 - 13
14 Z1 20BK
14
Z1 18BK
* GAS
** DIESEL
*** LHD
EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT
J988W-3 NSGS8036
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37
BLACK
CAV CIRCUIT CAV CIRCUIT
BLACK
Z11 20BK/WT 1
1
Z1 18BK 1
7 1 2 Z2 20BK/LG 2
1 7
Z2 18BK/LG 3
3
Z2 20BK/LG 3
14 8 8 14
4 - 4
5 Z1 12BK 5 Z1 BUS BAR
G301 6 Z12 18BK (DIESEL) 6
(DIESEL) 7 Z1 20BK 7
8 Z1 18BK 8
9 Z1 20BK 9
10 Z1 18BK 10
11 Z1 18BK 11
12 Z1 18BK 12
13 Z1 18BK 13
14 Z1 20BK 14
BLACK
CAV CIRCUIT CAV CIRCUIT
BLACK
1 Z1 18BK 1
2 Z2 20BK/LG 2
7 1 3 Z2 20BK/LG 3
1 7
4 - 4
5 Z2 18BK/LG 5
14 8 6 - 8 14 6
Z1 20BK* Z1 BUS BAR
7 7
G301 Z1 20BK*
(GAS) 7 Z1 20BK** 7
8 Z1 20BK 8
9 Z1 20BK 9
10 Z1 18BK 10
11 Z1 18BK 11
12 Z1 18BK 12
13 Z1 18BK 13
14 Z1 20BK 14
* EXCEPT BUILT-UP-EXPORT/CHRYSLER
** EXCEPT BUILT-UP-EXPORT/PLYMOUTH, DODGE
BUILT-UP-EXPORT
NSGS8037 J988W-3
8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
3 2
GENERATOR
(GAS)
* REAR A/C-HEATER
J988W-3 NSGS8038
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39
BLUE
CAV CIRCUIT FUNCTION
1 2 1 F41 20PK/VT FUSED B(+)
2 M20 20BR COURTESY LAMP GROUND
BLACK
BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
1 - 1 2 1 -
2 1
4 3 2 - 3 4 2 -
3 F35 14RD 3 F35 14RD
HS6P 4 - S02 4 -
* BUILT-UP-EXPORT
NSGS8039 J988W-3
8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
* EXCEPT BUILT-UP-EXPORT
J988W-3 NSGS8040
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41
NATURAL
1
CAV CIRCUIT FUNCTION
2 1 G70 18BR/TN HOOD AJAR SWITCH SENSE
2 Z1 18BK GROUND
HOOD AJAR
SWITCH
BLACK
CAV CIRCUIT FUNCTION
1 K59 18VT/BK IDLE AIR CONTROL MOTOR NO.4 DRIVER
1 4 2 K40 18BR/WT IDLE AIR CONTROL MOTOR NO.3 DRIVER
3 K60 18YL/BK IDLE AIR CONTROL MOTOR NO.2 DRIVER
IDLE AIR 4 K39 18GY/RD IDLE AIR CONTROL MOTOR NO.1 DRIVER
CONTROL
MOTOR
BLACK
BLACK
GREEN
BLACK
IGNITION SWITCH - C3
J988W-3 NSGS8042
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43
DARK
GRAY
1 2 CAV CIRCUIT FUNCTION
1 K4 18BK/LB SENSOR GROUND
2 K21 18BK/RD INTAKE AIR TEMPERATURE SIGNAL
INTAKE AIR
TEMPERATURE SENSOR
(2.4L)
BLACK
A D
CAV CIRCUIT FUNCTION
A K4 18BK/LB SENSOR GROUND
B K21 18BK/RD INTAKE AIR TEMPERATURE SIGNAL
INTAKE AIR C K6 18VT/WT 5 VOLT SUPPLY
TEMPERATURE/ D K1 18DG/RD MAP SENSOR SIGNAL
MANIFOLD ABSOLUTE
PRESSURE SENSOR
(2.0L)
BLACK
CAV CIRCUIT CAV CIRCUIT
6 1
1 6 1 Z1 12BK 1 Z1 12BK
2 L50 20WT/TN 2 L50 20WT/TN
3 M11 20PK/LB 3 M11 20PK/LB
4 F133 20BR/RD 4 F133 20BR/RD
J02A 5 F136 20VT/WT L15 5 F136 20VT/WT
6 L77 20BR/LB 6 L77 20BR/LB
BLACK
1 6 CAV CIRCUIT 6 1 CAV CIRCUIT
1 C15 12BK/WT 1 C15 12BK/WT
2 V13 18BR/LG 2 V13 18BR/LG
3 V23 18BR/PK 3 V23 18BR/PK
4 G78 18TN/BK 4 G78 18TN/BK
J03A L16
5 - 5 -
6 P98 20WT/RD 6 P98 20WT/RD
NSGS8043 J988W-3
8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS NS/GS
CAV CIRCUIT FUNCTION
E2 20OR PANEL LAMPS FEED
1
E2 20OR** PANEL LAMPS FEED
2 L7 12BK/YL PARK LAMP RELAY OUTPUT
GRAY
F39 18PK/LG FUSED B(+)
7 1 3
F39 18PK/LG FUSED B(+)
14 8
18 15 4 A2 12PK/BK FUSED B(+)
22 19 5 L77 20BR/YL FUSED LEFT INBOARD TAIL LAMP
23 L77 20BR/YL FUSED LEFT INBOARD TAIL LAMP
29 5
36 30 L77 18BR/YL FUSED LEFT INBOARD TAIL LAMP
6 C15 12BK/WT REAR DEFOGGER RELAY OUTPUT
7 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT
JUNCTION BLOCK - C1
E2 20OR PANEL LAMPS FEED
8
E2 20OR PANEL LAMPS FEED
9 F131 20BK/PK DRIVER UNLOCK RELAY OUTPUT
10 - -
11 F133 20BR/RD LOCK RELAY OUTPUT
12 L94 20OR/WT LOW BEAM RELAY CONTROL
M1 20PK FUSED B (+)
13
M1 20PK FUSED B (+)
14 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT
F136 20VT/WT UNLOCK RELAY OUTPUT
15
F136 20VT/WT UNLOCK RELAY OUTPUT
L43 18VT* FUSED LEFT LOW BEAM OUTPUT
16
L43 18VT* FUSED LEFT LOW BEAM OUTPUT
17 - -
L77 20BR/LB FUSED LEFT INBOARD TAIL LAMP
18
L77 20BR/LB FUSED LEFT INBOARD TAIL LAMP
F136 20VT/YL UNLOCK RELAY OUTPUT
19
F136 20VT/YL UNLOCK RELAY OUTPUT
20 F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN-OFF)
21 - -
22 X1 16DG/RD NAME BRAND SPEAKER RELAY OUTPUT
L78 20DG/YL FUSED B(+)
23
L78 20DG/YL FUSED B(+)
24 - -
25 L39 18LB FOG LAMP RELAY OUTPUT
F133 20BR/YL LOCK RELAY OUTPUT
26
F133 20BR/YL LOCK RELAY OUTPUT
27 - -
28 - -
29 - -
F87 18WT/BK FUSED IGNITION SWITCH OUTPUT
30
F87 18WT/BK FUSED IGNITION SWITCH OUTPUT
L39 18LB* FOG LAMP SWITCH OUTPUT
31
L39 18LB* FOG LAMP SWITCH OUTPUT
F133 20BR LOCK RELAY OUTPUT
32
F133 20BR LOCK RELAY OUTPUT
33 A2 12PK/BK FUSED B(+)
34 V53 18RD/YL WASHER RELAY OUTPUT
35 A4 12BK/RD FUSED B(+)
36 P174 20YL/RD POWER MIRROR UNFOLD RELAY
* CHRYSLER
** REAR A/C-HEATER
MEMORY SEAT
BUILT-UP-EXPORT
EXCEPT BUILT-UP-EXPORT
EATX
DIESEL
J988W-3 NSGS8044
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45
* REAR A/C
** GAS, EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT
NSGS8045 J988W-3
8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS NS/GS
* LHD
** BUILT-UP-EXPORT
GAS
GAS, EXCEPT BUILT-UP-EXPORT
RHD
J988W-3 NSGS8046
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47
NSGS8047 J988W-3
8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS NS/GS
WHITE
KEY-IN HALO
LAMP
GREEN
GRAY
4 BLACK
CAV CIRCUIT FUNCTION
1 L63 18DG/RD LEFT TURN SIGNAL
2 1 Z1 18BK
5 2 GROUND
Z1 18BK
3 L50 18WT/TN STOP LAMP SWITCH OUTPUT
3
L50 18WT/TN STOP LAMP SWITCH OUTPUT
LEFT COMBINATION 4 L615 18OR LEFT COMBINATION RELAY OUTPUT
RELAY 5 - -
(TRAILER TOW)
BLACK
* RHD
** LHD
J988W-3 NSGS8048
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49
BLACK
CAV CIRCUIT FUNCTION
1 F39 18PK/LG FUSED PARK LAMP RELAY OUTPUT
2 1 2 Z39 20BK FOG LAMP SWITCHED GROUND
LEFT
FOG LAMP
(BUILT-UP-EXPORT)
PURPLE**
GRAY*
LEFT FRONT
PARK/TURN
SIGNAL LAMP
(EXCEPT BUILT-UP-EXPORT)
BLACK
BLACK
1
2
CAV CIRCUIT FUNCTION
1 L33 20RD FUSED LEFT HIGH BEAM OUTPUT
3 2 L43 18VT FUSED LEFT LOW BEAM OUTPUT
LEFT HEADLAMP 3 Z1 20BK GROUND
(BUILT-UP-EXPORT)
BLACK
BLACK
J988W-3 NSGS8050
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51
BLACK
2 1
CAV CIRCUIT FUNCTION
M11 20PK/LB COURTESY LAMP RELAY OUTPUT
1
M11 20PK/LB COURTESY LAMP RELAY OUTPUT
2 Z1 20BK GROUND
LEFT LIFTGATE
FLOOD LAMP
GRAY
CAV CIRCUIT FUNCTION
1 M113 20LB/PK READING LAMP FEED
3 1
2 M20 20BR COURTESY LAMP GROUND
3 F41 20PK/VT FUSED B (+)
LEFT MID
READING LAMP
NATURAL*
BLACK
1 CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2
2 G77 18TN/OR LEFT REAR DOOR AJAR SWITCH SENSE
3 - -
LEFT REAR
DOOR AJAR
SWITCH
BLACK
CAV CIRCUIT FUNCTION
3 1 1 Z1 20BK GROUND
2 L36 20LG REAR FOG LAMP SWITCH OUTPUT
6 4 3 L77 20BR/LB FUSED LEFT INBOARD TAIL LAMP
4 L1 20VT/BK BACK-UP SWITCH OUTPUT
LEFT REAR 5 L63 18DG/RD LEFT TURN SIGNAL
LAMP ASSEMBLY 6 L50 18WT/TN STOP LAMP SWITCH OUTPUT
(BUILT-UP-EXPORT)
BLACK
CAV CIRCUIT FUNCTION
3 1 1 L63 18DG/RD LEFT TURN SIGNAL
2 - -
6 4 3 L1 20VT/BK BACK-UP SWITCH OUTPUT
4 L77 20BR/YL FUSED LEFT INBOARD TAIL LAMP
LEFT REAR 5 L50 18WT/TN STOP LAMP SWITCH OUTPUT
LAMP ASSEMBLY 6 Z1 20BK GROUND
(EXCEPT BUILT-UP-EXPORT) * DIESEL
NSGS8051 J988W-3
8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
GRAY
CAV CIRCUIT FUNCTION
3 1 1 M113 20LB/PK COURTESY LAMP RELAY OUTPUT
2 M20 20BR COURTESY LAMP GROUND
3 F41 20PK/VT FUSED B (+)
LEFT REAR
READING LAMP
BLACK
BLACK
NATURAL
NATURAL
3 1
CAV CIRCUIT FUNCTION
1 - -
2 Q14 18GY LEFT REAR VENT MOTOR (CLOSE)
LEFT REAR 3 Q24 18DG LEFT REAR VENT MOTOR (OPEN)
VENT MOTOR
(RHD)
GRAY
GRAY
2 1
CAV CIRCUIT FUNCTION
1 L63 18DG/RD LEFT REPEATER LAMP SIGNAL
LEFT REPEATER 2 Z1 18BK GROUND
LAMP
(BUILT-UP-EXPORT)
BLACK
NSGS8053 J988W-3
8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS NS/GS
GRAY
CAV CIRCUIT FUNCTION
3 1 1 Z1 20BK GROUND
2 L77 20BR/LB FUSED LEFT INBOARD TAIL LAMP
3 - -
LICENSE LAMP
BLACK
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
3 1 2 - -
3 G78 18TN/BK LIFTGATE AJAR SWITCH SENSE
LIFTGATE
AJAR SWITCH
GRAY
1 2
CAV CIRCUIT FUNCTION
1 G18 20BK/PK COOLANT LEVEL SWITCH SENSE
2 Z1 20BK GROUND
LOW COOLANT
LEVEL SWITCH
(DIESEL)
BLACK
BLACK
CAV CIRCUIT FUNCTION
A Z1 20BK GROUND
B A B G29 20BK/TN WASHER FLUID SWITCH SENSE
LOW WASHER
FLUID SWITCH
J988W-3 NSGS8054
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55
BLACK
BLACK
BLACK
CAV CIRCUIT FUNCTION
A P29 20BR/WT 5 VOLT SUPPLY
A C
B P26 22BR SEAT FRONT VERTICAL POSITION SENSE
C P28 20BR/RD SEAT POSITION SENSE COMMON
MEMORY SEAT
FRONT VERTICAL
POSITION SENSOR
BLACK
NSGS8055 J988W-3
8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
CAV CIRCUIT FUNCTION
A C A P28 20BR/RD SEAT POSITION SENSE COMMON
B P25 22VT/RD SEAT HORIZONTAL POSITION SENSE
C P29 20BR/WT 5 VOLT SUPPLY
MEMORY SEAT
HORIZONTAL
POSITION SENSOR
BLACK
MEMORY SEAT
REAR VERTICAL
POSITION SENSOR
BLACK
CAV CIRCUIT FUNCTION
A P43 14GY/LB SEAT RECLINER (REARWARD)
A B B P41 14GY/WT SEAT RECLINER (FORWARD)
MEMORY SEAT
RECLINER MOTOR
BLACK
CAV CIRCUIT FUNCTION
A P28 20BR/RD SEAT POSITION SENSE COMMON
A C
B P47 22LB SEAT RECLINER POSITION SENSE
C P29 20BR/WT 5 VOLT SUPPLY
MEMORY SEAT
RECLINER
POSITION SENSOR
J988W-3 NSGS8056
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57
NSGS8057 J988W-3
8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS NS/GS
* DIESEL
J988W-3 NSGS8058
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59
NSGS8059 J988W-3
8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
OUTPUT SHAFT
SPEED SENSOR
* REAR A/C
J988W-3 NSGS8060
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61
NATURAL
CAV CIRCUIT CAV CIRCUIT
1 D1 20VT/BR 1 -
2 G96 22LG/RD 2 -
3 1
3 D2 20WT/BK 3 -
8 4 4 F11 20RD/WT 4 -
5 L91 20DB/PK 5 -
6 X12 20RD/WT 6 -
P50
7 M1 22PK 7 -
(RHD)
8 Z1 18BK 8 -
BLACK
1 3
CAV CIRCUIT FUNCTION
1 L1 18VT/BK BACK-UP LAMP RELAY OUTPUT
PARK/NEUTRAL 2 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
POSITION SWITCH 3 F20 18WT FUSED IGNITION (RUN)
(EATX)
BLACK
3 1
CAV CIRCUIT FUNCTION
1 T3 18VT PARK/NEUTRAL POSITION SWITCH OUTPUT
PARK/NEUTRAL
2 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
POSITION SWITCH
(MTX) 3 F11 18RD/WT FUSED IGNITION (ST-RUN-OFF)
YELLOW
CAV CIRCUIT FUNCTION
1 R44 18DG/YL PASSENGER AIRBAG LINE NO. 2
4 1
2 R42 18BK/YL PASSENGER AIRBAG LINE NO. 1
PASSENGER 3 - -
AIRBAG SQUIB 4 - -
BLACK
2 1
CAV CIRCUIT FUNCTION
1 Z2 20BK/LG GROUND
PASSENGER DOOR 2 P96 20WT/LG PASSENGER DOOR SWITCH MUX
ARM/DISARM SWITCH
NSGS8061 J988W-3
8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
1 2 CAV CIRCUIT FUNCTION
1 M11 20PK/LB COURTESY LAMP RELAY OUTPUT
2 Z1 20BK GROUND
Z1 20BK
PASSENGER DOOR
COURTESY LAMP
BLACK
* BUILT-UP-EXPORT
** RKE
NSGS8063 J988W-3
8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
CAV CIRCUIT FUNCTION
4 1 1 F55 12TN/DG FUSED IGNITION SWITCH OUTPUT (RUN/ACC)
2 Q26 12VT/WT RIGHT FRONT WINDOW (DOWN)
8 5
3 Q16 12BR/WT RIGHT FRONT WINDOW (UP)
4 - -
PASSENGER POWER 5 Q22 14VT RIGHT FRONT WINDOW (DOWN)
WINDOW SWITCH 6 E2 20OR PANEL LAMPS FEED
7 Z1 20BK GROUND
8 Q12 14BR RIGHT FRONT WINDOW (UP)
BLACK
CAV CIRCUIT FUNCTION
A P18 14YL/LG SEAT FRONT VERTICAL (UP)
A B B P20 14RD/LG SEAT FRONT VERTICAL (DOWN)
PASSENGER SEAT
FRONT VERTICAL
MOTOR
BLACK
J988W-3 NSGS8064
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65
BLACK
BLACK
RED
PASSENGER
WINDOW MOTOR
NSGS8065 J988W-3
8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS NS/GS
DK. GREEN
EATX
MTX
* DODGE/PLYMOUTH OR BUILT-UP-EXPORT
** CHRYSLER (PREMIUM)
J988W-3 NSGS8066
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67
BLACK
CAV CIRCUIT FUNCTION
4 6 1 A22 12BK/OR IGNITION SWITCH RUN ONLY FEED
1 3 2 Z1 18BK GROUND
3 A1 12RD FUSED B (+)
4 - -
5 A2 12PK/BK BATTERY FEED TO IGNITION SWITCH
POWER
6 A10 12RD/DG FUSED LINK TO ABS PUMP MOTOR RELAY
DISTRIBUTION
CENTER - C4
* EXCEPT BUILT-UP-EXPORT
** BUILT-UP-EXPORT
DIESEL
GAS
NSGS8067 J988W-3
8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS NS/GS
GRAY
CAV CIRCUIT FUNCTION
4 6 1 - -
1 3 2 - -
3 T40 12BR STARTER MOTOR RELAY OUTPUT
4 A17 12RD/BK* FUSED B(+)
POWER 5 - -
DISTRIBUTION 6 A16 12GY FUSED B(+)
CENTER - C7
BLACK
1 2
POWER FOLDING
MIRROR SWITCH
(BUILT-UP-EXPORT)
* DIESEL
J988W-3 NSGS8068
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69
GRAY
CAV CIRCUIT FUNCTION
1 2 1 A3 12PK/BK FUSED B(+)
F35 14RD FUSED B(+)
2
POWER SEAT F35 14RD*
CIRCUIT BREAKER
BLACK
CAV CIRCUIT FUNCTION
1 K10 18DB/OR POWER STEERING PRESSURE SWITCH SENSE
2 1 2 Z1 18BK GROUND
POWER STEERING
PRESSURE SWITCH CAV CIRCUIT FUNCTION
(2.0L/2.4L) 1 Z12 16BK/TN GROUND
2 K159 20VT/RD ENGINE SPEED SENSOR SIGNAL
3 K90 20TN ENGINE STARTER MOTOR RELAY CONTROL
4 K140 18TN/WT FUEL QUANTITY ACTUATOR SIGNAL
5 K140 18TN/WT FUEL QUANTITY ACTUATOR SIGNAL
6 C24 20DB/PK LOW SPEED RADIATOR FAN RELAY NO. 2 CONTROL
7 K57 20LG/OR CONTROL SLEEVE POSITION SENSOR
8 K24 18GY/BK ENGINE SPEED SENSOR FEED
23 68 9 - -
10 - -
11 K68 20LG/YL NEEDLE MOVEMENT SENSOR RETURN
12 K67 20BR/BK NEEDLE MOVEMENT SENSOR SIGNAL
13 C18 20DB A/C PRESSURE SWITCH SIGNAL
14 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
15 K22 20OR/DB ACCELERATOR PEDAL SENSOR SIGNAL
16 - -
17 K119 20LG/BK CLUTCH SWITCH SIGNAL
18 - -
19 K7 20OR 5 VOLT SUPPLY
20 K29 20WT/PK BRAKE SWITCH SENSE
21 K3 20BK/VT ENGINE SPEED SENSOR RETURN
22 - -
23 A142 16DG/OR DIESEL POWER RELAY OUTPUT
24 Z12 16BK/TN GROUND
1 46 25 K35 20GY/YL EGR SOLENOID CONTROL
26 G85 20OR/BK GLOW PLUG LAMP DRIVER
27 V38 20LB/RD SPEED CONTROL LAMP DRIVER
28 C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
29 K134 20LB/BK SLEEVE POSITION SENSOR
POWERTRAIN 30 - -
CONTROL 31 - -
MODULE 32 - -
(DIESEL) 33 K4 20BK/LB SENSOR GROUND
34 - -
35 - -
36 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
37 C103 20DG/LB A/C SWITCH SIGNAL
38 F87 18WT/BK FUSED IGNITION (ST-RUN)
39 - -
40 K1 20DG/RD BOOST PRESSURE SENSOR SIGNAL
* MEMORY SEAT
CONTINUED ON NEXT PAGE
NSGS8069 J988W-3
8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS NS/GS
(CONTINUED)
J988W-3 NSGS8070
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71
* 2.0L
NSGS8071 J988W-3
8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
J988W-3 NSGS8072
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73
NATURAL
CAV CIRCUIT FUNCTION
1 Z13 18BK/RD GROUND
3 1 2 T42 18VT/WT PRNDL SWITCH GROUND
3 T1 18LG/BK PRNDL SWITCH SENSE
PRNDL SWITCH
BLACK
BLACK
RADIATOR FAN
NO. 1
BLACK
CAV CIRCUIT FUNCTION
1 C23 12DG LOW SPEED RADIATOR FAN RELAY OUTPUT
2 1 2 Z1 12BK GROUND
RADIATOR FAN
NO.2
BLACK
NSGS8073 J988W-3
8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS NS/GS
NATURAL
3 2 1
CAV CIRCUIT FUNCTION
6 5 4 2 Z1 12BK GROUND
4 A142 18DG/OR AUTO SHUTDOWN RELAY OUTPUT
9 8 7 5 C27 12DB/PK HIGH SPEED RADIATOR FAN RELAY CONTROL
6 C137 20YL HIGH SPEED RADIATOR FAN RELAY CONTROL
8 C116 12LG/WT HIGH SPEED RELAY OUTPUT
RADIATOR
FAN RELAY
NO. 1
(DIESEL)
NATURAL
3 2 1
CAV CIRCUIT FUNCTION
6 5 4 2 C25 12YL RADIATOR FAN RELAY OUTPUT
4 A142 18DG/OR AUTO SHUTDOWN RELAY OUTPUT
9 8 7 6 C24 20DB/PK LOW SPEED RADIATOR FAN RELAY CONTROL
8 A16 12GY FUSED B(+)
RADIATOR
FAN RELAY
NO. 2
(DIESEL)
3 2 1
CAV CIRCUIT FUNCTION
6 5 4 2 C27 12DB/PK RADIATOR FAN RELAY CONTROL
4 A142 18DG/OR AUTO SHUTDOWN RELAY OUTPUT
9 8 7 6 C137 20YL HIGH SPEED RADIATOR FAN RELAY CONTROL
8 A17 12RD/BK FUSED B(+)
RADIATOR
FAN RELAY
NO. 3
(DIESEL)
CAV CIRCUIT FUNCTION
1 - -
X55 20BR/RD LEFT DOOR SPEAKER (-)
2
GRAY X55 20BR/RD* LEFT DOOR SPEAKER (-)
X56 20DB/RD RIGHT DOOR SPEAKER (-)
3
X56 20DB/RD* RIGHT DOOR SPEAKER (-)
7 1 4 E17 20YL/BK STEP DIMMER SWITCH SENSE
5 E2 20OR PANEL LAMPS FEED
RADIO - C1 6 X12 18RD/WT FUSED IGNITION (RUN-ACC)
7 M1 20PK FUSED B(+)
* PREMIUM
J988W-3 NSGS8074
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75
BLACK
CAV CIRCUIT FUNCTION
1 D1 20VT/BR CCD BUS(+)
2 D2 20WT/BK CCD BUS(-)
1 2
RADIO - C3
(EXCEPT BUILT-UP-EXPORT)
LT.GRAY
1 2 CAV CIRCUIT FUNCTION
1 X1 16DG/RD NAME BRAND SPEAKER RELAY OUTPUT
2 X13 16RD/DG RADIO CHOKE OUTPUT
RADIO CHOKE
LT. GREEN
CAV CIRCUIT FUNCTION
1 C34 20DB/WT A/C MODE DOOR DRIVER (A)
2 C61 20DB DUAL ZONE A/C ACTUATOR
5 1
3 C40 12BR/WT REAR BLOWER RELAY OUTPUT
10 6 4 C65 14BK/OR REAR BLOWER MEDIUM SPEED
5 C60 16BK/LB REAR BLOWER MEDIUM SPEED
6 C70 12DG REAR BLOWER HIGH SPEED
REAR A/C-HEATER UNIT 7 - -
8 - -
9 - -
10 - -
* PREMIUM
NSGS8075 J988W-3
8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
CAV CIRCUIT FUNCTION
1 C70 12DG REAR BLOWER HIGH SPEED
8 1 2 - -
3 C60 16BK/LB REAR BLOWER MEDIUM SPEED
4 - -
REAR BLOWER FRONT 5 C50 12BK/LG REAR BLOWER LOW SPEED
CONTROL SWITCH 6 - -
7 Z1 12BK GROUND
8 E2 20OR PANEL LAMPS FEED
BLACK
CAV CIRCUIT FUNCTION
4 1 1 C60 16BK/LB REAR BLOWER MEDIUM SPEED
2 C65 14BK/OR REAR BLOWER MEDIUM SPEED
8 5 3 C70 12DG REAR BLOWER HIGH SPEED
4 Z1 18BK GROUND
REAR BLOWER 5 C50 12BK/LG REAR BLOWER LOW SPEED
REAR CONTROL 6 - -
SWITCH 7 - -
8 E2 20OR PANEL LAMPS FEED
RED
J988W-3 NSGS8076
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77
BLACK
CAV CIRCUIT
1 - -
3 1 2 READING LAMP FEED
M113 20LB/PK
3 M20 20BR COURTESY LAMP GROUND
REAR DOME
LAMP
BLACK
BLACK
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
3 1
2 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT
3 V13 18BR/LG REAR WIPER MOTOR CONTROL
REAR WIPER
MOTOR
NATURAL
CAV CIRCUIT FUNCTION
1 C34 20DB/WT COMMON DOOR DRIVER
5 1 2 - -
3 - -
RECIRCULATION 4 - -
DOOR ACTUATOR 5 C32 20GY/DB RECIRCULATION DOOR DRIVER
NSGS8077 J988W-3
8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
4
CAV CIRCUIT FUNCTION
2 L62 18BR/RD
1 RIGHT TURN SIGNAL
5 L62 18BR/RD
3 2 Z1 18BK GROUND
3 L50 18WT/TN STOP LAMP SWITCH OUTPUT
RIGHT COMBINATION 4 L605 18DG RIGHT TURN SIGNAL
RELAY 5 - -
(TRAILER TOW)
BLACK
BLACK
GRAY
CAV CIRCUIT FUNCTION
1 F39 18PK/LG FUSED PARK LAMP RELAY OUTPUT
2 1 2 Z39 20BK FOG LAMP SWITCHED GROUND
RIGHT
FOG LAMP
(BUILT-UP-EXPORT)
PURPLE**
GRAY*
BLACK
CAV CIRCUIT FUNCTION
1 4 X155 20BR/WT RIGHT FRONT I/P SPEAKER (-)
1
X156 20VT/WT RIGHT FRONT I/P SPEAKER (-)
RIGHT FRONT 2 - -
PANEL SPEAKER 3 - -
(PREMIUM) X153 20WT/BR RIGHT FRONT I/P SPEAKER (+)
4
X154 20WT/VT RIGHT FRONT I/P SPEAKER (+)
* DODGE/PLYMOUTH
** CHRYSLER
RHD
LHD
DIESEL
J988W-3 NSGS8078
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79
BLACK
BLACK
3 1
CAV CIRCUIT FUNCTION
1 L60 18TN RIGHT TURN SIGNAL
2 L78 20DG/YL FUSED B(+)
RIGHT FRONT
3 Z1 20BK GROUND
PARK/TURN
SIGNAL LAMP
(EXCEPT BUILT-UP-EXPORT)
BLACK
BLACK
RIGHT FRONT
WHEEL SPEED SENSOR
BLACK
1
CAV CIRCUIT FUNCTION
1 L34 20RD/OR FUSED RIGHT HIGH BEAM RELAY OUTPUT
2 2 L44 20VT/RD FUSED RIGHT LOW BEAM OUTPUT
3 Z1 20BK GROUND
3
RIGHT HEADLAMP
(BUILT-UP-EXPORT)
NSGS8079 J988W-3
8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
BLACK
BLACK
1 2 CAV CIRCUIT FUNCTION
1 M11 20PK/LB COURTESY LAMP RELAY OUTPUT
2 Z1 20BK GROUND
RIGHT LIFTGATE
FLOOD LAMP
RIGHT LOW
HEADLAMP (CHRYSLER)
(EXCEPT BUILT-UP-EXPORT)
J988W-3 NSGS8080
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81
GRAY
CAV CIRCUIT FUNCTION
1 M113 20LB/PK READING LAMP FEED
3 1 2 M20 20BR COURTESY LAMP GROUND
3 F41 20PK/VT FUSED B(+)
RIGHT MID
READING LAMP
NATURAL*
1 BLACK
BLACK
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
3 1 2 L36 20LG REAR FOG LAMP
3 L78 20DG/YL FUSED B(+)
6 4 4 L1 20VT/BK BACK-UP LAMP FEED
5 L62 18BR/RD RIGHT TURN SIGNAL
RIGHT REAR
6 L50 18WT/TN STOP LAMP SWITCH OUTPUT
LAMP ASSEMBLY
(BUILT-UP-EXPORT)
BLACK
GRAY
CAV CIRCUIT FUNCTION
1 M113 20LB/PK READING LAMP FEED
3 1
2 M20 20BR COURTESY LAMP GROUND
3 F41 20PK/VT FUSED B(+)
RIGHT REAR
READING LAMP * DIESEL
NSGS8081 J988W-3
8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
NATURAL
GRAY
GRAY
CAV CIRCUIT FUNCTION
1 L62 18BR/RD RIGHT TURN SIGNAL
2 1 2 Z1 18BK GROUND
RIGHT REPEATER
LAMP
(BUILT-UP-EXPORT)
* PREMIUM
J988W-3 NSGS8082
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83
BLACK
4
CAV CIRCUIT FUNCTION
2 L50 18WT/TN STOP LAMP SWITCH OUTPUT
5 1
L50 18WT/TN
3 Z1 18BK
2 GROUND
Z1 18BK
RIGHT 3 L74 18LG STOP LAMP SWITCH OUTPUT
STOP/TURN 4 L62 18BR/RD RIGHT TURN SIGNAL
SIGNAL RELAY 5 L605 18DG RIGHT COMBINATION RELAY OUTPUT
(TRAILER TOW)
BLACK
CAV CIRCUIT FUNCTION
A B A M20 20BR COURTESY LAMP GROUND
B F41 20PK/VT FUSED B(+)
RIGHT VISOR/
VANITY MIRROR LAMPS
BLACK
1 2 CAV CIRCUIT FUNCTION
1 G10 18LG/RD SEAT BELT SWITCH SENSE
2 Z1 20BK GROUND
SEAT BELT
SWITCH
BLACK
CAV CIRCUIT FUNCTION
1 L97 29PK/DB PARK LAMP RELAY CONTROL
4 1 2 - -
3 V38 20LB/RD SPEED CONTROL RELAY CONTROL
SPEED CONTROL
4 V32 20YL/RD SPEED CONTROL ON/OFF SWITCH SENSE
DIMMING MODULE
GRAY
* GAS
NSGS8083 J988W-3
8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS NS/GS
WHITE
WHITE
BLACK
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
1 3
2 B27 20RD/YL TRACTION CONTROL SWITCH SENSE
3 E2 20OR PANEL LAMP FEED
TRACTION CONTROL
SWITCH
J988W-3 NSGS8084
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85
NSGS8085 J988W-3
8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS NS/GS
(CONTINUED)
J988W-3 NSGS8086
NS/GS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87
GRAY
TURBINE
SPEED SENSOR
GRAY
CAV CIRCUIT FUNCTION
1 2 1 Z1 18BK GROUND
2 A142 18DG/OR ASD RELAY OUTPUT
3 4 3 K4 18BK/LB SENSOR GROUND
4 K41 18BK/DG UPSTREAM HEATED OXYGEN SENSOR SIGNAL
UPSTREAM HEATED
OXYGEN SENSOR
BLACK
NSGS8087 J988W-3
8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS NS/GS
BLACK
BLACK
1 4
CAV CIRCUIT FUNCTION
1 V3 12BR/WT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT
2 V7 20DG/WT WIPER PARK SWITCH SENSE
WIPER 3 V4 12RD/YL WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT
MODULE 4 Z1 14BK GROUND
(BUILT-UP-EXPORT)
BLACK
CAV CIRCUIT FUNCTION
1 V3 12BR/WT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT
2 V7 20DG/WT WIPER PARK SWITCH SENSE
5 1 3 V4 12RD/YL WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT
10 6 4 Z1 14BK GROUND
5 - -
6 - -
WIPER 7 - -
MODULE 8 - -
(EXCEPT BUILT-UP-EXPORT) 9 - -
10 - -
* DIESEL
J988W-3 NSGS8088
NS/GS 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1
INDEX
page page
DESCRIPTION AND OPERATION number identification. Refer to the index for the
proper figure number.
INTRODUCTION
This section provides illustrations identifying the CONNECTOR/GROUND LOCATIONS
general location of components, grounds, and connec- For items not shown in this section a N/S is placed
tors in the vehicle. A index is provided. Use the wir- in the Fig. column.
ing diagrams in each section for connector/ground
INDEX
page page
DESCRIPTION AND OPERATION index is provided. Use the wiring diagrams in each
section for splice number identification. Refer to the
INTRODUCTION index for the proper splice number.
This section provides illustrations identifying the
general location of the splices in this vehicle. A splice
ENGINE
CONTENTS
page page
INDEX
page page
SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces to
remove all loose material. Inspect stamped parts to
ensure gasket rails are flat. Gasket surfaces must be
free of oil and dirt. Make sure old gasket material is
removed from blind attaching holes.
PREFERRED METHOD
Shimming the bearings adjacent to the bearing to
be checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14-20 N·m (10-15 ft. lbs.). The number of main bear-
Fig. 2 Cylinder Bore Cross-Hatch Pattern
ing will vary from engine to engine.
9-4 ENGINE NS
GENERAL INFORMATION (Continued)
ENGINE WITH 5 MAIN BEARINGS amount of clearance in thousandths of a millimeter.
• When checking #1 main bearing shim #2 main Differences in readings between the ends indicate the
bearing. amount of taper present. Record all readings taken.
• When checking #2 main bearing shim #1 & 3 Refer to Engine Specifications. Plastigage gener-
main bearing. ally is accompanied by two scales. One scale is
• When checking #3 main bearing shim #2 & 4 in inches, the other is a metric scale.
main bearing.
• When checking #4 main bearing shim #3 & 5 NOTE: Plastigage is available in a variety of clear-
main bearing. ance ranges. Use the most appropriate range for
• When checking #5 main bearing shim #4 main the specifications you are checking.
bearing.
CONNECTING ROD BEARING CLEARANCE
ENGINE WITH 4 MAIN BEARING
Engine connecting rod bearing clearances can be
• When checking #1 main bearing shim # 2 main
determined by use of Plastigage or equivalent. The
bearing.
following is the recommended procedure for the use
• When checking #2 main bearing shim #1 & #3
of Plastigage:
main bearing.
(1) Rotate the crankshaft until the connecting rod
• When checking #3 main bearing shim #2 & #4
to be checked is at the bottom of its stroke.
main bearing.
(2) Remove oil film from surface to be checked.
• When checking #4 main bearing shim #3 main
Plastigage is soluble in oil.
bearing.
(3) Place a piece of Plastigage across the entire
NOTE: REMOVE ALL SHIMS BEFORE REASSEM- width of the bearing shell in the bearing cap approx-
BLING ENGINE imately 6.35 mm (1/4 in.) off center and away from
the oil hole (Fig. 3). In addition, suspect areas can be
checked by placing plastigage in the suspect area.
(4) Assemble the rod cap with Plastigage in place.
Tighten the rod cap to the specified torque. Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the bearing cap and compare the
width of the flattened Plastigage (Fig. 4) with the
scale provided on the package. Locate the band clos-
est to the same width. This band indicates the
amount of oil clearance. Differences in readings
Fig. 4 Clearance Measurement between the ends indicate the amount of taper
present. Record all readings taken. Refer to Engine
ALTERNATIVE METHOD Specifications. Plastigage generally is accompa-
The weight of the crankshaft can be supported by a nied by two scales. One scale is in inches, the
jack under the counterweight adjacent to the bearing other is a metric scale. If the bearing clearance
being checked. exceeds 0.076 mm (0.003 in.) replace bearing.
PLASTIGAGE PROCEDURE NOTE: Plastigage is available in a variety of clear-
(1) Remove oil film from surface to be checked. ance ranges. Use the most appropriate range for
Plastigage is soluble in oil. the specifications you are checking.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil REPAIR OF DAMAGED OR WORN THREADS
holes (Fig. 3). (In addition, suspected areas can be Damaged or worn threads (including aluminum
checked by placing the Plastigage in the suspected head spark plug threads) can be repaired. Essen-
area). Torque the bearing cap bolts of the bearing tially, this repair consists of drilling out worn or
being checked to the proper specifications. damaged threads, tapping the hole with a special
(3) Remove the bearing cap and compare the Heli-Coil Tap, (or equivalent) and installing an insert
width of the flattened Plastigage (Fig. 4) with the into the tapped hole. This brings the hole back to its
metric scale provided on the package. Locate the original thread size.
band closest to the same width. This band shows the
NS ENGINE 9-5
GENERAL INFORMATION (Continued)
CAUTION: Be sure that the tapped holes maintain ing is at the MIN mark will result in a MAX reading
the original centerline. on these engines. For the 3.0L engine, add one full
quart when the level on the dipstick is at or below
Heli-Coil tools and inserts are readily available the ADD mark.
from automotive parts jobbers.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only, engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 5). Fig. 6 Engine Oil Container Standard Notations
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule.
ENGINE DIAGNOSIS
INDEX
page page
2.4L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION cylinder block. Oil pickup, pump and check valve pro-
vide oil flow to the main oil gallery.
ENGINE IDENTIFICATION
The engine identification number is located on the MAIN/ROD BEARINGS
rear of the cylinder block (Fig. 1). A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
ENGINE LUBRICATION SYSTEM route oil from main bearing journals to connecting
rod journals.
OIL PAN
A structural die cast aluminum oil pan provides CAMSHAFT/HYDRAULIC LASH ADJUSTERS
lower engine protection as well as serving as the A vertical hole at the number five bulkhead routes
engine oil reservoir. Oil pan is attached to block and pressurized oil through a restrictor up past a cylin-
sealed with a gasket. The oil pickup tube has a der head bolt to an oil gallery running the length of
strainer and cover. the cylinder head. The camshaft journals are par-
tially slotted to allow a predetermined amount of
PRESSURE LUBRICATION pressurized oil to pass into the bearing cap cavities
Oil drawn up through the pickup tube is pressur- with small holes directed to spray lubricate the cam-
ized by the pump and routed through the full flow fil- shaft lobes.
ter to the main oil gallery running the length of the
NS 2.4L ENGINE 9 - 15
DESCRIPTION AND OPERATION (Continued)
Engine—2.4L
These gears are driven by a short chain from the
crankshaft, to rotate at two times crankshaft speed.
This counterbalances certain engine reciprocating
masses.
CYLINDER BLOCK AND BEDPLATE ASSEM-
BLY: A closed deck design is used for cooling and
weight reduction with water pump molded into the
block. Nominal wall thickness is 4.5 mm. The bed-
plate incorporates main bearing caps. Rear seal
retainer is integral with the block.
CRANKSHAFT: A nodular cast iron crankshaft is
used. The engine has 5 main bearings, with number
3 flanged to control thrust. The 60 mm diameter
Fig. 1 Engine Identification main and 50 mm diameter crank pin journals (all)
BALANCE SHAFTS have undercut fillets that are deep rolled for added
Balance shaft lubrication is provided through an strength. To evenly distribute bearing loads and min-
oil passage from the number 1 main bearing cap imize internal stress, 8 counterweights are used.
through the balance shaft carrier support leg. This Hydrodynamic seals provide end sealing, where the
passage directly supplies oil to the front bearings and crankshaft exits the block. Anaerobic gasket material
internal machined passages in the shafts that routes is used for parting line sealing in the block. A sin-
oil from front to rear shaft bearing journals tered powder metal timing belt sprocket is mounted
on the crankshaft nose. This sprocket provides
SPLASH LUBRICATION motive power; via timing belt to the camshaft sprock-
Oil returning to the pan from pressurized compo- ets (providing timed valve actuation) and to the
nents supplies lubrication to the valve stems. Cylin- water pump.
der bores and wrist pins are splash lubricated from PISTONS: There is provisions for free wheeling
directed slots on the connecting rod thrust collars. valve train. Piston has a unique height. All engines
use pressed in piston pins to attach forged powder
ENGINE COMPONENTS metal connecting rods. Incorporate hex head cap
BALANCE SHAFTS: 2.4L engines are equipped screw threaded into the connecting rod. Piston and
with two balance shafts installed in a carrier Rods are serviced as a assembly.
attached to the lower crankcase. The shafts intercon- PISTONS RINGS: The piston rings include a
nect through gears to rotate in opposite directions. molybdenum faced top ring for reliable compression
9 - 16 2.4L ENGINE NS
DESCRIPTION AND OPERATION (Continued)
sealing and a chrome plated taper faced intermediate DIAGNOSIS AND TESTING
ring for additional cylinder pressure control. There
are also standard oil control rings. CHECKING ENGINE OIL PRESSURE
CYLINDER HEAD: Features a Dual Over Head (1) Remove oil pressure sending unit and install
Camshaft (DOHC) 4 valves per cylinder cross flow gauge assembly C-3292.
design. The valves are arranged in two inline banks, (2) Run engine until thermostat opens.
with the ports of the bank of two intake valves per
cylinder facing toward the radiator side of engine CAUTION: If oil pressure is 0 at idle, Do Not Run
and ports of the bank of two exhaust valves per cyl- engine at 3000 RPM
inder facing toward the dash panel. Incorporates
powder metal valve guides and seats. Integral oil gal- (3) Oil Pressure: Curb Idle 25 kPa (4 psi) mini-
leys within the cylinder head supplies oil to the mum 3000 RPM 170/550 kPa (25/80 psi).
hydraulic lash adjusters, camshaft and valve mecha- (4) If oil pressure is 0 at idle. Shut off engine,
nisms. check for pressure relief valve stuck open or a
CAMSHAFTS: The nodular iron camshafts have clogged oil pickup screen.
six bearing journals and 2 cam lobes per cylinder.
Flanges at the rear journals control camshaft end
SERVICE PROCEDURES
play. Provision for cam position sensor is located on
the intake camshaft at the rear of cylinder head. A
FITTING PISTONS
hydrodynamic oil seal is used for oil control at the
Piston and cylinder wall must be clean and dry.
front of the camshaft.
Piston diameter should be measured 90 degrees to
VALVES: 4 valves per cylinder are actuated by
piston pin about 14 mm (9/16 inch.) from the bottom
roller cam followers which pivot on stationary
of the skirt as shown in (Fig. 3). Cylinder bores
hydraulic lash adjusters. All valves have 6 mm diam-
should be measured halfway down the cylinder bore
eter chrome plated valve stems. The valve sizes are
and transverse to the engine crankshaft center line
34.8 mm (1.370 inch.) diameter intake valves and
shown in (Fig. 2). Refer to Cylinder Bore and Piston
30.5 mm (1.20 inch.) diameter exhaust valves. Viton
Specification Chart.
rubber valve stem seals are integral with the spring
Correct piston to bore clearance must be estab-
seats. Valve springs, spring retainers, and locks are
lished in order to assure quiet and economical oper-
conventional.
ation.
INTAKE MANIFOLD: The intake manifold is a
Chrysler engines use pistons designed specifically
two piece aluminum casting, attached to the cylinder
for each engine model. Clearance and sizing locations
head with ten screws. This long branch fan design
vary with respect to engine model.
enhances low and midspeed torque, while minimizing
undesirable inlet noise. NOTE: Pistons and cylinder bores should be mea-
EXHAUST MANIFOLD: The exhaust manifold is sured at normal room temperature, 70°F (21°C).
made of cast iron for strength and high tempera-
tures.
ENGINE LUBRICATION: Refer to Group 0 FITTING PISTON RINGS
Lubrication and Maintenance for recommended oil to (1) Wipe cylinder bore clean. Insert ring and push
be used in various engine application. System is full down with piston to ensure it is square in bore. The
flow filtration, pressure feed type. The oil pump is ring gap measurement must be made with the ring
mounted in the front engine cover and driven by the positioning at least 12 mm (0.50 inch) from bottom of
crankshaft. Pressurized oil is then routed through cylinder bore. Check gap with feeler gauge (Fig. 4).
the main oil gallery, running the length of the cylin- Refer to specification in Piston Ring Specification
der block, supplying main and rod bearings with fur- Chart.
ther routing. Pistons are lubricated from rod bearing (2) Check piston ring to groove side clearance (Fig.
throw off and lubricating slots on the connecting rod 5). Refer to specification in Piston Ring Specification
assemblies. Camshaft and valve mechanisms are Chart.
lubricated from a full length cylinder head oil gallery
supplied from the crankcase main oil gallery.
NS 2.4L ENGINE 9 - 17
SERVICE PROCEDURES (Continued)
Fig. 2 Checking Cylinder Bore Size Upper Ring 0.025 to 0.51 mm 0.8 mm
(0.0098 to 0.020 in.) (0.031 in.)
CYLINDER BORE AND PISTON
Intermediate 0.23 to 0.48 mm 0.8 mm
SPECIFICATION CHART
Ring (0.009 to 0.018 in.) (0.031 in.)
Standard Bore Maximum Maximum Oil Control 0.25 to 0.64 mm 1.0 mm
Out-Of-Round Taper Ring (0.0098 to 0.025 in.) (0.039 in.)
87.5 mm 0.051 mm 0.051 mm Ring Position Groove Clearance Max.
(3.445 in.) (0.002 in.) (0.002 in.) Clearance
Standard Piston Size Upper Ring 0.030 to 0.080 mm 0.10 mm
87.450 - 87.468 mm (3.4434 - 3.4441 in.) (0.0011 to 0.0031 in.) (0.004 in.)
Fig. 6 Piston Ring Installation Fig. 8 Piston Ring End Gap Position
a. Oil ring expander. FITTING CONNECTING ROD BEARINGS
b. Upper oil ring side rail. Engine connecting rod bearing clearances can be
c. Lower oil ring side rail. determined by use of Plastigage or equivalent. The
d. No. 2 Intermediate piston ring. following is the recommended procedure for the use
e. No. 1 Upper piston ring. of Plastigage:
(2) Install the side rail by placing one end (1) Rotate the crankshaft until the connecting rod
between the piston ring groove and the expander. to be checked is at the bottom of its stroke.
Hold end firmly and press down the portion to be (2) Remove oil film from surface to be checked.
installed until side rail is in position. Do not use a Plastigage is soluble in oil.
piston ring expander (Fig. 7). (3) Place a piece of Plastigage across the entire
(3) Install upper side rail first and then the lower width of the bearing shell in the bearing cap approx-
side rail. imately 6.35 mm (1/4 in.) off center and away from
(4) Install No. 2 piston ring and then No. 1 piston the oil hole (Fig. 9). In addition, suspect areas can be
ring. checked by placing plastigage in the suspect area.
Fig. 13 Main Bearing Caps/Bedplate Torque Fig. 14 Checking Crankshaft End Play—Typical
Sequence (1) Mount a dial indicator to front of engine, locat-
(5) Install lower main bearings into main bearing ing probe on nose of crankshaft (Fig. 14).
cap/bedplate. Make certain the bearing tabs are (2) Move crankshaft all the way to the rear of its
seated into the bedplate slots. Install the main bear- travel.
ing/bedplate into engine block. (3) Zero the dial indicator.
(6) Before installing bolts, lubricate the threads (4) Move crankshaft all the way to the front and
with clean engine oil, wipe off any excess oil. read the dial indicator. Refer to Crankshaft Specifi-
(7) Install main bearing bedplate to engine block cation Chart for end-play specification.
bolts 11, 17 and 20 finger tight. Tighten these bolts CRANKSHAFT SPECIFICATION CHART
down together until the bedplate contacts the cylin-
der block. Crankshaft End-Play
(8) To ensure correct thrust bearing alignment, New Part: 0.09 - 0.24mm
perform the following steps: (0.0035 - 0.0094 in.)
• Step 1: Rotate crankshaft until number 4 piston
is at TDC. Wear Limit: 0.37 mm
• Step 2: Move crankshaft rearward to limits of (0.015 in.)
travel.
NS 2.4L ENGINE 9 - 21
SERVICE PROCEDURES (Continued)
OPTIONAL CRANKSHAFT END PLAY CHECK VALVE GUIDE SPECIFICATION CHART
(1) Move crankshaft all the way to the rear of its
travel using a lever inserted between a main bearing Valve Guide Diameter
cap and a crankshaft cheek, using care not to dam- Intake and 5.975 - 6.000 mm
age any bearing surface. DO NOT loosen main bear- Exhaust Valve: (0.2352 - 0.2362 in.)
ing cap.
Valve Guide Clearance
(2) Use a feeler gauge between number three
New Service
thrust bearing and machined crankshaft surface to
Limit
determine end play.
Intake Valve: 0.048 - 0.066 mm
VALVE SERVICE RECONDITION (0.0018 - 0.0025 in.)
0.25 mm
VALVE REMOVAL (0.010 in.)
(1) With cylinder head removed, compress valve Exhaust Valve: 0.0736 - 0.094 mm
springs using Special Tool C-3422-B or equivalent. (0.0029 - 0.0037 in.)
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves, remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides. Identify valves to insure
installation in original location.
VALVE INSPECTION
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. Measure stem
about 60 mm beneath the valve lock grooves.
(3) If valve stems are worn more than 0.05 mm
(0.002 in.), replace valve.
VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner. Fig. 16 Valve Guide Height
(2) Using a small hole gauge and a micrometer, inches). Turn tool table until surface is in line with
measure valve guides in 3 places top, middle and bot- the 33.34 mm (1 5/16 in.) mark on the threaded stud
tom (Fig. 15). Refer to Valve Guide Specification and the zero mark on the front. Place spring over
Chart. Replace guides if they are not within specifi- stud on the table and lift compressing lever to set
cation. tone device (Fig. 17). Pull on torque wrench until
(3) Check valve guide height (Fig. 16). ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Discard the springs that do not meet
specifications. The Following specifications apply to
both intake and exhaust valve springs;
• Valve Closed Nominal Tension— 76 lbs. @ 38.0
mm (1.50 in.)
• Valve Open Nominal Tension— 136 lbs. @ 29.75
mm (1.17 in.)
(2) Inspect each valve spring for squareness with a
Fig. 15 Checking Wear on Valve Guide—Typical steel square and surface plate, test springs from both
ends. If the spring is more than 1.5 mm (1/16 inch)
TESTING VALVE SPRINGS out of square, install a new spring.
(1) Whenever valves have been removed for inspec-
tion, reconditioning or replacement, valve springs REFACING VALVES AND VALVE SEATS
should be tested. As an example, the compression (1) The intake and exhaust valve seats and valve
length of the spring to be tested is 33.34 mm (1 5/16 face have a 45 and a 45 1/2 degree angles.
9 - 22 2.4L ENGINE NS
SERVICE PROCEDURES (Continued)
VALVE SPECIFICATION CHART
Face Angle
Intake and Exhaust: 44.5°-45°
Head Diameter
Intake: 34.67 - 34.93 mm
(1.364 - 1.375 in.)
Exhaust: 30.37 - 30.63 mm
(1.195 - 1.205 in.)
Length (Overall)
Intake: 112.76 - 113.32 mm
(4.439 - 4.461 in.)
Exhaust: 109.59 - 110.09 mm
(4.314 - 4.334 in.)
INSTALLATION
(1) Reverse removal procedure for installation and
Fig. 21 Valve Stem Oil Seal Special Tool C4745 tighten fasteners in this order. For engine mount
9 - 24 2.4L ENGINE NS
REMOVAL AND INSTALLATION (Continued)
adjustment procedure, refer to Adjustments, Engine
Mounts in this Section.
(a) Tighten bolts 2, 3 and 4 to 108 N·m (80 ft.
lbs.)
(b) Tighten bolts 1 and 5 to 54 N·m (40 ft. lbs.).
(2) Install six screws to air dam and tighten to 12
N·m (105 in. lbs.).
CAMSHAFT
REMOVAL
(1) Remove cylinder head cover using procedure
Fig. 29 Cylinder Head Cover Gasket and Spark Plug outlined in this section.
Seals (2) Remove timing belt, sprockets and covers.
Refer to Timing Belt Service outlined in this section.
INSTALLATION (3) Bearing caps are identified for location.
Remove the outside bearing caps first (Fig. 31).
NOTE: Replace spark plug well seals when install-
(4) Loosen the camshaft bearing cap attaching
ing a new cylinder head cover gasket.
fasteners in sequence shown (Fig. 32) one camshaft
(1) Clean all sealing surfaces. at a time.
(2) Install new cylinder head cover gaskets and
CAUTION: Camshafts are not interchangeable. The
spark plug seals (Fig. 29).
intake cam number 6 thrust bearing face spacing is
wider.
NS 2.4L ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)
(5) Identify the camshafts before removing from
the head. The camshafts are not interchangeable.
INSTALLATION
(1) Install valve seal/valve spring seat assembly
(Fig. 48). Push the assembly down to seat it onto the
valve guide.
(2) Install valve spring and retainer, use Special
Tool MD-998772-A with adapter 6779 to compress
valve springs only enough to install locks (Fig. 47).
Correct alignment of tool is necessary to avoid nick-
ing valve stems.
(3) Remove air hose and install spark plugs.
(4) Install camshafts as previously outlined in this
Fig. 46 Chain Tension Adjustment section.
(5) Install cylinder head cover as previously out-
lined in this section.
9 - 34 2.4L ENGINE NS
REMOVAL AND INSTALLATION (Continued)
(8) Remove power steering pump assembly and
set aside.
(9) Disconnect coil pack wiring connector and
remove coil pack and plug wires from engine.
(10) Remove cam sensor and fuel injectors wiring
connectors.
(11) Remove timing belt and camshaft sprocket.
Refer to procedure outlined in this section.
(12) Remove timing belt idler pulley and rear tim-
ing belt cover.
(13) Remove cylinder head cover using procedure
outlined in this section.
(14) Remove camshafts and cam followers. Refer to
procedures outlined in this section for procedures.
(15) Remove cylinder head bolts and remove cyl-
inder head from engine block.
Fig. 47 Valve Spring—Removal/Installation (16) Inspect and clean cylinder head. Refer to
Cleaning and Inspection outlined in this section for
procedures.
INSTALLATION
INSTALLATION
(1) Coat valve stems with clean engine oil and
insert in cylinder head.
(2) Install new valve stem seals on all valves
using a valve stem seal tool (Fig. 51). The valve stem
seals should be pushed firmly and squarely over
valve guide.
REMOVAL
(1) Remove crankshaft damper. Refer to crank-
shaft damper removal for procedure.
(2) Remove front timing belt cover fasteners (Fig.
55) and remove covers.
INSTALLATION
(1) Set crankshaft sprocket to TDC by aligning
the sprocket with the arrow on the oil pump housing.
(2) Set camshafts timing marks so that the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 61).
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 77) until the tool bot- Fig. 77 Crankshaft Seal Special Tool 6926-2
toms out against the block (Fig. 78).
NOTE: Crankshaft can not be removed when (3) Oil the bearings and journals. Install crank-
engine is in vehicle. shaft.
(1) Remove oil filter and oil pan. Refer to proce- CAUTION: Use only the specified anaerobic sealer
dure outlined in this section. on the bedplate or damage may occur to the
(2) Remove Timing Belt Cover, Timing Belt and engine.
Oil Pump. Refer to procedure outlined in this section.
(3) Remove Balance Shafts Assembly. Refer to pro- (4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
cedure outlined in this section. Mopar Torque Cure Gasket Maker to cylinder block
(4) Remove all main bearing cap bedplate bolts as shown in (Fig. 83).
from the engine block. Refer to procedure outlined in
this section.
(5) Using a mallet gently tap the bedplate loose
from the engine block dowel pins.
INSTALLATION
Fig. 83 Main Bearing Caps/Bedplate Sealing
Fig. 82 Installing Main Bearing Upper Shell Fig. 84 Main Bearing Caps/Bedplate Torque
(1) Install the main bearing shells with the lubri- Sequence
cation groove in the cylinder block (Fig. 82). (5) Install lower main bearings into main bearing
(2) Make certain oil holes in block line up with oil cap/bedplate. Make certain the bearing tabs are
hole in bearings and bearing tabs seat in the block seated into the bedplate slots. Install the main bear-
tab slots. ing/bedplate into engine block.
(6) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.
NS 2.4L ENGINE 9 - 47
REMOVAL AND INSTALLATION (Continued)
(7) Install main bearing bedplate to engine block (1) Turn counterclockwise to remove.
bolts 11, 17 and 20 finger tight. Tighten these bolts (2) To install, lubricate new filter gasket. Check
down together until the bedplate contacts the cylin- filter mounting surface. The surface must be smooth,
der block. flat and free of debris or old pieces of rubber. Screw
(8) To ensure correct thrust bearing alignment per- filter on until the gasket contacts base. Tighten to 21
form the following steps: N·m (15 ft. lbs.).
• Step 1: Rotate crankshaft until number 4 pis-
ton is at TDC. OIL PUMP
• Step 2: Move crankshaft rearward to limits of
travel. REMOVAL
• Step 3: Then, move crankshaft forward to lim- (1) Disconnect negative cable from battery.
its of travel. (2) Remove Timing Belt. Refer to procedure out-
• Step 4: Wedge an appropraite tool between the lined in this section.
rear of the cylinder block (NOT BED PLATE) and (3) Remove Oil Pan. Refer to procedure outlined in
the rear crankshaft counterweight. This will hold the this section.
crankshaft in it’s furthest forward position. (4) Remove Crankshaft Sprocket using Special Tool
• Step 5: Install and tighten bolts (1-10) in 6793 and insert C-4685-C2 (Fig. 85).
sequence shown in (Fig. 84) to 41 Nzm (30 ft. lbs.).
• Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1-10) again to 41 Nzm (30 ft. lbs)
+ 1/4 turn in sequence shown in (Fig. 84).
(10) Install main bearing bedplate to engine block
bolts (11-20), and torque each bolt to 28 Nzm (20 ft.
lbs.) in sequence shown in (Fig. 84).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 Nzm (50 in. lbs.).
OIL FILTER
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can to base lock Fig. 85 Crankshaft Sprocket—Removal
seam. The lock seam joining the can to the base is
reinforced by the base plate. (5) Remove oil pick-up tube.
(6) Remove oil pump, (Fig. 86) and front crank-
shaft seal.
9 - 48 2.4L ENGINE NS
REMOVAL AND INSTALLATION (Continued)
Fig. 93 Piston—Installation
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 93). Be sure position of rings does not
change during this operation.
(4) The directional stamp on the piston should
face toward the front of the engine (Fig. 90).
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston assembly 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 connecting rod journal.
Fig. 95 Oil Pressure Relief Valve
NOTE: The rod bearing bolts should not be reused.
(2) Remove oil pump cover screws, and lift off
(7) Before installing the NEW bolts the threads
cover.
should be coated with clean engine oil.
(3) Remove pump rotors.
NS 2.4L ENGINE 9 - 51
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Wash all parts in a suitable solvent and Chart. Replace guides if they are not within specifi-
inspect carefully for damage or wear. cation.
(3) Check valve guide height (Fig. 98).
ASSEMBLY
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Prime oil pump before installation by filling
rotor cavity with engine oil.
(3) Install cover and tighten screws to 12 N·m
(105 in. lbs.).
CRANKSHAFT
The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 99). Limits of
taper or out-of-round on any crankshaft journals
should be held to .025 mm (.001 inch). Journal grind-
ing should not exceed .305 mm (.012 inch) under the
standard journal diameter. DO NOT grind thrust
faces of Number 3 main bearing. DO NOT nick
Fig. 100 Oil Pump
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out
all passages.
ADJUSTMENTS
ENGINE MOUNTS
ENGINE MOUNT INSULATOR ADJUSTMENT
(1) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack.
(2) Loosen the right engine mount insulator verti-
cal fastener and the fore and aft fasteners, and the
front engine mount bracket to front crossmember
screws.
(3) Pry the engine right or left as required to
achieve the proper drive shaft assembly length. Refer
to Group 2, Suspension and Driveshafts for drive-
shaft identification and related assembly length mea-
suring.
Fig. 107 Checking Cylinder Bore Size (4) Tighten engine mounts and fasteners in the
The cylinder walls should be checked for out-of- following order:
round and taper with Tool C119 (Fig. 107). The cyl- (a) Right engine mount insulator vertical bolts
inder bore out-of-round is 0.050 mm (0.002 in.) to 102 N·m (75 ft. lbs.) and the fore and aft bolts to
maximum and cylinder bore taper is 0.051 mm (0.002 150 N·m (110 ft. lbs.).
in.) maximum. If the cylinder walls are badly scuffed (b) Front engine mount screws to 54 N·m (40 ft.
or scored, the cylinder block should be replaced, and lbs.) the clearance between the snubbers and the
new pistons and rings fitted. engine should be 2 mm (0.078 inch.) each side.
Measure the cylinder bore at three levels in direc- (c) Left engine mount through bolt to 75 N·m (55
tions A and B (Fig. 107). Top measurement should be ft. lbs.).
10 mm (3/8 in.) down and bottom measurement (5) Recheck driveshaft length.
should be 10 mm (3/8 in.) up from bottom of bore.
Refer to Cylinder Bore and Piston Specification
Chart.
NS 2.4L ENGINE 9 - 55
SPECIAL TOOLS
2.4L ENGINE
Cradle 6710
Puller 1026
Dolly 6135
3.0L ENGINE
INDEX
page page
ENGINE LUBRICATION
System is a full flow filtration, pressure feed type.
The oil pump is mounted behind the timing belt
cover. The pump inner rotor is driven by the crank-
shaft. The engine oil pan contains a baffle plate to
control oil level fluctuation during engine operation.
ENGINE COMPONENTS
BLOCK: The cylinder block is a light weight
design created by reducing thickness in many parts
and a short 10 mm (3/8 in.) block skirt. High rigidity
is provided with ribs cast in the outer wall, a full
length water jacket, and a mono-block or beam type,
main bearing cap. This single unit four bearing cap
is designed to control vibration of the cylinder block
partition walls. Fig. 1 Engine Identification
CRANKSHAFT: A six throw, five weight crank- tions while a torsional vibration damper is used to
shaft is supported by four main bearings with num- control torsion caused vibration of the crankshaft.
ber three being the thrust bearing. The six separate Rubber lipped seals are used at front and rear. The
connecting rod throws pins reduce torque fluctua-
9 - 62 3.0L ENGINE NS
DESCRIPTION AND OPERATION (Continued)
front seal is retained in the oil pump case and the collected from the front cylinder bank, leave the front
rear is retained in a block-mounted housing. manifold through an end outlet and are fed through
PISTONS: Are aluminum alloy with a steel strut, an upper crossover tube to the rear manifold. The
short height, and thin wall so as to be autothermic collected exhaust from both manifolds are combined,
and light weight. The piston head with valve and exit to the exhaust pipe through an articulated
recesses, in combination with the cylinder head, joint.
forms a compact spherical head with clearance for
total valve lift with pistons at top dead center. The
piston skirt, top and second ring lands are finished to DIAGNOSIS AND TESTING
a tapered roughness for oil retention and high resis-
tance to scuffing. Piston pins, pressed into place, join CHECKING ENGINE OIL PRESSURE
the pistons to the connecting rods. Check oil pressure using gauge at oil pressure
CYLINDER HEAD: The alloy cylinder heads fea- switch location. Oil pressure should be 41 kPa ( 6
ture cross-flow type intake and exhaust ports. Valve psi.) at idle or 241 to 517 kPa (35 to 75 psi.) at 3000
guides and inserts are hardened cast iron. Valves of RPM.
heat resistance steel are arranged in a V with each (1) Remove pressure sending unit and install oil
camshaft on center. To improve combustion speed the pressure gauge. (Fig. 2).
chambers are a compact spherical design with a
squish area of approximately 30 percent of the piston
top area. The cylinder heads are common to either
cylinder bank by reversing the direction of installa-
tion.
CAMSHAFTS: Two overhead camshafts provide
valve actuation, one front (radiator side of cylinder
bank) and one rear. The front camshaft is provided
with a distributor drive and is longer. Both cam-
shafts are supported by four bearing journals, thrust
for the front camshaft is taken at journal two and
the rear at journal three. Front and rear camshaft
driving sprockets are interchangeable. The sprockets
and the engine water pump are driven by a single
notched timing belt.
ROCKER ARM SHAFTS: The shafts are retained
by the camshaft bearing journal caps. Four shafts are Fig. 2 Checking Engine Oil Pressure
used, one for each intake and exhaust rocker arm CAUTION: If oil pressure is 0 at idle, Do Not Run
assembly on each cylinder head. The hollow shafts engine at 3000 RPM.
provide a duct for lubricating oil flow from the cylin-
der head to the valve mechanisms. (2) Warm engine at high idle until thermostat
ROCKER ARMS: Are of light weight die-cast with opens.
roller type follower operating against the cam shaft.
The valve actuating end of the rocker arms are
machined to retain hydraulic lash adjusters, elimi- SERVICE PROCEDURES
nating valve lash adjustment.
VALVES: Are made of heat resistant steel, valve AUTO LASH ADJUSTER
springs are especially designed to be short. The valve The automatic lash adjusters are precision units
spring wire cross-section is oval shaped and provides installed in machined openings in the valve actuating
the same spring tension as longer springs. Valve ends of the rocker arms. Do not disassemble the auto
spring retainers, locks and seals are conventional. lash adjuster.
INTAKE MANIFOLD: The aluminum alloy mani-
fold is a cross type with long runners to improve FUNCTION CHECK
inertia. The runners, attaching below at the cylinder Check auto adjusters for free play by inserting a
head, also attach above and support an air plenum. small wire through the air bleed hole in the rocker
The air plenum chamber absorbs air pulsations cre- arm and very lightly pushing the auto adjuster ball
ated during the suction phase of each cylinder. check down (Fig. 3). While lightly holding the check
EXHAUST MANIFOLDS: Both manifolds are a ball down move the rocker up and down to check for
log style made of ductile cast iron. Exhaust gasses, free play. If there is no play replace the adjuster.
NS 3.0L ENGINE 9 - 63
SERVICE PROCEDURES (Continued)
CONNECTING ROD SIDE CLEARANCE
Using a feeler gauge, check connecting rod side
clearance (Fig. 5). Refer to Connecting Rod Specifica-
tion Chart.
PLASTIGAGE MEASUREMENT
(1) Remove oil from journal and bearing shell.
(2) Install crankshaft.
(3) Cut plastigage to same length as width of the
Fig. 4 Connecting Rod—Checking Bearing bearing and place it in parallel with the journal axis
Clearance (Fig. 8).
9 - 64 3.0L ENGINE NS
SERVICE PROCEDURES (Continued)
Fig. 6 Measure Crankshaft Journal O.D. Fig. 8 Measure Oil Clearance with Plastigage
(5) Carefully remove the bearing cap and measure
the width of the plastigage at the widest part using
the scale on the plastigage package (Fig. 9). Refer to
Crankshaft Clearance Specification Chart for proper
clearances. Also see Measuring Main and Connecting
Rod Bearing Clearance in Standard Service Proce-
dures.
Crankshaft End-Play
New Part: 0.05 - 0.25 mm
(0.002 - 0.001 in.)
Wear Limit: 0.30 mm (0.012 in.)
Main Bearing Oil Clearance Fig. 9 Measuring Clearance
New Part: 0.018 - 0.036 mm CRANKSHAFT BEARING INSTALLATION
(0.0007 - 0.0014 in.) When the bearings need replacing, select and
Wear Part: 0.10 mm (0.0039 in.) install the proper bearing by the following procedure.
(1) Measure the crankshaft journal diameter and
Crankshaft Main Bearing Journal confirm its classification from the following. In the
Standard Diameter: 59.980 mm (2.361 in.) case of a bearing supplied as a service part, its iden-
Crankshaft Connecting Rod Journal tification color is painted at the position show in (Fig.
10).
Standard Diameter: 50.00 mm (1.968 in.)
NOTE: Service replacement parts have identifica-
CAUTION: Do not rotate crankshaft or the plasti-
tion marks, but factory-assembled parts have no
gage will be smeared.
identification marks. Service crankshaft identifica-
(4) Install the main bearing cap carefully and tion may have marks or paint at counterweights.
tighten the bolts to specified torque. Refer to Crankshaft Size Classification Chart.
NS 3.0L ENGINE 9 - 65
SERVICE PROCEDURES (Continued)
CHECKING CRANKSHAFT END PLAY
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 11).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Crankshaft Specifi-
cation Chart.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove Air cleaner and hoses.
(4) Remove battery cover, battery and battery tray,
Fig. 22 Engine Mount—Left with integral vacuum reservoir, from vehicle.
REAR MOUNT (5) Block off heater hoses to rear heater assembly,
(1) Raise vehicle on hoist. if equipped.
(2) Support the transmission with a transmission (6) Drain cooling system. Refer to Group 7, Cooling
jack so it will not rotate. System for procedure.
(3) Remove the insulator through bolt from the (7) Disconnect heater hoses.
mount and rear suspension crossmember. (8) Remove fan module and radiator. Refer to
(4) Remove the four transmission mount fasteners Group 7, Cooling System for procedure.
and remove the mount. (9) Disconnect transmission shift linkage.
(5) Reverse the removal procedure for installation. (10) Disconnect throttle body linkage and vacuum
Refer to (Fig. 23). hoses from throttle body.
(11) Remove accessory drive belts. Refer to Acces-
sory Drive System located in Group 7, Cooling Sys-
tem for procedure.
(12) Remove air conditioning compressor from
engine and set it aside.
(13) Disconnect generator wiring harness and
remove generator.
(14) Hoist vehicle and remove axle shafts. Refer to
Group 2, Driveshaft for procedure.
(15) Remove right and left inner splash shields.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front engine mount and bracket as an
assembly.
(18) Remove rear transmission mount and bracket.
(19) Remove power steering pump and bracket
assembly.
(20) Remove wiring harness and connectors from
front of engine.
(21) Remove bending braces and install tool num-
ber 6910 on engine.
(22) Remove trans inspection cover and mark flex-
plate to torque converter.
(23) Remove driveplate to torque converter bolts.
Fig. 23 Engine Mount—Rear (24) Lower the vehicle.
9 - 70 3.0L ENGINE NS
REMOVAL AND INSTALLATION (Continued)
(25) Remove ground straps to body. (3) Slowly raise vehicle enough to remove the
(26) Raise vehicle enough to allow engine dolly engine dolly and cradle Special Tools 6135, 6710,
Special Tool 6135 and cradle Special Tool 6710 with 6848 and 6909.
post Special Tool 6848 and adaptor Special Tool 6909 (4) Remove Special tools 6910 and install bending
to be installed under vehicle (Fig. 24). braces.
(27) Loosen cradle engine mounts to allow move- (5) Lower vehicle. Install generator and wiring
ment for positioning onto engine locating holes on the harness.
engine. Lower vehicle and position cradle mounts (6) Connect wiring harness on the front of the
until the engine is resting on mounts. Tighten engine.
mounts to cradle frame. This will keep mounts from (7) Install Air Conditioning Compressor.
moving when removing or installing engine and (8) Install power steering pump and bracket and
transmission. accessory drive belt. Refer to Group 7. Accessory
(28) Lower vehicle so the weight of ONLY THE Drive Belts Section for installation procedure.
ENGINE AND TRANSMISSION is on the cradle. (9) Raise vehicle and install axle shafts. Refer to
(29) Remove right engine mount assembly and left Group 2, Driveshafts for procedure.
transmission mount through bolt. Refer to Engine (10) Install transmission and engine mount and
Mounts Section of this Group. bracket assemblies. Refer to Engine Mounts in this
(30) Raise vehicle slowly. It may be necessary to section for procedure.
move the engine/transmission assembly on the cradle (11) Connect exhaust system to manifold. Refer to
to allow for removal around body flanges. Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(12) Install left and right inner splash shields.
(13) Connect automatic transmission shifter link-
age. Refer to Group 21, Transmission for procedures.
(14) Lower vehicle and connect fuel line and
heater hoses. Remove plugs from rear heater hoses
and install, if equipped.
(15) Install ground straps. Connect engine and
throttle body connections and harnesses.
(16) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(17) Install radiator and fan module assembly.
Install radiator hoses. Fill cooling system. Refer to
Group 7, Cooling for procedures.
(18) Install battery tray, battery and cover.
(19) Install air cleaner and hoses.
(20) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(21) Start engine and run until operating temper-
ature is reached.
(22) Adjust transmission linkage, if necessary.
INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Install new gasket.
(2) See (Fig. 25) and apply sealant such as Mopar
Silicone Rubber Adhesive Sealant to cover ends.
(3) Install cover and tighten cover bolt washer and
gasket assembly to 10 N·m (88 in. lbs.).
(4) Reverse removal procedures for installation.
CAMSHAFT SEAL
CAMSHAFT END SEAL (PLUG)— IN VEHICLE
Fig. 28 Checking Camshafts
SERVICE
(1) Remove air cleaner assembly from engine.
(2) Use a small punch and a hammer, carefully
remove cam plug from cylinder head.
NS 3.0L ENGINE 9 - 73
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Mark belt running direction for installation
(Fig. 38).
(2) Loosen timing belt tensioner bolt (Fig. 40) and
remove timing belt.
(3) Remove crankshaft sprocket flange shield (Fig.
36).
OIL PAN
Oil pan to crankcase sealing is provided with
Fig. 42 Oil Pan Sealing
Mopart Silicone Rubber Adhesive Sealant or equiva-
lent gasket material. See Form-In-Place Gaskets in
Standard Service Procedures.
(1) Apply sealant as shown in (Fig. 42).
(2) Install pan and tighten screws to 6 N·m (50 in.
lbs.) in sequence shown in (Fig. 43).
Ring Position Ring Gap Ring Gap Wear Groove Clearance Maximum Groove
Limit Clearance
Upper Ring 0.30 - 0.45 mm 0.8 mm (0.031 in.) 0.05 - 0.09 mm 0.10 mm (0.004 in.)
(0.012 - 0.018 in.) (0.002 - 0.0035 in.)
Intermediate Ring 0.25 - 0.40 mm 0.8 mm (0.031 in.) 0.02 - 0.06 mm 0.10 mm (0.004 in.)
(0.010 - 0.016 in.) (0.0007 - 0.002 in.)
Oil Control Ring 0.30 - 0.90 mm 1.0 mm (0.039 in.) Oil Ring Side Rails Must Be Free To Rotate
(0.012 - 0.035 in.) After Assembly
9 - 80 3.0L ENGINE NS
REMOVAL AND INSTALLATION (Continued)
c. Lower oil ring side rail.
d. No. 2 Intermediate piston ring.
e. No. 1 Upper piston ring.
REMOVAL
(1) Remove front mounted oil pump assembly and
gasket (Fig. 57) and (Fig. 58).
REASSEMBLE
(1) Align the camshaft bearing caps with arrows
(depending on cylinder bank) directed as shown in
9 - 86 3.0L ENGINE NS
DISASSEMBLY AND ASSEMBLY (Continued)
• Rubber back side is glossy, hardened back with-
out resilience and leaves no indent when pressed
with fingernail.
• Cracks on rubber back.
• Cracks or peeling of canvas.
• Cracks on rib root.
• Missing teeth.
• The sides are normal if they are sharp as if cut
by a knife (Fig. 74).
CYLINDER HEAD
CLEANING AND INSPECTION
Fig. 72 Number One Camshaft Bearing Cap
(1) Before cleaning, check for leaks, damage and
CLEANING AND INSPECTION cracks.
(2) Clean cylinder head and oil passages.
TIMING BELT (3) Check cylinder head for flatness (Fig. 76).
(4) Cylinder head must be flat within:
INSPECTION • Standard dimension = less than 0.05 mm (.002
(1) Remove the upper front outer timing belt cover in.)
by loosening the three attaching bolts (Fig. 75). • Service Limit = 0.2 mm (.008 in.)
(2) Inspect both sides of the timing belt drive & • Grinding Limit = Maximum of 0.2 mm (.008 in.)
back. Replace belt if any of the following conditions is permitted.
exist:
ADJUSTMENTS
ENGINE MOUNTS
ENGINE MOUNT INSULATOR ADJUSTMENT
Fig. 79 Measuring Clearance Between Outer Rotor (1) Remove the load on the engine motor mounts
and Case by carefully supporting the engine and transmission
assembly with a floor jack.
(5) Using a feeler gauge, measure clearance between
(2) Loosen the right engine mount insulator verti-
inner rotor tip and outer rotor (Fig. 80). Clearance spec-
cal fastener and the fore and aft fasteners, and the
ification is: 0.06 - 0.18 mm (0.003 - 0.007 in.). Replace
front engine mount bracket to front crossmember
both rotors if not within specifications
screws.
(3) Pry the engine right or left as required to
achieve the proper drive shaft assembly length. Refer
to Group 2, Suspension and Driveshafts for drive-
shaft identification and related assembly length mea-
suring.
(4) Tighten engine mounts and fasteners in the
following order:
(a) Right engine mount insulator vertical bolts
to 102 N·m (75 ft. lbs.) and the fore and aft bolts to
150 N·m (110 ft. lbs.).
(b) Front engine mount screws to 54 N·m (40 ft.
lbs.) the clearance between the snubbers and the
engine should be 2 mm (0.078 inch.) each side.
(c) Left engine mount through bolt to 75 N·m (55
ft. lbs.).
(5) Recheck driveshaft length.
Fig. 80 Measuring Clearance Between Rotors
NS 3.0L ENGINE 9 - 89
SPECIAL TOOLS
3.0L ENGINE
Adaptor 6910
Dolly 6135
Cradle 6710
Adaptor 6909
3.3/3.8L ENGINE
INDEX
page page
CAUTION: If oil pressure is 0 at idle, do not run MEASURING TIMING CHAIN FOR STRETCH
engine at 3000 RPM. (1) Place a scale next to timing chain so that any
movement of chain may be measured.
(2) Warm engine at high idle until thermostat (2) Place a torque wrench and socket on camshaft
opens. sprocket attaching bolt and apply torque in direction
of crankshaft rotation to take up slack; 41 N·m (30 ft.
lb.) with cylinder head installed or 20 N·m (15 ft. lb.)
with cylinder heads removed. With a torque
applied to the camshaft sprocket bolt, crank-
shaft should not be permitted to move. It may
be necessary to block crankshaft to prevent
rotation.
(3) Holding a scale even, with dimension reading
as shown (Fig. 6), along edge of chain links. Apply
torque in the reverse direction to 41 N·m (30 ft. lbs.)
with cylinder heads installed, or 20 N·m (15 ft. lbs.)
with cylinder heads removed. Check amount of chain
movement.
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
(5) If chain is not satisfactory, refer to Timing
Fig. 5 Checking Oil Pump Pressure Chain Removal and Installation in this section.
NS 3.3/3.8L ENGINE 9 - 97
SERVICE PROCEDURES (Continued)
CYLINDER BORE AND PISTON
SPECIFICATION CHART
Maximum
Standard Maximum
Engine Out-Of-
Bore Taper
Round
3.3L 92.993 - 0.076 mm 0.51 mm
93.007 mm
(3.661 - (0.003 in.) (0.002 in.)
3.6617 in.)
3.8L 95.993 - Same Same
96.007 mm
3.7792 -
3.780 in.
Standard Piston Size
Fig. 6 Measuring Timing Chain Wear and Stretch
3.3L 92.950 - 92.968 mm (3.6594 - 3.6602 in.)
FITTING PISTONS AND RINGS
3.8L 95.950 - 95.968 mm (3.7776 - 3.7783 in.)
FITTING PISTONS Piston to Bore Clearance: 0.025 - 0.057 mm
The piston and cylinder wall must be clean and (0.0009 - 0.0022 in.)
dry. Piston diameter should be measured 90 degrees Measurements taken at Piston Size Location.
to piston pin at size location shown in (Fig. 8). Cyl-
inder bores should be measured halfway down the
cylinder bore and transverse to the engine crankshaft
center line shown in (Fig. 7). Refer to Cylinder Bore
and Piston Specification Chart. Pistons and cylin-
der bores should be measured at normal room
temperature, 70°F (21°C).
Ring Position Ring Gap Wear Limit Groove Clearance Maximum Clearance
Upper Ring 0.30 - 0.55 mm 1.0 mm (0.039 in.) 0.030 - 0.085 mm 0.10 mm (0.004 in.)
(0.012 - 0.022 in.) (0.001 - 0.003 in.)
Intermediate Ring 0.30 - 0.55 mm 1.0 mm (0.039 in.) 0.030 - 0.095 mm 0.10 mm (0.004 in.)
(0.012 - 0.022 in.) (0.001 - 0.0037 in.)
Oil Control Ring 0.25 - 1.00 mm 1.88 mm (0.074 in.) 0.014 - 0.266 mm 0.266 mm (0.009 in.)
(0.010 - 0.039 in.) (0.0005 - 0.009 in.)
Crankshaft End-Play
New Part: 0.09 - 0.24 mm
(0.0036 - 0.0095 in.)
Wear Limit: 0.38 mm
(0.015 in.)
VALVES
(1) Inspect the remaining margin after the valves
are refaced Refer to Valve Dimension Chart.
Fig. 18 Intake and Exhaust Valves
VALVE SEATS
VALVE GUIDE SPECIFICATION CHART
CAUTION: Remove metal from valve seat only. Do
Intake Valve Exhaust Valve
not remove metal from cylinder head (Fig. 20).
Dial Indicator 0.247 mm 0.414 mm
Reading (0.009 in.) (0.016 in.) (1) When refacing valve seats, it is important that
(Maximum): the correct size valve guide pilot be used for reseat-
Valve Guide Valve Guide Size ing stones. A true and complete surface must be
Reamer obtained.
Oversize (2) Measure the concentricity of valve seat using
0.15 mm 8.125 - 8.150 mm dial indicator. Total runout should not exceed 0.051
(0.005 in.) (0.3198 - 0.3208 in.) mm (0.002 in.) total indicator reading.
0.40 mm 8.375 - 8.400 mm
(0.015 in.) (0.3297 - 0.3307 in.)
0.80 mm 8.775 - 8.800 mm
(0.030 in.) (0.3454 - 0.3464 in.)
CYLINDER HEAD
REMOVAL
(1) Drain cooling system. Refer to Group 7, Cooling
System for procedure and disconnect negative cable
from battery.
(2) Remove upper and lower intake manifolds.
Refer to Group 11, Exhaust System and Intake Man-
ifold.
Fig. 34 Head Gasket Installation
WARNING: INTAKE MANIFOLD GASKET IS MADE (3) The cylinder head bolts are torqued using
OF VERY THIN METAL AND MAY CAUSE PER- the torque yield method, they should be exam-
SONAL INJURY, HANDLE WITH CARE. ined BEFORE reuse. If the threads are necked
down, the bolts should be replaced (Fig. 35).
(3) Disconnect coil wires, sending unit wire, heater
(4) Necking can be checked by holding a scale or
hoses and bypass hose.
straight edge against the threads. If all the threads
(4) Remove PCV system hoses, evaporation control
do not contact the scale the bolt should be replaced.
system hose and cylinder head covers.
(5) Remove exhaust manifolds.
(6) Remove rocker arm and shaft assemblies.
Remove push rods and mark positions to ensure
installation in original locations.
(7) Remove the 9 head bolts from each cylinder
head and remove cylinder heads (Fig. 33).
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets in their original positions.
(3) With roller tappets, install aligning yokes (Fig.
Fig. 41 Checking Valve Installed Height 43).
(5) Compress valve springs with Valve Spring (4) Install yoke retainer and torque screws to 12
Compressor Tool C-3422-B, with adapter 6412 install N·m (105 in. lbs.) (Fig. 43).
locks and release tool. If valves and/or seats are (5) Install cylinder heads. Refer to cylinder head
reground, measure the installed height of installation of this section for procedure.
springs dimension B, make sure measurements
NS 3.3/3.8L ENGINE 9 - 111
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure cor-
rect oil pump engagement. Fig. 46 Timing Chain Case Cover
that the lower edge of the gasket is flush to 0.5 mm
NOTE: DO NOT USE SEALER ON COVER GASKET (0.020 in.) passed the lower edge of the cover. Refer
to Oil Pan sealing outlined in this section.
(2) Use a new cover gasket, and O-rings (Fig. 47).
Adhere new gasket to chain case cover, making sure
9 - 112 3.3/3.8L ENGINE NS
REMOVAL AND INSTALLATION (Continued)
(3) Rotate crankshaft so that the oil pump drive
flats are vertical.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 47).
(5) Install cover onto crankshaft. Make sure the oil
pump is engaged on the crankshaft correctly or
severe damage may result.
(6) Install chain case cover screws and torque to
27 N·m (20 ft. lbs.).
(7) Install crankshaft oil seal (Fig. 48).
(8) Install crankshaft pulley (Fig. 49).
TIMING CHAIN
Fig. 47 Timing Chain Case Cover Gaskets and
REMOVAL
O-Rings
(1) Disconnect negative cable from battery.
(2) Remove timing chain cover. Refer to procedure
outlined in this section.
(3) Remove camshaft sprocket attaching bolt, and
timing chain with camshaft sprocket.
(4) Using a suitable puller remove the crankshaft
sprocket. Be careful not to damage the crankshaft
surface.
INSTALLATION
(1) Position a new crankshaft sprocket on the
shaft, install sprocket with suitable tool and mallet.
Be sure sprocket is seated into position.
(2) Rotate crankshaft so the timing arrow is to the
12 o’clock position.
(3) Place timing chain around camshaft sprocket
and place the timing mark to the 6 o’clock position.
Fig. 48 Crankshaft Oil Seal—Installation (4) Align the dark colored links with the dot on the
camshaft sprocket, place timing chain around crank-
(9) Install engine bracket (Fig. 45) and torque fas-
shaft sprocket with the dark colored link lined up
teners to 54 N·m (40 ft. lbs.).
NS 3.3/3.8L ENGINE 9 - 113
REMOVAL AND INSTALLATION (Continued)
with the dot on the sprocket and install camshaft
sprocket into position.
(5) Use a straight edge to check alignment of tim-
ing marks (Fig. 50).
(6) Install camshaft bolt and washer. Tighten to 54
N·m (40 ft. lbs.).
(7) Rotate crankshaft 2 revolutions. Timing marks
should line up. If timing marks do not line up
remove cam sprocket and realign.
(8) Check camshaft end play. With new thrust
plate the specification is 0.0127 to 0.304 mm (0.005
to 0.012 in.). Old thrust plate specification is 0.31
mm (0.012 in.) maximum. If not within these limits
install new thrust plate.
CRANKSHAFT
MAIN BEARINGS
Bearing caps are not interchangeable and should
Fig. 62 Main Bearing Cap Identification
be marked at removal to insure correct assembly
(Fig. 62). Upper and lower bearing halves are NOT Upper and lower Number 2 bearing halves are
interchangeable. Lower main bearing halves of 1, 3 flanged to carry the crankshaft thrust loads and are
and 4 are interchangeable. Upper main bearing NOT interchangeable with any other bearing halves
halves of 1, 3 and 4 are interchangeable. in the engine (Fig. 63). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
CRANKSHAFT MAIN JOURNALS before installation. Bearing shells are available in
The crankshaft journals should be checked for standard and the following undersizes: 0.025 mm
excessive wear, taper and scoring. (Fig. 61) Limits of (0.001 in.) and 0.254 mm (0.010 in). Never install an
taper or out-of-round on any crankshaft journals undersize bearing that will reduce clearance below
should be held to 0.025 mm (0.001 in.). Journal specifications.
grinding should not exceed 0.305 mm (0.012 in.)
under the standard journal diameter. Do NOT grind REMOVAL
thrust faces of Number 2 main bearing. Do NOT nick (1) Remove oil pan and identify bearing caps
crank pin or bearing fillets. After grinding, remove before removal.
rough edges from crankshaft oil holes and clean out (2) Remove bearing caps one at a time. Remove
all passages. upper half of bearing by inserting Special Main Bear-
ing Tool C-3059. (Fig. 64) into the oil hole of crank-
CAUTION: With the nodular cast iron crankshafts shaft.
used it is important that the final paper or cloth pol-
NS 3.3/3.8L ENGINE 9 - 117
REMOVAL AND INSTALLATION (Continued)
(5) Rotate the crankshaft until number 6 piston is
at TDC.
(6) To ensure correct thrust bearing alignment the
following procedure must be done:
a. Move crankshaft all the way to the rear of its
travel.
b. Then, move crankshaft all the way to the front
of its travel.
c. Wedge a appropriate tool between the rear of
the cylinder block and rear crankshaft counter-
weight. This will hold the crankshaft in it’s most for-
ward position.
d. Tighten the #2 Thrust Bearing cap bolts to 41
N·m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the
holding tool.
(7) Install oil pan.
Fig. 63 Main Bearing Identification (8) Fill engine crankcase with proper oil to correct
(3) Slowly rotate crankshaft clockwise, forcing out level.
upper half of bearing shell.
CRANKSHAFT OIL SEAL—FRONT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist. Remove right wheel and
inner splash shield.
(3) Remove drive belt. Refer to Group 7, Cooling
System for procedure.
(4) Remove crankshaft damper (Fig. 65).
When installing a new upper bearing shell, slightly Fig. 65 Crankshaft Damper—Removal
chamfer the sharp edges from the plain side. (5) Using Tool 6341A to remove oil seal (Fig. 66).
(1) Start bearing in place, and insert Main Bearing Be careful not to damage that crankshaft seal sur-
Tool C-3059 into oil hole of crankshaft (Fig. 64). face of cover.
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Special Main INSTALLATION
Bearing Tool C-3059. (1) Install new seal by using Tool C-4992 (Fig. 67).
(3) Install each main cap and tighten bolts finger (2) Place seal into opening with seal spring
tight. towards the inside of engine. Install seal until flush
(4) Tighten number 1, 3 and 4 main cap bolts to 41 with cover.
N·m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). (3) Install crankshaft pulley using plate L-4524.
Thrust Bearing/washer and 5.9 inch screw (Fig. 68).
9 - 118 3.3/3.8L ENGINE NS
REMOVAL AND INSTALLATION (Continued)
OIL FILTER
CAUTION: When servicing the oil filter (Fig. 71)
avoid deforming the filter can by installing the
Fig. 72 Core Hole Plug Removal
remove/install tool band strap against the can-to-
base lock seam. The lock seam joining the can to INSTALLATION
the base is reinforced by the base plate. Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
(1) Using Tool C-4065, turn filter counterclockwise Lightly coat inside of cup plug hole with Loctite Stud
to remove from base. Properly discard filter. N’ Bearing Mount or equivalent. Make certain the
(2) Wipe base clean, then inspect gasket contact new plug is cleaned of all oil or grease. Using proper
surface. drive plug, drive plug into hole so that the sharp
(3) Lubricate gasket of new filter with clean edge of the plug is at least 0.5 mm (0.020 in.) inside
engine oil. the lead-in chamfer.
(4) Install new filter until gasket contacts base.
Tighten filter 1 turn or 20 N·m (15 ft. lbs.). Use filter
wrench if necessary. DISASSEMBLY AND ASSEMBLY
(5) Start engine and check for leaks.
OIL PUMP
ENGINE OIL GALLERY PLUGS It is necessary to remove the oil pan, oil pickup
and chain case cover to service the oil pump rotors.
REMOVAL The oil pump pressure relief valve can be serviced by
Using a blunt tool such as a drift and a hammer, removing the oil pan and oil pickup tube. Refer to
strike the bottom edge of the cup plug. With the cup Timing Chain Cover Removal and Installation of this
plug rotated, grasp firmly with pliers or other suit- section for procedures.
able tool and remove plug (Fig. 72).
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
9 - 120 3.3/3.8L ENGINE NS
DISASSEMBLY AND ASSEMBLY (Continued)
(2) 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.
(3) Clamp screw into a vise and while supporting
chain case cover, remove cap by tapping chain case
cover using a soft hammer. Discard retainer cap and
remove spring and relief valve (Fig. 73).
HYDRAULIC TAPPETS
DISASSEMBLY
(1) Pry out plunger retainer spring clip (Fig. 74).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, flat or ball check valve, check valve spring,
check valve retainer and plunger spring. Check valve
could be flat or ball.
ASSEMBLY
(1) Clean all tappet parts in a solvent that will
remove all varnish and carbon.
(2) Replace tappets that are unfit for further ser- Fig. 75 Check Cylinder Head
vice with new assemblies.
NS 3.3/3.8L ENGINE 9 - 121
CLEANING AND INSPECTION (Continued)
OIL PAN
(1) Clean oil pan in solvent and wipe dry with a
clean cloth. Clean all gasket material from mounting
surfaces of pan and block.
(2) Inspect oil drain plug and plug hole for
stripped or damaged threads and repair as necessary.
Install a new drain plug gasket. Tighten to 27 N·m
(20 ft. lbs.).
(3) Inspect oil pan mounting flange for bends or
distortion. Straighten flange if necessary.
(4) Clean oil screen and pipe in clean solvent.
Inspect condition of screen.
OIL PUMP
INSPECTION AND REPAIR
(1) Clean all parts thoroughly. Mating surface of Fig. 77 Checking Oil Pump Cover Flatness
the chain case cover should be smooth. Replace pump
cover if scratched or grooved. of 0.10 mm (0.004 in.) or more can be inserted
(2) Lay a straightedge across the pump cover sur- between rotors and the straightedge, replace pump
face (Fig. 77). If a 0.025 mm (0.001 in.) feeler gauge assembly (Fig. 82). ONLY if rotors are in specs.
can be inserted between cover and straight edge, (8) Inspect oil pressure relief valve plunger for
cover should be replaced. scoring and free operation in its bore. Small marks
(3) Measure thickness and diameter of outer rotor. may be removed with 400-grit wet or dry sandpaper.
If outer rotor thickness measures 7.64 mm (0.301 in.) (9) The relief valve spring has a free length of
or less (Fig. 78), or if the diameter is 79.95 mm approximately 49.5 mm (1.95 inches) it should test
(3.148 inches.) or less, replace outer rotor. between 19.5 and 20.5 pounds when compressed to
(4) If inner rotor measures 7.64 mm (0.301 in.) or 34 mm (1-11/32 inches). Replace spring that fails to
less replace inner rotor (Fig. 79). meet specifications (Fig. 73).
(5) Slide outer rotor into chain case cover, press to (10) If oil pressure is low and pump is within spec-
one side with fingers and measure clearance between ifications, inspect for worn engine bearings or other
rotor and chain case cover (Fig. 80). If measurement reasons for oil pressure loss.
is 0.39 mm (0.015 in.) or more, replace CCC only if
outer rotor is in specification.
ENGINE BLOCK AND BORE
(6) Install inner rotor into chain case cover. If
CLEANING AND INSPECTION
clearance between inner and outer rotors (Fig. 81) is
(1) Clean cylinder block thoroughly and check all
0.203 mm (0.008 in.) or more, replace both rotors.
core hole plugs for evidence of leaking.
(7) Place a straightedge across the face of the
chain case cover, between bolt holes. If a feeler gauge
9 - 122 3.3/3.8L ENGINE NS
CLEANING AND INSPECTION (Continued)
Fig. 79 Measuring Inner Rotor Thickness Fig. 82 Measuring Clearance Over Rotors
SPECIAL TOOLS
3.3/3.8L ENGINE
Adaptor 6912
Dolly 6135
Puller 1023
Cradle 6710
Adaptor 6909
9 - 128 3.3/3.8L ENGINE NS
SPECIAL TOOLS (Continued)
Tester Valve Spring C-647 Camshaft Bearing Remover and Installer C-3132–A
Valve Spring Compressor C-3422–B Crankshaft Main Bearing Remover and Installer
C-3059
ENGINE
CONTENTS
page page
INDEX
page page
Ring Position Ring Gap Ring Gap Wear Groove Clearance Maximum Groove
Limit Clearance
Upper Ring 0.23 - 0.52 mm 0.8 mm (0.031 in.) 0.025 - 0.065 mm 0.10 mm (0.004 in.)
(0.009 - 0.020 in.) (0.0010 - 0.0026 in.)
Intermediate Ring 0.49 - 0.78 mm 1.0 mm (0.039 in.) 0.025 - 0.065 mm 0.10 mm (0.004 in.)
(0.019 - 0.031 in.) (0.0010 - 0.0026 in.)
Oil Control Ring 0.23 - 0.66 mm 1.0 mm (0.039 in.) Oil Ring Side Rails Must Be Free To Rotate After
(0.009 - 0.026 in.) Assembly
9-6 ENGINE NS/GS
SERVICE PROCEDURES (Continued)
CONNECTING ROD SPECIFICATION CHART (3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
Connecting Rod Bearing Oil Clearance read the dial indicator. Refer to Crankshaft Specifi-
New Part: 0.026 - 0.059 mm (0.001 - 0.0023 in.) cation Chart for specifications.
Wear Limit: 0.075 mm (0.003 in.)
FEELER GAGE METHOD
Connecting Rod Side Clearance (1) Move crankshaft all the way to the rear of its
New Part: 0.13 - 0.38 mm (0.005 - 0.015 in.) travel using a lever inserted between a main bearing
Wear Limit: 0.40 mm (0.016 in.) cap and a crankshaft cheek, using care not to dam-
age any bearing surface. Do not loosen main bearing
FITTING CRANKSHAFT BEARINGS cap.
Refer to Measuring Main Bearing Clearance in (2) Use a feeler gauge between number three
Standard Service Procedures. Refer to Crankshaft thrust bearing and machined crankshaft surface to
Specification Chart for specifications. determine end play.
INSTALLATION
Before installation, clean cylinder head and cover
mating surfaces. Make certain the cylinder head
cover mating surface is flat.
(1) Install new valve cover gasket.
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. Refer to Group 14,
Fuel System
(2) Remove the cylinder head cover. Refer to proce-
dure outlined in this section.
(3) Mark rocker arm shaft assemblies so that they
are installed in their original positions.
(4) Remove rocker arm shaft bolts. Refer to proce-
dure outlined in this section.
(5) Remove timing belt, timing belt tensioner, and
camshaft sprocket. Refer to timing belt service out-
lined in this section.
(6) Remove inner timing belt cover.
Fig. 11 Servicing Spark Plug Tubes (7) Remove cylinder head. Refer to procedure out-
(3) Clean area around spark plug with Mopart lined in this section.
parts cleaner or equivalent. (8) Remove camshaft sensor and camshaft target
(4) Apply Mopart Stud and Bearing Mount or magnet.
equivalent to a new tube approximately 1 mm from (9) Remove camshaft from the rear of cylinder
the end in a 3 mm wide area. head.
(5) Install sealer end of tube into the cylinder
head. Then carefully install the tube using a hard- INSPECT CYLINDER HEAD FOR THE FOLLOWING:
wood block and mallet until the tube is seated into
the bottom of the bore. NOTE:
(6) Install valve cover. Refer to procedure outlined • Check oil feed holes for blockage.
in this section. • Inspect cylinder head camshaft bearings for
wear, Refer to Cylinder Head, Inspection and Clean-
SPARK PLUG TUBE SEALS ing.
The spark plug tube seals are located in the cylin- • Check camshaft bearing journals for scratches
der head cover (Fig. 12). These seals are pressed into and worn areas. If light scratches are present, they
the cylinder head cover to seal the outside perimeter may be removed with 400 grit sand paper. If deep
9-8 ENGINE NS/GS
REMOVAL AND INSTALLATION (Continued)
scratches are present, replace the camshaft and (9) Install timing belt tensioner and timing belt.
check the cylinder head for damage. Replace the Refer to procedures outlined in this section.
cylinder head if worn or damaged. Check the lobes (10) Install rocker arm assemblies in correct order
for pitting and wear. If the lobes show signs of as removed. Tighten the rocker arm assemblies in
wear, check the corresponding rocker arm roller for sequence shown in (Fig. 14) to 28 N·m (250 in. lbs.).
wear or damage. Replace rocker arm/hydraulic lash
adjuster if worn or damaged. If lobes show signs of
pitting on the nose, flank or base circle; replace the
camshaft.
INSTALLATION
(1) Lubricate the camshaft journals with oil and
install camshaft without rocker arm assemblies
installed.
(2) Install camshaft target magnet into the end of
the camshaft. Tighten mounting screw to 3.4 N·m (30
in. lbs.).
(3) Install camshaft position sensor and tighten
mounting screws to 9 N·m (80 in. lbs.).
(4) Measure camshaft end play using the following
procedure:
• Mount dial indicator C-3339 or equivalent, to a Fig. 14 Rocker Arm Shaft Tightening Sequence
stationary point on cylinder head (Fig. 13). (11) Install cylinder head cover and tighten fasten-
• Using a suitable tool, move camshaft to rear- ers to 12 N·m (105 in. lbs.).
ward limits of travel. (12) Install ignition coil pack and ignition cables.
• Zero the dial indicator. (13) Perform camshaft and crankshaft timing
• Move camshaft forward to limits of travel and relearn procedure as follows:
read dial indicator. • Connect the DRB scan tool to the data link
• End play travel: 0.13 - 0.33 mm (0.005 - 0.013 (diagnostic) connector. This connector is located in
in.). the passenger compartment; at the lower edge of
instrument panel; near the steering column.
• Turn the ignition switch on and access the “mis-
cellaneous” screen.
• Select “re-learn cam/crank” option and follow
directions on DRB screen.
REMOVAL
(1) Remove rocker arm shafts assemblies as previ-
ously 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 MD-998772A with adapter
6779 (Fig. 19) compress valve springs and remove
valve locks.
CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. Refer to Group 14,
Fig. 19 Removing and Installing Valve Spring Fuel System
(5) Remove valve spring. (2) Disconnect negative battery cable. Drain cool-
(6) Remove valve stem seal by using a valve stem ing system. Refer to Group 7, Cooling System.
seal tool (Fig. 20). (3) Disconnect all vacuum lines, electrical wiring
and fuel lines from throttle body.
(4) Remove throttle linkage.
(5) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(6) Remove power brake vacuum hose from intake
manifold.
(7) Raise vehicle and remove exhaust pipe from
manifold.
(8) Remove power steering pump assembly and set
aside.
(9) Disconnect coil pack wiring connector and
remove coil pack and bracket from engine.
(10) Remove cylinder head cover.
(11) Remove cam sensor and fuel injectors wiring
Fig. 20 Valve Stem Oil Seal Tool connectors.
(12) Remove intake manifold. Removal procedure
outline in Group 11.
NS/GS ENGINE 9 - 11
REMOVAL AND INSTALLATION (Continued)
Fig. 31 Timing Belt Cover (3) When plunger is compressed into the tensioner
CAMSHAFT AND CRANKSHAFT TIMING body install a 1.9 mm (5/64) allen wrench or pin
PROCEDURE AND BELT INSTALLATION through the body and plunger to retain plunger in
—SOHC ENGINE place until tensioner is installed.
(1) When tensioner is removed from the engine it (4) Set crankshaft sprocket to TDC by aligning the
is necessary to compress the plunger into the ten- sprocket with the arrow on the oil pump housing,
sioner body. then back off to 3 notches before TDC (Fig. 35).
NS/GS ENGINE 9 - 15
REMOVAL AND INSTALLATION (Continued)
Fig. 34 Compressing Timing Belt Tensioner Fig. 37 Adjusting Crankshaft Sprocket for Timing
Belt Installation
OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove transmission inspection cover. Fig. 42 Right Inner Splash Shield
(3) If equipped with air conditioning remove oil fil- (5) Clean oil pan and all gasket surfaces.
ter and adaptor. Refer to Oil Filter Adapter Removal
and Installation in this section.
(4) Remove oil pan.
9 - 18 ENGINE NS/GS
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block. Install O-ring
into recess in the block (Fig. 65).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
Fig. 62 Rear Crankshaft Seal—Installation
CAUTION: Do not pry up on one side of the bed- CAUTION: Do Not get oil on the bedplate mating
plate. Damage may occur to cylinder block and bed- surface. It will affect the sealer ability to seal the
plate alignment. bedplate to cylinder block.
NS/GS ENGINE 9 - 23
REMOVAL AND INSTALLATION (Continued)
PISTON RINGS—INSTALLATION
(1) Install rings with manufacturers I.D. mark fac-
ing up, to the top of the piston (Fig. 78).
Fig. 73 Front Crankshaft Seal—Installation
CAUTION: Install piston rings in the following
order: b. Upper oil ring side rail.
c. Lower oil ring side rail.
a. Oil ring expander. d. No. 2 Intermediate piston ring.
NS/GS ENGINE 9 - 27
REMOVAL AND INSTALLATION (Continued)
VIBRATION DAMPER
NOTE: If a gap is found in the crankshaft damper,
in the area where the Poly-V Generator belt rides
this is normal and is acceptable (Fig. 82).
VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 87). Refer to Valve Guide Specification
Chart for specifications. Replace guides if they are
not within specification.
(3) Check valve guide height (Fig. 88).
Face Angle
Intake and 45 - 45 1/2°
Exhaust:
Head Diameter
Intake: 33.12 - 33.37 mm (1.303 - 1.313 in.)
Exhaust: 28.57 - 28.83 mm (1.124 - 1.135 in.)
Length (Overall)
Intake: 114.69 - 115.19 mm (4.515 - 4.535 in.)
Exhaust: 116.94 - 117.44 mm (4.603 - 4.623 in.)
Stem Diameter
Intake: 5.934 - 5.952 mm (0.2337 - 0.2344 in.)
Exhaust: 5.906 - 5.924 mm (0.2326 - 0.2333 in.)
Fig. 91 Valve Seat Refacing
Valve Margin
Intake: 1.15 - 1.48 mm (0.0452 - 0.0582 in.)
Exhaust: 1.475 - 1.805 mm (0.0580 - 0.0710 in.)
Fig. 96 Measuring Outer Rotor Thickness Fig. 98 Measuring Outer Rotor Clearance in
(4) If inner rotor measures 7.64 mm (.301 inch) or Housing
less replace inner rotor (Fig. 97).
2.5L VM DIESEL
INDEX
page page
Run engine until achieving normal operating tem- ENGINE OIL FILTER CHANGE
perature. (1) Position a drain pan under the oil filter.
(1) Position the vehicle on a level surface and turn (2) Using a suitable oil filter wrench loosen filter.
engine off. (3) Rotate the oil filter counterclockwise to remove
(2) Remove oil fill cap. it from the oil filter base (Fig. 6).
(3) Hoist vehicle. Refer to Hoisting and Jacking
Recommendations.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan (Fig. 5). Inspect drain plug
threads for stretching or other damage. Replace
drain plug if damaged.
TIMING PROCEDURE
CAUTION: If a timing gear is removed you must
loosen the rocker arm supports before rotating the
crankshaft or camshaft. This will prevent the valves
hitting the pistons.
MOUNT—LEFT SIDE
(1) Raise vehicle on hoist and remove left front
wheel.
Fig. 13 Measuring Crankshaft End Play
(2) Remove inner splash shield.
NOTE: If engine is disassembled refer to Crank- (3) Support the transmission with a transmission
shaft Main Bearing Removal and Installation for this jack.
procedure. (4) Remove the insulator thru bolt from the mount
(Fig. 16).
(5) Remove the transmission mount bolts and
REMOVAL AND INSTALLATION remove mount. It may be necessary to lower trans-
mission slightly to remove mount.
ENGINE MOUNT—FRONT (6) Reverse removal procedure for installation.
(1) Disconnect battery. (7) Install mount. Torque transmission mount bolts
(2) Remove lower air dam at front fascia. to 54 N·m (40 ft. lbs.).
(3) Remove the bolts holding tow bracket and front (8) Align mount into frame bracket with transmis-
mount to the lower crossmember. sion jack, install thru bolt. Torque thru bolt to 71
N·m (53 ft. lbs.).
9 - 52 ENGINE NS/GS
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Install valve spring and retainer.
(2) Compress the valve spring with Valve Spring
Compressor Tool and insert the valve locks. Release
the spring tension and remove the tool. Tap the
spring from side-to-side to ensure that the spring is
seated properly on the engine cylinder head.
(3) Disconnect the air hose. Remove the adaptor
from the fuel injector hole and install the fuel injec-
tor.
(4) Repeat the procedures for each remaining valve
Fig. 22 Rocker Arm Retaining Nut spring to be removed.
(5) Install the push rods. Ensure the bottom end of
(3) Install cylinder head cover, torque nuts to 14.7 each rod is centered in the plunger cap seat of the
N·m (132 in. lbs.). hydraulic valve tappet.
(4) Install coolant pressure tank. (6) Install the rocker arm assemblies, at their orig-
(5) Install breather hose. inal location.
(6) Install generator bracket, tighten bolts to 7 (7) Tighten the rocker arm assembly nut to 106
N·m (4 ft. lbs.). N·m (78 ft. lbs.) torque.
(7) Connect the service valves to the A/C compres- (8) Install the engine cylinder head cover, refer to
sor ports, if equipped with air conditioning. cylinder head cover installation in this section.
(8) Connect battery cable.
CYLINDER HEAD
VALVE SPRINGS—CYLINDER HEAD NOT
REMOVED REMOVAL
This procedure can be done with the engine cylin- (1) Disconnect the battery cable.
der head installed on the block.
WARNING: DO NOT REMOVE THE CYLINDER
REMOVAL BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
Each valve spring is held in place by a retainer DRAIN COCK WITH THE SYSTEM HOT AND PRES-
and a set of conical valve locks. The locks can be SURIZED BECAUSE SERIOUS BURNS FROM THE
removed only by compressing the valve spring. COOLANT CAN OCCUR.
(1) Remove the engine cylinder head cover, refer to
cylinder head cover removal in this section. (2) Drain the cooling system. Refer to Group 7,
(2) Remove rocker arms assemblies for access to Cooling.
each valve spring to be removed. (3) Remove wiper module. Refer to Group 8K,
(3) Remove push rods. Retain the push rods, and Windshield Wiper Unit Removal for procedure.
rocker arms assemblies in the same order and posi- (4) Remove coolant pressure bottle.
tion as removed. (5) Remove intercooler hose at intake manifold
(4) Inspect the springs and retainer for cracks and (Fig. 23).
possible signs of weakening. (6) Remove intercooler hose at turbocharger inter-
(5) Install an air hose adaptor in the fuel injector cooler tube.
hole. (7) Remove the upper radiator hose.
(6) Connect an air hose to the adapter and apply (8) Remove water manifold.
air pressure slowly. Maintain at least 621 kPa (90 (9) Disconnect the heater hoses and coolant pres-
sure bottle hoses.
9 - 56 ENGINE NS/GS
REMOVAL AND INSTALLATION (Continued)
Fig. 24 Turbocharger
(10) Disconnect EGR tube from EGR valve (Fig.
25).
(11) Remove exhaust pipe from turbocharger elbow
and.
(12) Disconnect oil feed line from turbo (Fig. 24).
(13) Disconnect oil drain line from turbo. Fig. 26 Rocker Arm Oil Feed Lines
(14) Remove Intake manifold. Refer to Group 11,
Exhaust System and Intake Manifold. (20) Remove Crankcase breather hose from valve
(15) Remove lift eye and brake vacuum tube at cover
rear of exhaust manifold. (21) Remove the engine cylinder head cover.
NS/GS ENGINE 9 - 57
REMOVAL AND INSTALLATION (Continued)
(22) Remove the injector sensor wire at the con-
nector, and glow plug Connectors.
(31) Stuff clean lint free shop towels into the cyl-
inder bores.
REMOVAL
(1) Remove the engine cylinder head from the cyl-
inder block. Refer to cylinder head removal in this
section.
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
INSTALLATION
(1) Fit each valve to its respective valve guide.
Fig. 34 Tappet and Rocker Arm Assembly
NOTE: If valves and valve seats have been refaced
refer to Service Procedures in this section. Follow
The Valve Stand Down procedure.
HYDRAULIC TAPPETS
REMOVAL
(1) Remove coolant pressure bottle.
(2) Remove cylinder head cover. Refer to cylinder
head cover removal in this section.
(3) Remove rocker assembly and push rods. Iden-
tify push rods to ensure installation in original loca- Fig. 35 Tappet and Yoke
tion (Fig. 34).
(4) Remove cylinder head, intake manifold, and CAUTION: The plunger and tappet bodies are not
exhaust manifold. Refer to cylinder head removal in interchangeable. The plunger and valve must
this section. always be fitted to the original body. It is advisable
(5) Remove yoke retainer and aligning yokes (Fig. to work on one tappet at a time to avoid mixing of
35). parts. Mixed parts are not compatible. DO NOT dis-
(6) Slide Hydraulic Tappet Remover/Installer Tool assemble a tappet on a dirty work bench.
through opening in block and seat tool firmly in the
head of tappet. INSTALLATION
(7) Pull tappet out of bore with a twisting motion. (1) Lubricate tappets.
If all tappets are to be removed, identify tappets to (2) Install tappets and yoke retainers in their orig-
ensure installation in original location. inal positions. Ensure that the oil feed hole in the
(8) If the tappet or bore in cylinder block is scored, side of the tappet body faces up (away from the
scuffed, or shows signs of sticking, ream the bore to crankshaft).
next oversize. Replace with oversize tappet.
NS/GS ENGINE 9 - 61
REMOVAL AND INSTALLATION (Continued)
(3) Install cylinder head, intake manifold, and (4) Install both accessary drive belts. Refer to
exhaust manifold. Refer to cylinder head installation Group 7, Cooling.
in this section. (5) Install right splash shield.
(4) Install push rods in original positions. (6) Lower vehicle.
(5) Install rocker arms in original positions. (7) Connect the battery cable.
(6) Install cylinder head cover. Refer to cylinder
valve cover installation in this section. TIMING GEAR COVER OIL SEAL
(7) Start and operate engine. Warm up to normal
operating temperature. REMOVAL
(1) Disconnect the battery cable.
CAUTION: To prevent damage to valve mechanism, (2) Remove vibration damper. Refer to vibration
engine must not be run above fast idle until all damper removal in this section.
hydraulic tappets have filled with oil and have (3) Pry out seal (Fig. 36).
become quiet.
INSTALLATION
Remove the oil seal ring. The seating diameter
VIBRATION DAMPER must be 68.000 - 68.030 mm.
(1) Install new seal using special tool VM-1015.
REMOVAL (2) Install vibration damper. Refer to vibration
(1) Disconnect the battery cable. damper installation in this section.
(2) Raise vehicle on hoist. (3) Connect the battery cable.
(3) Remove right side lower splash shield.
(4) Remove generator, power steering belt. Refer to
Group 7, Cooling.
(5) Remove water pump belt. Refer to Group 7,
Cooling.
(6) Remove engine starter. Refer to Group, 8B for
procedure
(7) Install flywheel locking tool VM.1014 to pre-
vent engine rotation.
CAUTION: Remove old loctite from threads on (5) Install vibration damper.
pump.
CAUTION: Correct torque on the vibration damper
(8) Remove pump shaft support bracket assembly. nut is important or engine damage can occur.
(9) Disconnect the water drain pipe hose at the
timing cover. (6) Tighten vibration damper nut to 441 N·m (325
ft. lbs.).
CAUTION: When separating the timing geat cover (7) Install accessary drive belts. Refer to Group 7,
from the block take care not to damage the mating cooling for procedure.
surface of the timing gear cover or block. Also take (8) Install splash shield.
care not to damage the timing gears or components (9) Lower vehicle.
located inside the timing gear cover near the edge. (10) Connect battery cable.
(10) Remove timing gear cover.
CAMSHAFT
INSTALLATION
(1) Apply a continuous 3 mm bead of Silicone REMOVAL
Sealer to timing cover, install within 10 minutes, (1) To service the camshaft (Fig. 38) the engine
tighten Torx bolts to 11 N·m (96 in. lbs) (Fig. 37). must be removed from the vehicle.
CAMSHAFT BEARINGS
This procedure requires that the engine is removed
from the vehicle.
REMOVAL
(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
Tool) at back of each bearing shell. Drive out bearing
shells.
INSTALLATION
Fig. 39 Camshaft Removal (1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool by sliding the new
THRUST PLATE INSPECTION
camshaft bearing shell over proper adapter.
Check the thickness (Fig. 40) of the plate at points
(2) Position rear bearing in the tool. Install horse-
a-b-c-d. If the measurement is not between 3.950 -
shoe lock and by reversing removal procedure, care-
4.050 it must be changed.
fully drive bearing shell into place.
(3) Install remaining bearings in the same man-
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft. Be sure this plug does not leak.
CAUTION: Use NEW flywheel bolt for the following Fig. 44 Crankshaft and Carrier Bearing Assembly
procedure.
d. Loosen the last 2 bolts, 180° apart and follow
(22) Install new O-ring on flywheel. Install fly- the same procedure.
wheel. The 6 flywheel bolts must be tightened as fol- (23) Install Transmission. Refer to procedure in
lows: Group 21, Transmission.
a. Torque the 6 flywheel bolts to 60 N·m (44 ft. (24) Install pistons and connecting rod assemblies,
lbs.). refer to piston and connecting rods in this section.
b. Loosen 2 of the 6 bolts, 180° apart. Torque the 2 (25) Install oil pick up tube and tighten bolts to 25
bolts to 20 N·m (180 in. lbs.). Then using a torque N·m (18 ft. lbs.).
angle gauge rotate the 2 bolts 65° additional. (26) Install oil pan, refer to oil pan installation in
c. Loosen the next 2 bolts, 180° apart and follow this section.
the same procedure. (27) Install vacuum pump. Tighten retaining
screws to 20 N·m (15 ft. lbs.).
9 - 66 ENGINE NS/GS
REMOVAL AND INSTALLATION (Continued)
does not spin freely loosen bolts and perform pro-
cedures again.
VACUUM PUMP
REMOVAL
(1) Remove the front cover refer to front cover
removal in this section.
(2) Remove 4 bolts.
INSTALLATION
(1) To install the vacuum pump, align the outer
part of the gear with the inner part using a screw-
driver or similar tool, align with timing marks on
gear set and install.
(2) Install bolts and tighten to 20 N·m (15 ft. lbs.).
(3) Install front cover.
Fig. 54 Vacuum Pump Mounting Hole (8) After removal, install bearing cap on the mat-
covered during this operation. Mark piston with ing rod.
matching cylinder number.
PISTON PIN—REMOVAL
(6) Pistons and connecting rods must be removed
(1) Secure connecting rod in a soft jawed vice.
from top of cylinder block. Rotate crankshaft so that
(2) Remove 2 clips securing piston pin (Fig. 57).
each connecting rod is centered in cylinder bore.
(3) Push piston pin out of piston and connecting
(7) Remove connecting rod cap. Push each piston
rod.
and rod assembly out of cylinder bore.
PISTON—INSTALLATION
(1) Before installing pistons, and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 62).
CYLINDER LINER
REMOVAL
(1) Remove cylinder heads (refer to cylinder head
removal in this section).
(2) Remove Oil pan (refer to oil pan removal in
this section).
(3) Remove pistons (refer to piston removal in this
Fig. 64 Cylinder Liner—Removal
section).
(4) Use tool VM-1001 to remove liners (Fig. 64). the liners in position using special tool (VM-1016)
(5) Remove shims from cylinder liner or cylinder and bolts (Fig. 66). Clean the residual LOCTITE on
block recess. Keep shims with each cylinder liner. the upper surface of the block deck.
(9) Recheck the liner protrusion. It should be 0.01
INSTALLATION - 0.06 mm.
(1) Carefully clean residual sealer from liner and
crankcase, and degrease the crankcase where it NOTE: A period of six hours must elapse between
comes into contact with the liners. Referring to (Fig. the liners being installed and engine start-up. If
65), install the liners in the crankcase as shown (A), engine assembly is not continued after liner instal-
rotating them back and forth by 45° in order to guar- lation, the liners need to be clamped for twelve
antee correct positioning. hours minimum.
(2) Measure the liner recess relative to block deck
with a dial indicator mounted on a special tool (10) Refer to Cylinder Head Removal and Installa-
VM-1010 A. All the measurements must be taken tion procedure in this section. To measure piston pro-
on camshaft side. Zero dial gauge on block deck. trusion for installation of proper head gasket
(3) Move dial gauge to cylinder liner record read- thickness.
ing on dial gauge.
(4) Remove liner and special tool. CRANKSHAFT—REMOVAL
(5) Then select the correct shim thickness to give Refer to CRANKSHAFT MAIN BEARING
proper protrusion (0.01 - 0.06 mm). REMOVAL in this section.
(6) Fit the shim and the O-rings onto the liner.
(7) Lubricate the lower liner location in the block. REAR CRANKSHAFT OIL SEAL
Apply LOCTITE 275 to the corner of the liner seat.
REMOVAL
Apply LOCTITE 275 uniformly to the upper part of
(1) Remove transmission. Refer to Group 21,
the liner at area.
Transmission for removal procedure.
(8) Fit the liners in the crankcase making sure
(2) Remove flywheel.
that the shim is positioned correctly in the seat. Lock
NS/GS ENGINE 9 - 73
REMOVAL AND INSTALLATION (Continued)
INSPECTION
Inspect the pivot surface area of each rocker arm.
Replace any that are scuffed, pitted, cracked or
excessively worn.
Inspect the valve stem tip contact surface of each
rocker arm and replace any rocker arm that is deeply
pitted.
Inspect each push rod end for excessive wear and
replace as required. If any push rod is excessively
Fig. 67 Flywheel worn because of lack of oil, replace it and inspect the
retainer and plunger spring. Check valve could be corresponding hydraulic tappet for excessive wear.
flat or ball. Inspect the push rods for straightness by rolling
Assemble tappets in reverse order. them on a flat surface or by shining a light between
the push rod and the flat surface.
A wear pattern along the length of the push rod is
not normal. Inspect the engine cylinder head for
obstruction if this condition exists.
NS/GS ENGINE 9 - 75
CLEANING AND INSPECTION (Continued)
DESCRIPTION . . . . . . . . . . . SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . 425CLIEE (36B)
Number of Cylinder . . . . . . . . . . . . . . . . . . . . . . 4
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 mm
Capacity . . . . . . . . . . . . . . . . . . . . . . . 2499.5 cm3
Injection Order . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Compression Ratio . . . . . . . . . . . . . . . 21:1 (6 0.5)
Crankshaft
Fig. 78 Bearing Clearance Front Journal Diameter . . . . . . . . . . . . . . . . . . . .
(3) If internal diameter of original bearing is being Nominal . . . . . . . . . . . . . . . . . 62.985–63.000 mm
checked and figures are not within specifications, –0.25 . . . . . . . . . . . . . . . . . . . . 62.735–62.750 mm
new bearings must be used. –0.125 . . . . . . . . . . . . . . . . . . . 62.860–62.875 mm
(4) Check crankshaft main bearing journals to Front Bearing Diameter . . . . . . . . . . . . . . . . . . . .
bearing clearances. Clearances of main bearings is Nominal . . . . . . . . . . . . . . . . . 63.043–63.088 mm
.03 to .088mm (.0011 to .0035 in.). –0.25 . . . . . . . . . . . . . . . . . . . . 62.793–62.838 mm
–0.125 . . . . . . . . . . . . . . . . . . . 62.918–62.963 mm
OIL PAN Clearance Between Journal and Bearing:
Remove all gasket material from cylinder block. Be 0.043–0.103 mm . . . . . . . . . . . . . . . . . . . . . . . . . .
careful not gouge pan sealing surface. Center Journal Diameter . . . . . . . . . . . . . . . . . . .
NS/GS ENGINE 9 - 79
SPECIFICATIONS (Continued)
DESCRIPTION . . . . . . . . . . . SPECIFICATIONS DESCRIPTION . . . . . . . . . . . SPECIFICATIONS
Nominal . . . . . . . . . . . . . . . . . 63.005–63.020 mm Gasket thickness: . . . . . . . 1.52 6 0.1 mm 2 Holes
–0.25 . . . . . . . . . . . . . . . . . . . . 62.755–62.770 mm End Plates
–0.125 . . . . . . . . . . . . . . . . . . . 62.880–62.895 mm Height . . . . . . . . . . . . . . . . . . . . . 89.02–90.00 mm
Center Bearing Diameter . . . . . . . . . . . . . . . . . . . Connecting Rods
Nominal . . . . . . . . . . . . . . . . . 63.050–63.093 mm Weight (Without the crank
–0.25 . . . . . . . . . . . . . . . . . . . . 62.800–62.843 mm bearing) . . . . . . . . . . . . . . . . . . 1129–1195 grams
–0.125 . . . . . . . . . . . . . . . . . . . 62.925–62.968 mm Small End Bearing Internal Diameter
Clearance Between Journal and Bearing: Minimum . . . . . . . . . . . . . . . . . . . . . . . 30.035 mm
0.030–0.088 mm . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum . . . . . . . . . . . . . . . . . . . . . . 30.050 mm
Rear Journal Diameter . . . . . . . . . . . . . . . . . . . . . Crankshaft Bearings Standard Internal
Nominal . . . . . . . . . . . . . . . . . 79.980–80.000 mm Diameter . . . . . . . . . . . . . . . . . 53.997–54.016 mm
–0.25 . . . . . . . . . . . . . . . . . . . . 79.730–79.750 mm Pistons
–0.125 . . . . . . . . . . . . . . . . . . . 79.855–79.875 mm Skirt Diameter . . . . . . . . . . . . 91.935–91.945 mm
Rear Bearing Diameter . . . . . . . . . . . . . . . . . . . . . (Measured at approximately 15 mm above the
Nominal . . . . . . . . . . . . . . . . . 80.045–80.070 mm bottom of the skirt)
–0.25 . . . . . . . . . . . . . . . . . . . . 79.795–79.820 mm Piston Clearance . . . . . . . . . . . . . 0.055–0.075 mm
–0.125 . . . . . . . . . . . . . . . . . . . 79.920–79.945 mm Top of Piston to Cylinder Head . . . . 0.80–0.89 mm
Clearance Between Journal and Bearing: Piston Protrusion . . . . . 0.53–0.62 mm Fit Gasket
0.045–0.090 mm (Wear Limit: 0.200 mm) . . . . . . . (1.42), 0 Holes
Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . Piston Protrusion . . . . . 0.73–0.82 mm Fit Gasket
Nominal . . . . . . . . . . . . . . . . . 53.940–53.955 mm (1.62), 1 Hole
–0.25 . . . . . . . . . . . . . . . . . . . . 53.690–53.705 mm Piston Protrusion . . . . . 0.63–0.72 mm Fit Gasket
–0.125 . . . . . . . . . . . . . . . . . . . 53.815–53.830 mm (1.52), 2 Holes
Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . . Piston Pins
Nominal . . . . . . . . . . . . . . . . . 53.977–54.016 mm Type . . . . . . . . . . . . . . . . . . . . . . . . . Full Floating
–0.25 . . . . . . . . . . . . . . . . . . . . 53.727–53.766 mm Pin Diameter . . . . . . . . . . . . . . 29.990–29.996 mm
–0.125 . . . . . . . . . . . . . . . . . . . 53.852–53.891 mm Clearance . . . . . . . . . . . . . . . . . . 0.004–0.014 mm
Clearance Between Journal and Bearing: Piston Rings (Clearance in Groove)
0.022–0.076 mm (Wear Limit: 0.200 mm) . . . . . . . Top . . . . . . . . . . . . . . . . . . . . . . . 0.080–0.130 mm
Crankshaft End Play Second . . . . . . . . . . . . . . . . . . . . . 0.070–0.102 mm
End Play . . . . . . . . . . . . . . . . . . . . . 0.08–0.21 mm Oil Control . . . . . . . . . . . . . . . . . 0.040–0.072 mm
Adjustment . . . . . . . . . . . . . . . . . Thrust Washers Piston Rings (Fitted Gap)
Thrust Washers Available . . . . . . . . 2.31–2.36 mm Top . . . . . . . . . . . . . . . . . . . . . . . . . 0.25–0.50 mm
Thrust Washers Available . . . . . . . . 2.41–2.46 mm Second . . . . . . . . . . . . . . . . . . . . . . 0.20–0.35 mm
Thrust Washers Available . . . . . . . . 2.51–2.56 mm Oil Control . . . . . . . . . . . . . . . . . . . 0.25–0.58 mm
Main Bearing Carriers Camshaft
Front . . . . . . . . . . . . . . . . . . . . 67.025–67.050 mm Journal Diameter Front . . . . . 53.460–53.480 mm
Center . . . . . . . . . . . . . . . . . . . 66.670–66.690 mm Bearing Clearance . . . . . . . . . . . . . 0.06–0.13 mm
Rear . . . . . . . . . . . . . . . . . . . . 85.985–86.005 mm Journal Diameter Center . . . . 53.460–53.480 mm
Liners Bearing Clearance . . . . . . . . . . . . . 0.06–0.13 mm
Internal Diameter . . . . . . . . . . 92.000–92.010 mm Journal Diameter Rear . . . . . . 53.460–53.480 mm
Protrusion . . . . . . . . . . . . . . . . . . . . 0.01–0.06 mm Bearing Clearance . . . . . . . . . . . . . 0.06–0.13 mm
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . Shims Tappets
Available Shims: . . . . . . . . . . . . . . . . . . . 0.15 mm Outside Diameter . . . . . . . . . . 22.195–22.212 mm
Available Shims: . . . . . . . . . . . . . . . . . . . 0.17 mm Rocker Gear
Available Shims: . . . . . . . . . . . . . . . . . . . 0.20 mm Shaft Diameter . . . . . . . . . . . . . 21.979–22.00 mm
Available Shims: . . . . . . . . . . . . . . . . . . . 0.23 mm Bushing internal diameter . . . 22.020–22.041 mm
Available Shims: . . . . . . . . . . . . . . . . . . . 0.25 mm Assembly Clearance . . . . . . . . . . 0.020–0.062 mm
Cylinder Head Valves (Intake)
Minimum Thickness . . . . . . . . . . 89.95–90.05 mm Opens . . . . . . . . . . . . . . . . . . . . . . . . 26° B.T.D.C.
Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Closes . . . . . . . . . . . . . . . . . . . . . . . . 58° A.B.D.C.
Gasket thickness: . . . . . . . 1.42 6 0.1 mm 0 Holes Valves (Exhaust)
Gasket thickness: . . . . . . . 1.62 6 0.1 mm 1 Holes Opens . . . . . . . . . . . . . . . . . . . . . . . . 64° B.B.D.C.
Closes . . . . . . . . . . . . . . . . . . . . . . . . 38° A.T.D.C.
9 - 80 ENGINE NS/GS
SPECIFICATIONS (Continued)
DESCRIPTION . . . . . . . . . . . SPECIFICATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE
Valve Face Angle EGR Tube to EGR Valve
Intake . . . . . . . . . . . . . . . . . . . . . . . 55°30’– 55°50’ Bolts . . . . . . . . . . . . . . . . . . . . 26 N·m (19 ft. lbs.)
Exhaust . . . . . . . . . . . . . . . . . . . . . 45°25’– 45°35’ Engine Mount—Front
Valve Head Diameter Support Bracket Engine Bolts . 68 N·m (50 ft. lbs.)
Intake . . . . . . . . . . . . . . . . . . . . . 40.05–40.25 mm Support Bracket Transmission
Exhaust . . . . . . . . . . . . . . . . . . . . . 33.8–34.0 mm Bolts . . . . . . . . . . . . . . . . . . . 101 N·m (75 ft. lbs.)
Valve Head Stand Down Support Cushion Crossmember
Intake . . . . . . . . . . . . . . . . . . . . . . . 1.08–1.34 mm Bolts . . . . . . . . . . . . . . . . . . . . 54 N·m (40 ft. lbs.)
Exhaust . . . . . . . . . . . . . . . . . . . . . 1.99–1.25 mm Support Cushion Thru Bolt . . . 65 N·m (48 ft. lbs.)
Valve Stem Diameter Engine Mount—Rear
Intake . . . . . . . . . . . . . . . . . . . . . 7.940–7.960 mm Support Bracket Transmission
Exhaust . . . . . . . . . . . . . . . . . . . . 7.922–7.940 mm Bolts . . . . . . . . . . . . . . . . . . . 101 N·m (75 ft. lbs.)
Valve Clearance in Guide Support Bracket to Engine
Intake . . . . . . . . . . . . . . . . . . . . . 0.040–0.075 mm Bracket . . . . . . . . . . . . . . . . . 101 N·m (75 ft. lbs.)
Exhaust . . . . . . . . . . . . . . . . . . . . 0.060–0.093 mm Support Cushion Thru Bolt . . . 68 N·m (50 ft. lbs.)
Valve Guide Engine Mount—Left
Inside Diameter . . . . . . . . . . . . . . . 8.0–8.015 mm Transmission Mounting Bolts . 54 N·m (40 ft. lbs.)
Fitted Height . . . . . . . . . . . . . . . . . 13.5–14.0 mm Support Cushion Thru Bolt . . . 71 N·m (53 ft. lbs.)
Valve Spring Engine Mount—Right
Free Length . . . . . . . . . . . . . . . . . . . . . 44.65 mm Mount to Frame Rail Bolts . . . 68 N·m (50 ft. lbs.)
Fitted Length . . . . . . . . . . . . . . . . . . . . . 38.6 mm Mount Bolt (Horizontal) . . . 145 N·m (107 ft. lbs.)
Load at Fitted Length . . . . . . . . . . . . 34 6 6% Kg Mount Bolt (Vertical) . . . . . . . 101 N·m (75 ft. lbs.)
Load at Top of Lift . . . . . . . . . . . . . 92.5 6 4% Kg Right Engine Mount Bracket
Number of Coils . . . . . . . . . . . . 5.33 Valve Timing Bolts . . . . . . . . . . . . . . . . . . . . 40 N·m (30 ft. lbs.)
Oil Pressure Exhaust Pipe to Turbocharger
at 4000 rpm . . . . . 3.0 to 4.5 bar (Oil at 90–100°C) Bolts . . . . . . . . . . . . . . . . . . . 28 N·m (250 in. lbs.)
Pressure Relief Valve Opens . . . . . . . . . . 6.38 bar Exhaust Manifold Outlet to Turbo
Pressure Relief Valve–Free Length . . . . . 57.5 mm Nuts . . . . . . . . . . . . . . . . . . . . 32 N·m (24 ft. lbs.)
Oil Pump Exhaust Elbow to Turbo
Outer Rotor End Float . . . . . . . . . . 0.03–0.09 mm Bolts . . . . . . . . . . . . . . . . . . . . 30 N·m (22 ft. lbs.)
Inner Rotor End Float . . . . . . . . . . 0.03–0.09 mm Exhaust Manifold Mounting
Outer Rotor to Body Diameter Nuts . . . . . . . . . . . . . . . . . . . . 30 N·m (22 ft. lbs.)
Clearance . . . . . . . . . . . . . . . . . . 0.130–0.230 mm Flywheel
Rotor Body to Drive Gear Clearance (Pump Not Bolts . . . . . See Rear Crankshaft Seal Installation
Fitted) . . . . . . . . . . . . . . . . . . . . . . 3.27–3.73 mm Procedure
Engine Adaptor Plate
TORQUE Bolts . . . . . . . . . . . . . . . . . . . . 47 N·m (35 ft. lbs.)
Front Timing Gear Cover
DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE
Bolts . . . . . . . . . . . . . . . . . . . . 11 N·m (96 in. lbs.)
Generator Mounting Bracket
Fuel Filter
Bolts . . . . . . . . . . . . . . . . . . . . 47 N·m (35 ft. lbs.)
Nuts . . . . . . . . . . . . . . . . . . . 28 N·m (250 in. lbs.)
Camshaft Thrust Plate Retaining Bolts
Glow Plugs
Bolt . . . . . . . . . . . . . . . . . . . . . 24 N·m (18 ft. lbs.)
Plugs . . . . . . . . . . . . . . . . . . 14 N·m (120 in. lbs.)
Cylinder Head
Idler Pulley Pump Support Bracket
Bolts . . See Cylinder Head Installation Procedure
Nuts . . . . . . . . . . . . . . . . . . . 26 N·m (228 in. lbs.)
Connecting Rod
Idler Pulleys (left handed threads)
Bolts . . . . . . . . . . . 29.5 N·m +60° (22 ft. lbs. +60°)
Bolts . . . . . . . . . . . . . . . . . . . . 47 N·m (35 ft. lbs.)
Crankshaft Bearing Carrier
Injector Pump fuel lines
Bolts . . . . . . . . . . . . . . . . . . . . 44 N·m (32 ft. lbs.)
Nuts . . . . . . . . . . . . . . . . . . 17.6 N·m (156 in. lbs.)
Crankshaft damper (Pulley)
Injector Pump Gear
Nut . . . . . . . . . . . . . . . . . . . 441 N·m (325 ft. lbs.)
Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . 86 N·m
EGR Valve to Intake Manifold
Injector Pump Mounting
Tube . . . . . . . . . . . . . . . . . . . . 26 N·m (19 ft. lbs.)
Nuts . . . . . . . . . . . . . . . . . . 27.5 N·m (240 in. lbs.)
NS/GS ENGINE 9 - 81
SPECIFICATIONS (Continued)
DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE SPECIAL TOOLS
Injector
Tighten to . . . . . . . . . . . . . . . . 65 N·m (48 ft. lbs.) 2.5L VM DIESEL
Intake Manifold Mounting
Nuts . . . . . . . . . . . . . . . . . . . 30 N·m (264 in. lbs.)
Main Bearing Oil Delivery Union
Bolts . . . . . . . . . . . . . . . . . . . . 54 N·m (40 ft. lbs.)
Oil Feed Line To Rocker Arms
Bolts . . . . . . . . . . . . . . . . . 12.7 N·m (108 in. lbs.)
Oil Feed Line to Block
Bolts . . . . . . . . . . . . . . . . . 12.7 N·m (108 in. lbs.)
Oil Feel Line to Vacuum Pump
Bolts . . . . . . . . . . . . . . . . . 16.7 N·m (145 in. lbs.)
Oil Filter
Tighten to . . . . . . . . . . . . . . . 9.8 N·m (85 in. lbs.)
Oil Filter Adaptor
Fastener . . . . . . . . . . . . . . . . . 49 N·m (36 ft. lbs.)
Oil Filter Base
Fastener . . . . . . . . . . . . . . . . . 49 N·m (36 ft. lbs.)
Oil Pan Mounting Crankshaft Pulley and Gear Remover VM.1000A
Bolts . . . . . . . . . . . . . . . . . . . 12 N·m (108 in. lbs.)
Oil Pickup Tube
Bolts . . . . . . . . . . . . . . . . . . 11.3 N·m (100 in. lbs.)
Oil Pump Mounting
Bolts . . . . . . . . . . . . . . . . . 27.5 N·m (240 in. lbs.)
Oil Pan Drain
Plug . . . . . . . . . . . . . . . . . . . . . 54 N·m (40 ft. lbs.)
Power Steering Pressure Hose
Fastener . . . . . . . . . . . . . . . . 28 N·m (240 in. lbs.)
Power Steering Pulley
Nut . . . . . . . . . . . . . . . . . . . 170 N·m (125 ft. lbs.)
Rear Crankshaft Bearing Carrier
Bolts . . . . . . . . . . . . . . . . . . 10.8 N·m (95 in. lbs.)
Rocker Arm Cover
Bolts . . . . . . . . . . . . . . . . . 14.7 N·m (132 in. lbs.)
Rocker Arm Mounting
Cylinder Liner Puller VM.1001
Nuts . . . . . . . . . . . . . . . . . . 29.4 N·m (264 in. lbs.)
Power Steering Pump Mounting
Nuts . . . . . . . . . . . . . . . . . . 24.5 N·m (216 in. lbs.)
Turbocharger Mounting
Nuts . . . . . . . . . . . . . . . . . . . 32 N·m (288 in. lbs.)
Turbocharger Oil Delivery
Bolt . . . . . . . . . . . . . . . . . . 27.5 N·m (240 in. lbs.)
Turbocharger Oil Drain
Bolts . . . . . . . . . . . . . . . . . . 10.8 N·m (95 in. lbs.)
Vacuum Pump Mounting
Bolts . . . . . . . . . . . . . . . . . . 10.8 N·m (95 in. lbs.)
Water Manifold Mounting
Bolts . . . . . . . . . . . . . . . . . . 11.8 N·m (108 in. lbs.)
Water Pump Pulley
Bolts . . . . . . . . . . . . . . . . . 27.5 N·m (240 in. lbs.)
page page
HEAT SHIELDS
Heat shields (Fig. 2) are needed to protect both the
vehicle and the floor pan from the high temperatures
developed near the catalytic converter and muffler.
Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
Fig. 3 Flex-Joint
equipped. Light over spray near the edges is
permitted. Application of coating will greatly
INSTALLATION
(1) Assemble pipes, muffler support and clamp
loosely to permit alignment of all parts.
(2) Beginning at front of system, align and clamp
each component to maintain position and proper
clearance with underbody parts.
(3) Tighten the clamp and support to the proper
torques and clearances (Fig. 4).
(14) Remove upper intake manifold bolts. Remove Fig. 10 Intake Manifold Rear Support Bracket
upper intake manifold.
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD NS
REMOVAL AND INSTALLATION (Continued)
(12) Install air intake tube and resonator box to
throttle body.
(13) Connect negative cable to battery.
REMOVAL
(1) Perform fuel system pressure release proce-
dure before attempting any repairs.
(2) Remove upper intake manifold. Refer to proce-
dure in this section.
INSTALLATION
INSTALLATION
(1) Position new intake manifold gaskets on cylin-
der head and install intake (cross) manifold.
(2) Install nuts and washers and tighten in sev-
eral steps in order shown in (Fig. 26) to 20 N·m (174
in. lbs.). Fig. 26 Fastener Tightening Sequence for Intake
(3) Make sure the injector holes are clean and all (Cross) Manifold
plugs have been removed. (7) Install fuel supply and the vacuum crossover
(4) Lube injector O-ring with a drop of clean tube hold-down bolt and torque to 10 N·m (95 in.
engine oil to ease installation. lbs.).
(5) Put the tip of each injector into their ports. (8) Remove covering from lower intake manifold
Push the assembly into place until the injectors are and clean surface.
seated in the ports. (9) Place intake manifold gaskets with beaded
(6) Install the fuel rail attaching bolts and torque sealant side up on lower manifold. Put air intake in
to 13 N·m (115 in. lbs.). place. Install attaching fasteners and tighten in sev-
eral steps in sequence shown (Fig. 27) to 13 N·m (115
in. lbs.).
NS EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11
REMOVAL AND INSTALLATION (Continued)
(2) Disconnect Oxygen Sensor lead wire at the
rear exhaust manifold (Fig. 28).
(3) Remove bolts attaching cross-over pipe to
manifold (Fig. 30).
(4) Remove rear heat shield (Fig. 29).
(5) Remove nuts attaching rear manifold to cylin-
der head and remove manifold.
INSTALLATION
(1) Install rear exhaust manifold and tighten
attaching bolts to 23 N·m (200 in. lbs.).
(2) Install generator.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Band Clamp (Torca)
Fastener . . . . . . . . . . . . . . . . . .75 N·m (55 ft. lbs.)
Exhaust Manifold—2.4L
Fastener . . . . . . . . . . . . . . . . .23 N·m (200 in. lbs.)
Exhaust Manifold—3.0L
Nuts . . . . . . . . . . . . . . . . . . . .22 N·m (191 in. lbs.)
Exhaust Manifold—3.3/3.8L
Fastener . . . . . . . . . . . . . . . . .23 N·m (200 in. lbs.)
Exhaust Manifold—3.3/3.8L
Stud . . . . . . . . . . . . . . . . . . . .23 N·m (200 in. lbs.)
Exhaust Manifold Heat Shield—3.0L
Fasteners . . . . . . . . . . . . . . . .15 N·m (130 in. lbs.)
Exhaust Manifold Heat Shield—3.3/3.8L
Fasteners . . . . . . . . . . . . . . . .12 N·m (105 in. lbs.)
Exhaust Manifold Crossover—3.0L
Bolts . . . . . . . . . . . . . . . . . . . . .69 N·m (51 ft. lbs.)
Exhaust Manifold Crossover—3.3/3.8L
Fasteners. . . . . . . . . . . . . . . . . .54 N·m (40 ft. lbs.)
Exhaust Manifold Flange (All)
Fastener . . . . . . . . . . . . . . . . .28 N·m (250 in. lbs.)
Heat Shield—Muffler
Fastener . . . . . . . . . . . . . . . . . . .2 N·m (23 in. lbs.)
Heat Shield—Toe Board
Fastener . . . . . . . . . . . . . . . . . . .2 N·m (23 in. lbs.)
Insulator Mounting Bracket
on Muffler to Body
Bolts . . . . . . . . . . . . . . . . . . . .28 N·m (250 in. lbs.)
Insulator Mounting Bracket
on Resonator to Body
Bolts . . . . . . . . . . . . . . . . . . . .28 N·m (250 in. lbs.)
Intake Manifold Gasket Retainer
Fastener . . . . . . . . . . . . . . . . .12 N·m (105 in. lbs.)
Intake Air Plenum—3.0L
Bolts . . . . . . . . . . . . . . . . . . . .15 N·m (130 in. lbs.)
Intake (Cross) Manifold—3.0L
Bolts . . . . . . . . . . . . . . . . . . . .20 N·m (174 in. lbs.)
Intake Plenum Support Bracket—3.3/3.8L
Fastener . . . . . . . . . . . . . . . . . .54 N·m (40 ft. lbs.)
Intake Manifold—2.4L
Fastener . . . . . . . . . . . . . . . . .28 N·m (250 in. lbs.)
Intake Manifold Upper—2.4L
Bolts . . . . . . . . . . . . . . . . . . . .28 N·m (250 in. lbs.)
Intake Manifold—3.3/3.8L
Fastener . . . . . . . . . . . . . . . . .23 N·m (200 in. lbs.)
Intake Manifold Plenum—3.3/3.8L
Bolts . . . . . . . . . . . . . . . . . . . .28 N·m (250 in. lbs.)
Muffler Hanger Support Clamp
Fastener . . . . . . . . . . . . . . . . .17 N·m (150 in. lbs.)
NS FRAME AND BUMPERS 13 - 1
page page
INDEX
page page
INSTALLATION
(1) Position rear fascia on vehicle.
(2) Engage fascia tabs under liftgate.
(3) Engage hooks on sides of fascia to tabs in rear
fascia brackets.
FRAME
INDEX
page page
REMOVAL AND INSTALLATION (13) Separate high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
FRONT CROSSMEMBER (15) Remove bolts holding anti-lock brake sensor
The front suspension crossmember must be leads to crossmember.
installed in the design location to achieve proper (16) Position anti-lock brake leads out of the way.
front end suspension alignment. If the crossmember (17) Disconnect stabilizer bar links from ends of
is removed without applying reference marks on the stabilizer bar. Refer to Group 2, Suspension.
frame rails, align the crossmember according to the (18) Disconnect lower ball joints from lower control
dimensions provided in this group. arms. Refer to Group 2, Suspension.
(19) Remove bolt holding rear engine mount to
NOTE: If the caged nuts in the frame rails become crossmember (Fig. 2).
damaged and cannot be reused, a replacement nut (20) Using paint or grease pencil, mark outline of
can be obtained through a MoparT Parts supplier. crossmember on frame rails to aid installation.
(21) Support crossmember on suitable lifting
device (Fig. 4).
REMOVAL (22) Remove bolts holding crossmember to front
(1) Disconnect battery negative cable. frame rails (Fig. 3).
(2) Remove steering column lower cover from (23) Remove crossmember from vehicle (Fig. 4).
instrument panel. Refer to Group 8E, Instrument
Panel and Systems.
(3) Remove knee blocker reinforcement. Refer to
Group 8E, Instrument Panel and Systems.
(4) Position steering so front wheels are straight
ahead.
Fig. 4 Crossmember
NS FRAME AND BUMPERS 13 - 5
REMOVAL AND INSTALLATION (Continued)
(7) Connect lower ball joints to lower control arms. (2) Insert lower half of bushing into square hole in
Refer to Group 2, Suspension. crossmember.
(8) Connect stabilizer bar links to ends of stabi- (3) Place upper half of bushing on top of cross-
lizer bar. Refer to Group 2, Suspension. member aligned to receive square tube protruding
(9) Install bolts to hold anti-lock brake sensor upward from lower bushing half.
leads to crossmember. (4) Squeeze bushing halves together to ensure they
(10) Install high pressure hose to pump. are properly mated.
(11) Connect return hose to metal tube. (5) Lift crossmember upward to close gap between
(12) Tighten hose clamp at the crossmember cou- the bushing and frame.
pling. (6) Verify that lower bushing is fully seated into
(13) Remove pinch-off pliers. crossmember and upper bushing.
(14) Position steering so front wheels are straight (7) Install bolt to hold bushing and crossmember
ahead. to frame rail hand tight.
(15) Install steering column coupling to telescoping (8) Align crossmember to reference marks on
steering gear shaft. frame rails.
(16) Install clinch bolt to hold steering column cou- (9) Tighten crossmember to frame rails attaching
pling to steering gear shaft. bolts to 163 N·m (120 ft. lbs.) torque.
(17) Install knee blocker reinforcement. Refer to
Group 8E, Instrument Panel and Systems.
(18) Install steering column lower cover from SPECIFICATIONS
instrument panel. Refer to Group 8E, Instrument
Panel and Systems. FRAME AND BODY OPENING DIMENSIONS
(19) Connect battery negative cable. Frame dimensions are listed in metric scale. All
dimensions are from center to center of Principal
FRONT CROSSMEMBER MOUNT BUSHINGS Locating Point (PLP), or from center to center of PLP
and fastener location.
REMOVAL
(1) Using paint or grease pencil, mark outline of VEHICLE PREPARATION
crossmember on frame rails. Position the vehicle on a frame alignment rack,
(2) Loosen bolts holding crossmember to frame refer to instructions provided with equipment being
rails. used. Adjust the vehicle PLP heights to the specified
(3) Remove bolt on bushing that requires replace- dimension above the work surface (datum line). Ver-
ment. tical dimensions can be taken from the datum line to
(4) Allow crossmember to drop down enough to the locations indicated were applicable. Refer to (Fig.
gain clearance for bushing removal. 5), (Fig. 6), (Fig. 7), (Fig. 8), (Fig. 9), (Fig. 10) and
(5) Remove bushing from vehicle. (Fig. 11) for proper dimensions.
INSTALLATION
(1) Apply rubber lube or soap to replacement bush-
ing.
13 - 6 FRAME AND BUMPERS NS
SPECIFICATIONS (Continued)
page
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRAME
INDEX
page page
FUEL SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INDEX
page page
REPLACEMENT PARTS
Many components in your Flexible Fuel Vehicle
(FFV) are designed to be compatible with ethanol.
14 - 4 FUEL SYSTEM NS
INDEX
page page
QUICK-CONNECT FITTINGS
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a Fig. 4 Plastic Quick-Connect Fittings
single-tab type, a two-tab type or a plastic retainer
ring type. Some are equipped with safety latch clips. The fuel system operates at approximately 338 kPa
Refer to the Removal/Installation section for more (49 psi), 3.3L uses approximately 379 kPa (55 psi).
information. Check fuel system pressure at the test port on the
fuel rail (Fig. 5) or (Fig. 6).
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
Fig. 6 Fuel Pressure Test Port—3.3/3.8L Fig. 7 Checking Fuel Pressure at Fuel Rail
(1) Remove cap from fuel pressure test port on fuel • If the gauge reading equals 338 kPa (49 psi)
rail. 3.3L uses approximately 379 kPa (55 psi) further
(2) Connect Fuel Pressure Gauge C-4799B to test testing is not required. If pressure is not correct,
port (Fig. 7). record the pressure.
• If pressure is above specifications, check for a
CAUTION: When using the ASD Fuel System Test, kinked or restricted fuel return tube (from filter to
the ASD relay and fuel pump relay remain energized pump module). If the fuel return tube is not pinched
for 7 minutes or until the test is stopped, or until or restricted, replace the fuel pressure regulator.
the ignition switch is turned to the Off position. • If fuel pressure is below specifications, refer to
the diagnosis chart for Fuel Pressure Below Specifi-
(3) Place the ignition key in the ON position. cations.
Using the DRB scan tool, access ASD Fuel System (4) Replace Pressure test port cap when fin-
Test. The ASD Fuel System Test will activate the fuel ished doing pressure test.
pump and pressurize the system.
14 - 8 FUEL SYSTEM NS
DIAGNOSIS AND TESTING (Continued)
FUEL PRESSURE BELOW SPECIFICATIONS
NS FUEL SYSTEM 14 - 9
DIAGNOSIS AND TESTING (Continued)
FUEL LEVEL SENSOR
This procedure tests the resistance of the level sen-
sor itself. It does not test the level sensor circuit.
Refer to Group 8W - Wiring Diagrams for circuit
identification.
The level sensor is a variable resistor. Its resis-
tance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the
fuel level changes. To test the level sensor, connect
an ohmmeter across the sensor signal and sensor
ground terminals of the fuel pump module connector
(Fig. 8). Move the float lever to the positions shown
in the resistance chart (Fig. 8). Record the resistance
at each point. Replace the level sensor if the resis-
tance is not within specifications.
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE—2.4/3.3/3.8L
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
REMOVAL
(1) Perform fuel system pressure release.
(2) Disconnect quick-connect fittings from fuel
pump module and chassis fuel supply tube. Refer to
Quick-Connect Fittings in this section.
(3) Remove filter retaining screw (Fig. 13) and
remove filter from tank.
INSTALLATION
(1) Install fuel filter to tank.
(2) The fuel supply (to filter) tube, return tube (to Fig. 14 Fuel Line Retainers and Pump Connector
pump module) and fuel supply (to chassis fuel line) Lock
are permanently attached the fuel filter. The ends of (9) Slide fuel pump module electrical connector
the fuel supply and return tubes have different size lock to unlock.
quick-connect fittings. (10) Push down on connector retainer (Fig. 15) and
(3) Apply a light coating of clean 30 weight engine pull connector off module.
oil to the fuel filter nipples. Install fuel tubes. Refer
to Fuel Tubes and Quick-Connect Fittings in this sec-
tion.
REMOVAL
(1) Spread tangs on pressure regulator retainer
(Fig. 18).
(2) Pry fuel pressure regulator out of housing.
(3) Ensure both upper and lower O-rings were
removed with regulator.
INSTALLATION
(1) Lightly lubricate the O-rings with clean engine
Fig. 17 Fuel Pump Module Removal
oil and place them into opening in pump module (Fig.
(13) Discard old O-ring. 19).
(2) Push regulator into opening in pump module.
NS FUEL SYSTEM 14 - 15
REMOVAL AND INSTALLATION (Continued)
(3) Fold tangs on regulator retainer over tabs on reservoir body lock over the locking tangs on the
housing. strainer.
(4) Install fuel pump module. Refer to Fuel Pump
Module Installation in this section.
INSTALLATION
(1) Insert level sensor wires into bottom of opening
in module.
(2) Wrap wires into groove in back of level sensor
(Fig. 27).
FUEL TANK
Fig. 29 Fuel Line Retainers and Pump Connector
Lock
(9) Push down on connector retainer (Fig. 30) and
pull connector off module.
Fuel Tank
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
Fig. 30 Pump Module Connector Retainer and Lock
WHILE SERVICING THE VEHICLE.
(10) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps.
REMOVAL (11) Lower tank slightly. Carefully remove filler
(1) Disconnect negative cable from battery. hose from tank.
(2) Remove fuel filler cap and perform Fuel Sys- (12) Lower the fuel tank. Disconnect pressure
tem Pressure Release procedure. relief/rollover valve hose at the front of tank. Remove
(3) Insert fuel siphon hose into fuel filler neck and clamp and remove fuel filler tube vent hose. Remove
push it into the tank. fuel tank from vehicle.
(4) Drain fuel tank dry into holding tank or a
properly labeled GASOLINE safety container.
(5) Raise vehicle on hoist.
(6) Disconnect both the fuel fill and fuel vent rub-
ber hoses at the fuel tank.
14 - 18 FUEL SYSTEM NS
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect pressure relief/rollover valve hose. Connect fuel
filler tube vent hose and replace clamp.
(2) Raise tank into position and carefully work
filler tube into tank. A light coating of clean engine
oil on the tube end may be used to aid assembly.
(3) Feed filler vent line thru frame rail. Careful
not to cross lines.
(4) Tighten strap bolts to 54 N·m (40 ft. lbs.)
torque. Remove transmission jack.
(5) Tighten filler hose clamp to 3.3 N·m (30 in.
lbs.).
(6) Connect fuel pump/module electrical connector. Fig. 31 Vacuum Fitting on Rear of Intake Manifold
Place retainer in locked position.
(7) Lubricate the fuel supply line with clean 30
weight engine oil, install the quick connect fuel fit-
ting. Refer to Tube/Fitting Assembly in the Fuel
Delivery section of this Group.
(8) Attach filler line to filler tube. Pull on connec-
tor to make sure of connection.
(9) Fill fuel tank, replace cap, and connect battery
negative cable.
(10) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
INSTALLATION
REMOVAL
(1) Ensure injectors are seated into the receiver
(1) Perform fuel system pressure release proce-
cup of fuel rail with lock ring in place.
dure.
(2) Make sure the injector holes in the manifold
(2) Disconnect negative cable from battery.
are clean.
(3) Remove intake manifold cover.
(3) To ease installation, lubricate injector O-ring
(4) Remove air inlet resonator (Fig. 36).
with a drop of clean engine oil.
(5) Remove throttle cable and speed control cable
(4) Put the tip of each injector into their ports.
(if equipped) (Fig. 43) from throttle lever and
Push the assembly into place until the injectors are
bracket.
seated in the ports.
14 - 22 FUEL SYSTEM NS
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
Fig. 49 Ignition Coils (3) Put the tip of each injector into their ports.
(14) Remove generator bracket to intake manifold Push the assembly into place until the injectors are
bolt. seated in the ports.
14 - 24 FUEL SYSTEM NS
REMOVAL AND INSTALLATION (Continued)
(10) Following the tightening sequence in (Fig. 50),
tighten intake manifold bolts to 28 N·m (250 in. lbs.)
torque.
(11) Tighten generator bracket to intake manifold
bolt to 54 N·m (40 ft. lbs.) torque.
(12) Tighten the cylinder head to intake manifold
strut bolts to 54 N·m (40 ft. lbs.) torque.
(13) Connect ground strap and MAP sensor electri-
cal connector.
(14) Connect vacuum harness to intake plenum.
Connect PCV system hoses.
(15) Using a new gasket, connect the EGR tube to
the intake manifold plenum. Tighten screws to 22
N·m (200 in. lbs.) torque.
(16) Connect electrical connectors to the TPS and
idle air control motor.
Fig. 52 Camshaft Position Sensor Connector (17) Connect vacuum harness to throttle body.
(18) Install the direct ignition system (DIS) coils.
Tighten fasteners to 12 N·m (105 in. lbs.) torque.
(19) Install fuel hose quick connector fitting to
chassis tubes. Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section. Push the
fitting onto the chassis tube until it clicks into place.
Pull on the fitting to ensure complete insertion.
(20) Install throttle cable and speed control cable
(if equipped).
(21) Install air inlet resonator.
(22) Connect negative cable to battery.
FUEL INJECTOR—2.4L
The fuel rail must be removed first. Refer to Fuel
Fig. 53 Fuel Rail Removal Injector Rail Removal in this section.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N·m (200 in. lbs.) torque (Fig. 51).
REMOVAL
(1) Disconnect injector wiring connector from injec-
(5) Install fuel tube retaining bracket screw.
tor.
Tighten screw to 4 N·m (35 in. lbs.) torque.
(2) Position fuel rail assembly so that the fuel
(6) Connect electrical connectors to camshaft posi-
injectors are easily accessible (Fig. 54).
tion sensor and engine coolant temperature sensor.
(3) Rotate injector and pull injector out of fuel rail.
(7) Remove covering on lower intake manifold and
The clip will stay on the injector.
clean surface.
(4) Check injector O-ring for damage. If O-ring is
(8) Place intake manifold gasket on lower mani-
damaged, it must be replaced. If injector is reused, a
fold. Put upper manifold into place and install bolts
protective cap must be installed on the injector tip to
finger tight.
prevent damage. Replace the injector clip if it is dam-
(9) Install the generator bracket to intake mani-
aged.
fold bolt and the cylinder head to intake manifold
(5) Repeat for remaining injectors.
strut bolts (do not tighten.)
NS FUEL SYSTEM 14 - 25
REMOVAL AND INSTALLATION (Continued)
FUEL INJECTORS—3.0L
WARNING: THE 3.0L MPI FUEL SYSTEM IS UNDER
A CONSTANT PRESSURE OF APPROXIMATELY 330
KPA (48 PSI). PERFORM FUEL PRESSURE
RELEASE PROCEDURE BEFORE SERVICING THE
FUEL INJECTORS.
REMOVAL
(1) Perform the Fuel Pressure Release Procedure.
(2) Disconnect negative cable from battery.
(3) The fuel rail must be removed first to service
the injectors. Refer to Fuel Injector Rail Assembly
Removal in this section.
(4) Label each injector connector with its cylinder
number. Disconnect electrical connector from injector.
(5) Position fuel rail assembly so that the fuel
injectors are easily accessible.
(6) Remove injector clip from fuel rail and injector
(Fig. 54).
(7) Pull injector straight out of fuel rail receiver
Fig. 54 Fuel Injector and Rail—Typical
cup (Fig. 55).
INSTALLATION (8) Check injector O-ring for damage. If O-ring is
(1) Before installing an injector the rubber O-ring damaged, it must be replaced. If injector is to be
must be lubricated with a drop of clean engine oil to reused, a protective cap must be installed on the
aid in installation. injector tip to prevent damage.
(2) Install injector clip by sliding open end into the (9) Repeat procedure for remaining injectors.
top slot of the injector. The edge of the receiver cup
will slide into the side slots of clip. INSTALLATION
(3) Install injector top end into fuel rail receiver (1) Before installing an injector, the rubber O-ring
cap. Be careful not to damage O-ring during installa- must be lubricated with a drop of clean engine oil to
tion (Fig. 55). aid in installation.
(4) Repeat steps for remaining injectors. (2) Being careful not to damage O-ring, install
(5) Connect fuel injector wiring. injector nozzle end into fuel rail receiver cap.
(3) Install injector clip by sliding open end into
top slot of the injector. The edge of the receiver cup
will slide into the side slots of clip (Fig. 55)
(4) Repeat steps for remaining injectors.
(5) Install fuel rail assembly. Refer to Fuel Rail
Assembly Installation in this section.
(6) Connect electrical connectors to injectors in cor-
rect order.
(7) Connect negative battery cable.
INSTALLATION
(1) Before installing an injector the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Install injector clip by sliding open end into the
top slot of the injector. The edge of the receiver cup
will slide into the side slots of clip (Fig. 56).
(3) Install injector top end into fuel rail receiver
cap. Be careful not to damage O-ring during installa- Fig. 57 Accelerator Pedal and Throttle Cable—Front
tion (Fig. 56). View
(4) Repeat steps for remaining injectors.
(5) Connect fuel injector wiring.
THROTTLE CABLE
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not dam-
age or kink the core wire inside the cable sheath-
ing.
REMOVAL
(1) Working from the engine compartment, hold
the throttle body throttle lever in the wide open posi-
tion.
(2) Remove the throttle cable from the throttle
body cam (Fig. 59), (Fig. 60) and (Fig. 61).
(3) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the Fig. 60 Throttle Cable Attachment to Throttle Body
upper end of the pedal shaft (Fig. 57). Attachment—3.0L Engine
(4) Remove retainer clip from throttle cable and
grommet at dash panel (Fig. 58).
(5) From the engine compartment, pull the throttle
cable out of the dash panel grommet. The grommet
should remain in the dash panel.
(6) Remove the throttle cable from throttle bracket
by carefully compressing both retaining ears simulta-
neously. Then gently pull the throttle cable from
throttle bracket.
INDEX
page page
TESTING
The following procedure applies to the ASD and
fuel pump relays.
(1) Remove relay from connector before testing.
(2) With the relay removed from the vehicle, use
an ohmmeter to check the resistance between termi-
nals 85 and 86. The resistance should be between 75
65 ohms.
(3) Connect the ohmmeter between terminals 30
and 87A. The ohmmeter should show continuity
between terminals 30 and 87A.
(4) Connect the ohmmeter between terminals 87
and 30. The ohmmeter should not show continuity at
this time.
(5) Connect one end of a jumper wire (16 gauge or Fig. 95 MAP Sensor Connector
smaller) to relay terminal 85. Connect the other end (2) Test PCM terminal 36 for the same voltage
of the jumper wire to the ground side of a 12 volt described in the previous step to verify wire harness
power source. condition. Repair as required.
(6) Connect one end of another jumper wire (16 (3) Test the MAP sensor ground circuit at sensor
gauge or smaller) to the power side of the 12 volt connector terminal 1 and PCM terminal 43. If OK, go
power source. Do not attach the other end of the to next step. If not OK, repair as required.
jumper wire to the relay at this time. (4) Test MAP sensor supply voltage between sen-
sor connector terminals 2 and 1 with the key ON.
WARNING: DO NOT ALLOW OHMMETER TO CON- The voltage should be approximately 5 volts (6.5V).
TACT TERMINALS 85 OR 86 DURING THIS TEST. Five volts (6.5V) should also be at terminal 61 of the
NS FUEL SYSTEM 14 - 61
DIAGNOSIS AND TESTING (Continued)
PCM. If OK, replace MAP sensor. If not OK, repair or
replace the wire harness as required.
KNOCK SENSOR
The engine knock sensor is affected by a number of
factors. A few of these are: ignition timing, cylinder
pressure, fuel octane, etc. The knock sensor gener- Fig. 97 Engine Coolant Temperature Sensor—3.0L
ates an AC voltage whose amplitude increases with
the increase of engine knock. The knock sensor can
be tested with a digital voltmeter. The RMS voltage
starts at about 20mVac (at about 700 rpm) and
increases to approximately 600 mVac (5000 rpm). If
the output falls outside of this range a DTC will be
set.
INSTALLATION
(1) Reverse procedure for installation. Tighten
throttle body mounting nuts to 25 N·m (225 in. lbs.)
torque.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove electrical connector from idle air con-
Fig. 109 Servicing Throttle Position Sensor—2.4L trol motor.
INSTALLATION (3) Remove idle air control motor mounting screws
(1) Install throttle position sensor on throttle (Fig. 112).
shaft. Install mounting screws. Tighten screw to 2 (4) Remove motor from throttle body. Ensure the
N·m (17 in. lbs.) torque. O-ring is removed with the motor.
14 - 66 FUEL SYSTEM NS
REMOVAL AND INSTALLATION (Continued)
Fig. 112 Servicing Idle Air Control Motor Fig. 113 Map Absolute Pressure Sensor
INSTALLATION
(1) The new idle air control motor has a new
O-ring installed on it. If pintle measures more than 1
inch (25 mm) it must be retracted. Use the DRB Idle
Air Control Motor Open/Close Test to retract the
pintle (battery must be connected.)
(2) Carefully place idle air control motor into
throttle body.
(3) Install mounting screws. Tighten screws to 2
N·m (17 in. lbs.) torque.
(4) Connect electrical connector to idle air control
motor.
(5) Connect negative cable to battery.
INSTALLATION
(1) Reverse removal procedure to install a new
sensor.
New sensors are packaged with compound on the
threads and no additional compound is required. The
sensor must be tightened to 27 N·m (20 ft. lbs.)
torque.
KNOCK SENSOR
For removal/installation procedures refer to Group
8D- Ignition System, Service Procedures.
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 7 N·m
(60 in. lbs.) torque.
(2) Attach electrical connector to sensor. Fig. 132 Engine Coolant Temperature Sensor
(3) Fill cooling system. Refer to Group 7, Cooling
System. WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
ENGINE COOLANT TEMPERATURE SENSOR—3.0L MUST BE PARTIALLY DRAINED BEFORE REMOV-
The sensor is installed next to the thermostat ING THE COOLANT TEMPERATURE SENSOR.
housing (Fig. 114). REFER TO GROUP 7- COOLING.
Extractor C–4334
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Generator Brkt. to Intake Manifold Bolts—3.3/3.8L.54
N·m (40 ft. lbs.)
Coolant Sensor—2.4L . . . . . . . . . .7 N·m (62 in. lbs.)
Coolant Sensor—3.0L . . . . . . . . . .7 N·m (62 in. lbs.)
Coolant Sensor—3.3/3.8L. . . . . . . .7 N·m (62 in. lbs.)
Cly. Head to Intake Manifold
Fuel Pressure Test Adapter 6539
Strut Bolts—3.3/3.8L. . . . . . . . 54 N·m (40 ft. lbs.)
EGR Tube to Intake Manifold
Screws . . . . . . . . . . . . . . . . . .22 N·m (200 in. lbs.)
Idle Air Control Motor . . . . . . . . . .2 N·m (18 in. lbs.)
Ignition Coil Fasteners . . . . . . .12 N·m (105 in. lbs.)
Intake Air Temperature Sensor . .28 N·m (20 ft. lbs.)
MAP Sensor—2.4L . . . . . . . . . . . .4 N·m (35 in. lbs.)
MAP Sensor—3.0L . . . . . . . . . . . .4 N·m (35 in. lbs.)
MAP Sensor—3.3/3.8L. . . . . . . . . .4 N·m (35 in. lbs.)
Upstream O2S . . . . . . . . . . . . . . .27 N·m (20 ft. lbs.)
Downstream O2S . . . . . . . . . . . . .27 N·m (20 ft. lbs.) Spanner Wrench 6856
Throttle Body Bolts . . . . . . . . . .26 N·m (225 in. lbs.)
NS FUEL SYSTEM 14 - 73
SPECIAL TOOLS (Continued)
page page
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION—2.5L DIESEL
Certain components of the fuel system on the 2.5L
diesel engine are controlled by the Bosch Engine con-
troller which is a Powertrain Control Module (PCM).
Refer to Powertrain Control Module in the Fuel
Injection System—2.5L Diesel Engine section of this
group for a list of items controlled by the PCM. The
Body Control Module (BCM) is mounted to a bracket
located inside the vehicle under the dashpanel to the
left of the steering column (Fig. 1). The PCM is
mounted at the base of the center console in front of
the Air Bag Module. (Fig. 2).
The Fuel System consists of: the fuel tank, fuel
injection pump (engine mounted), fuel filter/water
separator, fuel tank module, electrical fuel gauge
sending unit, glow plugs, glow plug relay, PCM, and
all the electrical components that control the fuel
system. It also consists of fuel tubes/lines/hoses and
fittings, vacuum hoses, and fuel injector(s).
A Fuel Return System. A separate fuel return
system is used. This will route excess fuel: from the Fig. 1 BCM Location
fuel injectors; through individual injector drain The Fuel Tank Assembly consists of: the fuel
tubes; through the fuel injection pump overflow tank, two pressure relief/rollover valves, fuel filler
valve; and back to the fuel tank through a separate tube, fuel tank module containing a fuel gauge send-
fuel line. ing unit, and a pressure-vacuum filler cap.
14 - 2 FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE NS/GS
GENERAL INFORMATION (Continued)
INTRODUCTION—2.0L ENGINE
Refer to the introduction in group 14 for the 2.4/
3.0/3.3/3.8l engines.
GASOLINE/OXYGENATE BLENDS
Refer to Gasoline/Oxygenate blends for the 2.4/3.0/
Fig. 2 PCM Location 3.3/3.8l engines in group 14.
NS/GS FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 3
INDEX
page page
FUEL INJECTORS
Fuel drain tubes (Fig. 6) are used to route excess
fuel back to the overflow valve (Fig. 4) at the rear of
the injection pump. This excess fuel is then returned Fig. 7 Fuel Injector Sensor
to the fuel tank through the fuel return line.
Fuel enters the injector at the fuel inlet (top of
injector) and is routed to the needle valve bore. When
fuel pressure rises to approximately 15,000–15,800
kPa (2175–2291 psi), the needle valve spring tension
is overcome. The needle valve rises and fuel flows
through the spray holes in the nozzle tip into the
combustion chamber. The pressure required to lift
the needle valve is the injector opening pressure set-
ting. This is referred to as the “pop-off” pressure set-
ting.
Fuel pressure in the injector circuit decreases after
injection. The injector needle valve is immediately
closed by the needle valve spring and fuel flow into
the combustion chamber is stopped. Exhaust gases
are prevented from entering the injector nozzle by
the needle valve.
A copper washer (gasket) is used at the base of
each injector (Fig. 7) to prevent combustion gases
from escaping.
Fuel injector firing sequence is 1–3–4–2.
DIAGNOSIS AND TESTING the relay within the PDC, refer to label on PDC
cover.
GENERAL INFORMATION (4) Verify that the electrical connections for the
This section of the group will cover a general diag- fuel heater relay are clean and free of corrosion. This
nosis of diesel engine fuel system components. relay is located in the PDC. For the location of the
Diagnostic Trouble Codes: Refer to On-Board relay within the PDC, refer to label on PDC cover.
Diagnostics in Group 25, Emission Control System (5) Be sure the electrical connectors at the ends of
for a list of Diagnostic Trouble Codes (DTC’s) for cer- the glow plugs (Fig. 13) are tight and free of corro-
tain fuel system components. sion.
The PCM must be tested with the DRBIII scan
tool. The DRBIII should be the first step in any diag-
nosis of engine performance complaints. Refer to the
1997 GS 2.5L Diesel Powertrain Diagnostic Proce-
dures manual for diagnosis and testing of the diesel
engine control system.
VISUAL INSPECTION
A visual inspection for loose, disconnected, or incor-
rectly routed wires and hoses should be made before
attempting to diagnose or service the diesel fuel
injection system. A visual check will help find these
conditions. It also saves unnecessary test and diag-
nostic time. A thorough visual inspection of the fuel
injection system includes the following checks:
(1) Be sure that the battery connections are tight
and not corroded. Fig. 13 Glow Plug Connector
(2) Be sure that the 68 way connector is fully
engaged with the PCM (Fig. 12). (6) Be sure that the electrical connections at the
glow plug relay are tight and not corroded. The glow
plug relay is located in the engine compartment on
the left–inner fender (Fig. 14).
HIGH–PRESSURE LINES
Restricted (kinked or bent) high–pressure lines can
cause starting problems, poor engine performance
and black smoke from exhaust.
Examine all high–pressure lines for any damage.
Each radius on each high–pressure line must be
smooth and free of any bends or kinks.
Replace damaged, restricted or leaking high–pres-
sure fuel lines with the correct replacement line.
REMOVAL AND INSTALLATION (3) Loosen 2 clamps holding air cleaner housing
halves together.
ACCELERATOR PEDAL (4) Remove left side of air cleaner housing.
(5) Remove element from air cleaner housing.
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while INSTALLATION
servicing the accelerator pedal or throttle cable. (1) Install a new element in housing.
(2) Position left side of housing.
(3) Snap clamps into place.
REMOVAL (4) Install hoses and clamps.
FUEL HEATER
Fig. 29 Fuel Filter/Water Separator Location If the fuel heater element needs replacement, the
plastic filter bowl assembly must be replaced. Refer
WARNING: DO NOT ATTEMPT TO DRAIN WATER
to Fuel Filter/Water Separator for information.
FROM THE FILTER/SEPARATOR WITH THE ENGINE
HOT.
FUEL HEATER RELAY
(1) The bottom of the filter/separator bowl is The fuel heater relay is located in the PDC. For
equipped with a drain valve (Fig. 29). The drain the location of the relay within the PDC (Fig. 30),
valve is equipped with a fitting. Attach a piece of refer to label on PDC cover.
rubber hose to this fitting. This hose is to be used as
a drain hose.
(2) Place a drain pan under the drain hose.
(3) With the engine not running, open the drain
valve (unscrew—drain valve has right hand threads)
from the filter/separator bowl. To gain access to this
fitting, the two filter–to–mounting bracket nuts (Fig.
29) may have to be loosened a few turns.
(4) Hold the drain open until clean fuel exits the
drain.
(5) After draining, close drain valve.
(6) Remove rubber drain hose.
(7) Dispose of mixture in drain pan according to
applicable local or federal regulations.
FUEL INJECTORS
Four fuel injectors are used on each engine. Of these
four, two different types are used. The fuel injector used
on cylinder number one is equipped with a fuel injector
Fig. 46 Installing Dial Indicator and Special Adapter sensor (Fig. 47). The other three fuel injectors are iden-
Tools tical. Do not place the fuel injector equipped with
the fuel injector sensor into any other location
(14) Gauge reading should be at 0.60 mm. If not,
except the cylinder number one position.
the pump must be rotated for adjustment:
(a) Loosen the three injection pump mounting
nuts at the mounting flanges. These flanges are
equipped with slotted holes. The slotted holes are
used to rotate and position the injection pump for
fuel timing. Loosen the three nuts just enough to
rotate the pump.
(b) Rotate the pump clockwise (as viewed from
front) until .60 mm is indicated on the dial indica-
tor gauge.
(c) Tighten the three pump mounting nuts to 30
N·m (22 ft. lbs.) torque.
(d) Recheck the dial indicator after tightening
the pump mounting nuts. Gauge should still be
reading 0.60 mm. Loosen pump mounting nuts and
readjust if necessary.
(15) Remove dial indicator and adapter tools.
(16) Install access plug and washer to rear of Fig. 47 Fuel Injector Sensor—Number–1 Cylinder
injection pump. REMOVAL
(17) Install plug at timing gear cover. (1) Disconnect negative battery cable at battery.
(18) Remove dial indicator from valve stem. (2) Thoroughly clean the area around the injector
(19) Install valve spring and keepers. with compressed air.
(20) Install rocker arm assembly and tighten nuts. (3) Remove the fuel drain hoses (tubes) at each
(21) Install and connect the four high–pressure injector (Fig. 48) being serviced. Each of these hoses
fuel lines to the fuel injection pump. Also connect is slip–fit to the fitting on injector.
fuel lines at the fuel injectors. For procedures, refer (4) Remove the high–pressure fuel line at injector
to High–Pressure Fuel Lines in this group. being removed. Refer to High–Pressure Fuel Lines in
(22) Install electrical connector at engine coolant this group for procedures.
temperature sensor. (5) Remove the injector using special socket tool
(23) Connect electrical connector at fuel shutdown number VM.1012A. When removing cylinder number
solenoid.
NS/GS FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 23
REMOVAL AND INSTALLATION (Continued)
FUEL SHUTDOWN SOLENOID
The solenoid is mounted to the rear of the injection
pump (Fig. 50).
INSTALLATION INSTALLATION
(1) Clean the injector threads in cylinder head. (1) Install solenoid into injection pump.
(2) Install new copper washer (seal) to injector. (2) Install wiring and nut at solenoid.
(3) Install injector to engine. Tighten to 70 N·m (3) Install new sealing washers to banjo fitting.
(52 ft. lbs.) torque. (4) Install overflow valve, banjo fitting and fuel
(4) Install high–pressure fuel lines. Refer to High- return line to pump.
–Pressure Fuel Lines in this group for procedures. (5) Bleed air from system. Refer to Air Bleed Pro-
(5) Install fuel drain hoses (tubes) to each injector. cedures in this section of the group.
Do not use clamps at fuel drain hoses.
(6) Connect negative battery cable to battery. FUEL TANK
(7) Bleed the air from the high–pressure lines.
Refer to the Air Bleed Procedure section of this REMOVAL
group. (1) Disconnect negative cable from battery.
(2) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(3) Drain fuel tank dry into holding tank or a
properly labeled diesel safety container.
14 - 24 FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE NS/GS
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect fuel filler tube vent hose and replace clamp.
(2) Raise tank into position and carefully work
filler tube into tank. A light coating of clean engine
oil on the tube end may be used to aid assembly.
Fig. 51 Fuel Tank and Lines (3) Feed filler vent line thru frame rail. Careful
The fuel reservoir module electrical connec- not to cross lines.
tor has a retainer that locks it in place. (4) Tighten strap bolts to 54 N·m (40 ft. lbs.)
(7) Slide electrical connector lock to unlock (Fig. torque. Remove transmission jack.
52).
(8) Push down on connector retainer (Fig. 53) and CAUTION: Ensure straps are not twisted or bent
pull connector off module. before or after tightening strap nuts.
(9) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps. (5) Connect module electrical connector. Place
(10) Lower tank slightly. Carefully remove filler retainer in locked position.
hose from tank. (6) Lubricate the fuel supply and return lines with
clean 30 weight engine oil, install the quick connect
NS/GS FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 25
REMOVAL AND INSTALLATION (Continued)
fuel fitting. Refer to Tube/Fitting Assembly in the
Fuel Delivery section of this Group.
(7) Attach filler line to filler tube. Pull on connec-
tor to make sure of connection.
(8) Fill fuel tank, replace cap, and connect battery
negative cable.
(1) Disconnect negative cable from battery. Fig. 55 Module Connector Retainer and Lock
(2) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(3) Drain fuel tank dry into holding tank or a
properly labeled diesel safety container.
(4) Raise vehicle on hoist.
(5) Use a transmission jack to support the fuel
tank. Remove bolts from fuel tank straps. Lower
tank slightly.
(6) Clean area around fuel reservoir module and
tank to keep dirt and foreign material out of tank.
(7) Disconnect fuel lines from fuel module by
depressing quick connect retainers with thumb and
fore finger (Fig. 54).
INSTALLATION
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Position fuel reservoir module in tank with
Fig. 54 Fuel Line Retainers and Pump Connector locknut.
Lock (3) Tighten locknut to 58 N·m (43 ft. lbs.).
(8) Slide module electrical connector lock to (4) Connect fuel lines.
unlock. (5) Plug in electrical connector. Slide connector
(9) Push down on connector retainer (Fig. 55) and lock into position.
pull connector off module. (6) Raise fuel tank, install bolts into fuel tank
(10) Using Special Tool 6856, remove plastic lock- straps and tighten.
nut counterclockwise to release pump module (Fig. (7) Lower vehicle on hoist.
56). (8) Connect negative cable from battery.
(11) Carefully remove module and O-ring from (9) Fill fuel tank. Check for leaks.
tank (Fig. 57). (10) Install fuel filler cap.
14 - 26 FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE NS/GS
REMOVAL AND INSTALLATION (Continued)
Fig. 57 Fuel Reservoir Module Removal Fig. 58 Fuel Lines and Clamps/Holders
HIGH-PRESSURE LINES
All high–pressure fuel lines are of the same length
and inside diameter. Correct high–pressure fuel line
usage and installation is critical to smooth engine
operation.
REMOVAL
(1) Disconnect negative battery cable from battery.
(2) Remove the necessary clamps (Fig. 58) holding
the lines to the engine.
(3) Clean the area around each fuel line connec-
tion. Disconnect each line at the top of each fuel
injector (Fig. 59).
(4) Disconnect each high–pressure line fitting at
each fuel injection pump delivery valve. Fig. 59 Fuel Lines at Fuel Injectors
(5) Very carefully remove each line from the INSTALLATION
engine. Note the position (firing order) of each line (1) Carefully position each high–pressure fuel line
while removing. Do not bend the line while to the fuel injector and fuel injection pump delivery
removing. valve holder in the correct firing order. Also position
each line in the correct line holder.
CAUTION: Be sure that the high–pressure fuel lines (2) Loosely install the line clamp/holder bolts.
are installed in the same order that they were (3) Tighten each line at the delivery valve to 30
removed. Prevent the injection pump delivery valve N·m (22 ft. lbs.) torque.
holders (Fig. 58) from turning when removing or (4) Tighten each line at the fuel injector to 30 N·m
installing high–pressure lines from injection pump. (22 ft. lbs.) torque.
NS/GS FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 27
REMOVAL AND INSTALLATION (Continued)
Be sure the lines are not contacting each IDLE SPEED
other or any other component. 900 rpm 625 rpm with engine at normal operat-
(5) Tighten the clamp bracket bolts to 24 N·m (18 ing temperature.
ft. lbs.) torque.
(6) Bleed air from the fuel system. Refer to the Air FUEL INJECTOR FIRING SEQUENCE
Bleed Procedure section of this group. 1–3–4–2
INDEX
page page
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE—2.0L ENGINE
Refer to the Fuel System Pressure Release Proce-
dure for the 2.4/3.0/3.3/3.8L engines in the Fuel
Delivery System section of group 14 for more infor-
mation.
Fig. 3 Fuel Pressure Test Port—2.0L Fig. 4 Fuel Rail and Injectors
FUEL LEVEL SENSOR—2.0L ENGINE
Refer to the Fuel Pump Inlet Strainer for the 2.4/
3.0/3.3/3.8L engines under Removal and Installation
in the Fuel Delivery System section of group 14 for
more information.
FUEL INJECTORS
Fig. 5 Fuel Injector Retainer
REMOVAL
(1) Disconnect negative cable from battery.
(2) Release fuel system pressure. Refer to Fuel
System Pressure Release procedure in this section.
(3) Disconnect fuel supply tube from rail. Refer to
Quick-Connect Fittings in the Fuel Delivery section
of this group.
(4) Disconnect electrical connectors from fuel injec-
tors (Fig. 4).
(5) Remove fuel rail mounting screws.
(6) Lift rail off of intake manifold. Cover the fuel
injector openings in the intake manifold.
(7) Remove fuel injector retainer (Fig. 5).
(8) Pull injector out of fuel rail. Replace fuel injec-
tor O-rings (Fig. 6).
INSTALLATION
(1) Apply a light coating of clean engine oil to the Fig. 6 Fuel Injector O-Rings
upper O-ring. (5) Insert fuel injector nozzles into openings in
(2) Install injector in cup on fuel rail. intake manifold. Seat the injectors in place. Tighten
(3) Install retaining clip. fuel rail mounting screws to 22.5 N·m 6 3 N·m
(4) Apply a light coating of clean engine oil to the (200630 in. lbs.).
O-ring on the nozzle end of each injector. (6) Attach electrical connectors to fuel injectors.
NS/GS FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 31
REMOVAL AND INSTALLATION (Continued)
(7) Connect fuel supply tube to fuel rail. Refer to TORQUE SPECIFICATION
Quick Connect Fittings in the Fuel Delivery Section
of this Group. DESCRIPTION TORQUE
Accelerator Pedal to
ACCELERATOR PEDAL Dash Nuts . . . . . . . . . . . . . . 12 N·m (105 in. lbs.)
Refer to the Accelerator Pedal for the 2.4/3.0/.3.3/ Fuel Pump Module Locknut . . . . 58 N·m (43 ft. lbs.)
3.8L engines under Removal and Installation in the Fuel Tank Strap Bolts . . . . . . . . . 54 N·m (40 ft lbs.)
Fuel Delivery section of group 14 for more informa- Fuel Rail Bolts . . . . . . . . . . . . . 23 N·m (195 in. lbs.)
tion. Ignition Coil Mounting Bolts . . . 11 N·m (95 in. lbs.)
Intake Manifold Bolts . . . . . . . . 11 N·m (95 in. lbs.)
Throttle Control Shield . . . . . . . 5.6 N·m (50 in. lbs.)
14 - 32 FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE NS/GS
INDEX
page page
Fig. 21 Generator
(1) Test the MAP sensor output voltage at the ENGINE COOLANT TEMPERATURE SENSOR
MAP sensor connector between terminals 1 and 4
(Fig. 29). With the ignition switch ON and the engine
not running, output voltage should be 4 to 5 volts.
The voltage should drop to 1.5 to 2.1 volts with a hot,
neutral idle speed condition. If OK, go to next step. If
not OK, go to step 3.
INDEX
page page
GENERAL INFORMATION where, if possible, it will ignore the failed sensor, set
a code related to the sensor, and operate the engine
INTRODUCTION in a “Limp Home” mode. When the PCM is operating
This section will cover components either regulated in a “Limp Home” mode, the Diesel Glow Plug lamp
or controlled by the Powertrain Control Module on the instrument panel will be constantly illumi-
(PCM). The fuel heater relay, fuel heater and fuel nated, and the engine will most likely have a notice-
gauge are not operated by the PCM. These compo- able loss of performance. An example of this would be
nents are controlled by the ignition (key) switch. All an Accelerator Pedal Position Sensor failure, and in
other fuel system electrical components necessary to that situation, the engine would run at a constant
operate the engine are controlled or regulated by the 1100 RPM, regardless of the actual position of the
PCM. Refer to the following PCM description for pedal. This is the most extreme of the three “Limp
more information. Home” modes.
Certain fuel system component failures may cause In addition to indicating that the glow plugs are
a no start, or prevent the engine from running. It is hot enough to start combustion, the Glow Plug Lamp
important to know that the PCM has a feature is also used in the diagnosis of the PCM, and when
14 - 44 FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE NS/GS
GENERAL INFORMATION (Continued)
illuminated constantly, it usually indicates a problem through different system components. These compo-
has been detected somewhere within the fuel system. nents are referred to as PCM Outputs. The sensors
The DRBIII scan tool is the best method for commu- and switches that provide inputs to the PCM are con-
nicating with the PCM to diagnose faults within the sidered PCM Inputs.
system. PCM Inputs are:
• Air Conditioning Selection
• Theft Alarm
DESCRIPTION AND OPERATION • Clutch Switch
• Diesel PCM Relay
POWERTRAIN CONTROL MODULE (PCM) • ISO-Protocol
The Powertrain Control Module (PCM) is mounted • Control Sleeve
in the center consule to a bracket located in front of • Fuel Temperature
the Air Bag Module (Fig. 1). • Boost Pressure Sensor
• Accelerator Pedal Sensor
• EGR
• A/C Pressure
• Engine Coolant Temperature Sensor
• Low Idle Position Switch
• 5 Volt Supply
• Vehicle Speed Sensor
• Sensor Return
• Glow Plug
• Engine Speed Sensor (rpm)
• Fuel Injector #1 Sensor
• Starter Signal
• Brake Switch
• Speed Control Switch Position
• Power Ground
• Signal Ground
• Ignition (key) Switch Sense
• Battery Voltage
• SCI Receive (DRB scan tool connection)
PCM Outputs:
After inputs are received by the PCM, certain sen-
sors, switches and components are controlled or reg-
Fig. 1 PCM Location ulated by the PCM. These are considered PCM
Outputs. These outputs are for:
The PCM is a pre–programmed, dual micro–proces-
• A/C Clutch Relay (for A/C clutch operation)
sor digital computer. It will either directly operate or
• Speed Control LED
partially regulate the:
• Data Link Connectors (for DRB scan tool)
• Speed Control
• Diesel PCM Relay
• Speed Control LED lamp
• Diesel PCM Sense
• Fuel Timing Solenoid
• Accelarator Pedal
• Glow Plug Relay
• 5 Volts Supply
• Glow Plugs
• Glow Plug Relay
• EGR Solenoid
• Fan Relay
• Glow Plug Lamp
• Fuel Quantity
• Diesel PCM Relay
• Fuel Timing Solenoid
• Air Conditioning Operation
• Fuel Shut-Off Solenoid
• Tachometer
• Engine Speed Sensor
• Exhaust Gas Recirculation (EGR) Solenoid
• Glow Plug Lamp (malfunction indicator lamp)
The PCM can adapt its programming to meet
• Exhaust Gas Recirculation (EGR) Solenoid
changing operating conditions.
• Glow Plug Relay
The PCM receives input signals from various
• Tachometer
switches and sensors. Based on these inputs, the
• SCI transmit (DRB scan tool connection)
PCM regulates various engine and vehicle operations
NS/GS FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 45
DESCRIPTION AND OPERATION (Continued)
BOOST PRESSURE SENSOR If the PCM is put it on a vehicle without VTA the
The Boost Pressure Sensor is mounted to the top of Glow Plug Lamp will start to blink and the vehicle
the intake manifold. (Fig. 2) It is a sensor that mea- will not start.
sures both manifold vacuum and turbo boost, and it The PCM cannot be flashed to remove the VTA.
also contains an integrated intake air temperature
sensor. The Boost Pressure Sensor takes the place of BATTERY VOLTAGE—PCM INPUT
the Mass Air Flow (MAF). In the Intake Air Temper- The battery voltage input provides power to the
ature Sensor component, there is a ceramic element PCM. It also informs the PCM what voltage level is
that changes its resistance based on temperature. being supplied by the generator once the vehicle is
The ceramic element is part of an electronic circuit running.
connected to the PCM, and has a voltage applied to The battery input also provides the voltage that is
it. The ceramic element is exposed to the air inside needed to keep the PCM memory alive. The memory
the intake. This air has a cooling effect on the stores Diagnostic Trouble Code (DTC) messages.
ceramic element, and its resistance changes. This Trouble codes will still be stored even if the battary
causes the voltage flowing through the intake air voltage is lost.
temperature circuit to vary. The voltage signal pro-
duced by the Intake Air Temperature Sensor changes SENSOR RETURN—PCM INPUT (ANALOG
inversely to the temperature, and is measured by the GROUND)
PCM. As a general rule, when the temperature of the Sensor Return provides a low noise Analog ground
air in the intake is high, the voltage signal produced reference for all system sensors.
by the Intake Air Temperature Sensor is low. The
component of the Boost Pressure Sensor that mea- SIGNAL GROUND—PCM INPUT
sures manifold vacuum and turbo boost produces a Signal ground provides a low noise ground to the
voltage signal that is proportional to the pressure in data link connector.
the inake manifold. When the intake manifold pres-
sure is low, the voltage is low, and when the pressure IGNITION CIRCUIT SENSE—PCM INPUT
is high, the voltage is high. The PCM uses the volt- The ignition circuit sense input signals the PCM
age signals from the Boost Pressure Sensor, and the that the ignition (key) switch has been turned to the
Intake Air Temperature Sensor to determine the ON position. This signal initiates the glow plug con-
amount of air flowing through the intake manifold. trol routine to begin the “pre–heat” cycle.
POWER GROUND
Provides a common ground for power devices (sole-
noid and relay devices).
GLOW PLUGS
Glow plugs are used to help start a cold or cool
engine. The plug will heat up and glow to heat the
combustion chamber of each cylinder. An individual
plug is used for each cylinder. Each plug is threaded
into the cylinder head above the fuel injector (Fig. 12).
REMOVAL
INSTALLATION
(1) Check condition of electrical connector for dam-
age or corrosion. Repair as necessary.
(2) Install electrical connector to relay.
(3) Install relay to inner fender.
(4) Connect battery cable to battery.
INSTALLATION
(1) After the PCM electrical connector has been
separated from the PCM, inspect the pins for corro-
sion, being spread apart, bent or misaligned. Also
inspect the pin heights in the connector. If the pin
heights are different, this would indicate a pin has
separated from the connector. Repair as necessary.
(2) Engage 68–way connector into PCM. Move
Fig. 22 Glow Plug Relay Location slide bar to lock connector.
(3) Connect negative cable to battery.
REMOVAL
(1) Disconnect the negative battery cable at the VEHICLE SPEED SENSOR
battery. The vehicle speed sensor (Fig. 24) is located on the
(2) Remove relay mounting bolt. extension housing of the transmission.
14 - 56 FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE NS/GS
REMOVAL AND INSTALLATION (Continued)
STEERING
CONTENTS
page page
GENERAL INFORMATION
INDEX
page page
There is some noise in all power steering systems. One of the most common is a hissing sound evident at
standstill parking. Hiss is a very high frequency noise similar to that experienced while slowly closing a water
tap. The noise is present in every valve and results from high velocity fluid passing over the edges of the valve
orifice. There is no relationship between this noise and the performance of the vehicles steering system. Hiss
may be expected when the steering wheel is at the end of its travel or slowly turning when the vehicle is at
a standstill.
INDEX
page page
REMOVAL AND INSTALLATION (8) Remove the catalytic converter from the
exhaust manifold. Then remove all the exhaust sys-
2.4 LITER POWER STEERING PUMP tem hangers/isolators from the brackets on the
exhaust system.
REMOVE (9) Move the exhaust system as far rearward and
to the left side of the vehicle as possible (Fig. 4).
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(7) Remove the catalytic converter from the Fig. 13 Power Steering Return Hose At Return Line
exhaust manifold. Then remove all the exhaust sys-
tem hangers/isolators from the brackets on the
exhaust system.
(8) Move the exhaust system as far rearward and
to the left side of the vehicle as possible (Fig. 12).
(9) Raise the heat sleeve on the power steering
return hose to expose the return hose to steel tube
connection. Remove the hose from the power steering
fluid return line on the front suspension cradle (Fig.
13). Allow the remaining power steering fluid to
drain from the power steering pump and reservoir
through the removed hose.
(10) Remove the accessory drive splash shield
(Fig. 14).
(11) Remove the power steering fluid supply hose
coming from the remote fluid reservoir, from the fit-
ting on the power steering pump (Fig. 15). Drain off Fig. 14 Accessory Drive Splash Shield
excess power steering fluid from hose. NOTE: If the return hose is not removed from the
(12) Remove the power steering fluid pressure line power steering pump, it is very difficult to remove
(Fig. 15) from the power steering pump. Drain excess the power steering pump from the vehicle.
power steering fluid from tube.
NS STEERING 19 - 15
REMOVAL AND INSTALLATION (Continued)
mounting bolts (Fig. 16). Tighten the power steering
pump mounting bolts to a torque of 54 N·m (40 ft.
lbs.).
(3) Install the support bracket attaching rear of
power steering pump to engine (Fig. 16). Tighten the
nut and bolts to a torque of 54 N·m (40 ft. lbs).
INSTALL
Fig. 21 Power Steering Hoses At Power Steering
(1) Install power steering pump back in vehicle
Pump
using the reverse order of its removal through the
(12) Remove the power steering fluid pressure line exhaust tunnel are of the vehicle.
(Fig. 21) from the power steering pump. Drain excess (2) Install the power steering pump on its mount-
power steering fluid from tube. ing bracket. Install the 3 power steering pump
(13) Remove the power steering fluid return hose mounting bolts (Fig. 23). Tighten the power steering
(Fig. 21) from the power steering pump. Drain excess pump mounting bolts to a torque of 54 N·m (40 ft.
power steering fluid from tube. lbs.).
(14) Remove the support bracket at the rear of the (3) Install the support bracket attaching rear of
power steering pump attaching the pump to the rear power steering pump to engine (Fig. 22). Tighten the
of the engine (Fig. 22). nut and bolt holding the strut assembly to bracket
(15) Remove the 3 bolts mounting the power steer- and the intake manifold stud to a torque of 54 N·m
ing pump to the alternator/power steering pump and (40 ft. lbs).
belt tensioner mounting bracket (Fig. 23).
19 - 18 STEERING NS
REMOVAL AND INSTALLATION (Continued)
NOTE: Before installing power steering pressure (17) Connect the negative battery cable on the
hose on power steering pump, inspect the O-ring negative battery post.
on the power steering pressure hose for damage (18) Start engine and turn steering wheel several
and replace if required. times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
(4) Install the power steering fluid pressure line tem for leaks. See Checking Fluid Level.
onto the output fitting of the power steering pump
(Fig. 21). Tighten the pressure line to pump fitting POWER STEERING FLUID RESERVOIR TO PUMP
tube nut to a torque of 31 N·m (275 in. lbs.). SUPPLY HOSE
(5) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure REMOVE
fitting (Fig. 21). Be sure hose clamps are prop- (1) Remove the filler cap from remote power steer-
erly reinstalled. ing fluid reservoir (Fig. 24).
(6) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 21). Be sure hose is
clear of accessory drive belts and all hose
clamps are properly reinstalled.
(7) Install the serpentine drive belt (Fig. 20). See
Cooling, Group 7 for detailed installation procedure.
(15) Fill the remote power steering pump fluid res- Fig. 25 Power Steering Fluid Hose Routing Clip
ervoir to correct fluid level. (4) Raise vehicle on jack stands or centered on a
(16) Install cap on power steering fluid reservoir. frame contact type hoist. See Hoisting in the Lubri-
NS STEERING 19 - 19
REMOVAL AND INSTALLATION (Continued)
cation and Maintenance section of this service man- (12) Start the engine. Slowly turn the steering
ual, for the required lifting procedure to be used for wheel right and left, lightly contacting the wheel
this vehicle. stops.
(5) Remove at power steering pump, the power (13) Add power steering fluid if necessary.
steering fluid hose coming from the power steering (14) Lower the vehicle and turn the steering wheel
fluid reservoir. Let the power steering fluid drain out slowly from lock to lock.
of the reservoir and hose. (15) Stop the engine. Check the fluid level and
(6) Lower vehicle. refill as required.
(7) Remove hose clamp attaching the power steer- (16) If the fluid is extremely foamy, allow the vehi-
ing fluid supply hose to the power steering fluid res- cle to stand a few minutes and repeat the above pro-
ervoir (Fig. 24). cedure.
(8) Remove the power steering fluid supply hose
from the vehicle. Hose is removed from the top of the POWER STEERING FLUID PRESSURE HOSE
engine compartment. Service all power steering hoses with vehicle raised
on hoist. Cap all open ends of hoses, power steering
INSTALL pump fittings and steering gear ports to prevent
entry of foreign material into the components.
CAUTION: On V-6 engine applications, the power
steering fluid reservoir to power steering hose must WARNING: POWER STEERING OIL, ENGINE
be routed tightly against the strut tower and parallel PARTS AND THE EXHAUST SYSTEM MAY BE
to the dash panel. It must also be routed under the EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
wiring harness and below the drip tube. This rout- DO NOT START ENGINE WITH ANY LOOSE OR DIS-
ing will prevent the power steering fluid supply CONNECTED HOSES. DO NOT ALLOW HOSES TO
hose from coming in contact with the accessory TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
drive belt.
For part reference and part location for the vehicle
(1) Install and correctly route the power steering that is being serviced, refer to the following figure
fluid supply hose from remote fluid reservoir down to numbers. These show the hose bracket locations,
power steering pump. hose routings and fitting locations by the engine
(2) Install the fluid supply hose onto the power application of the vehicle. Use these figure numbers
steering fluid reservoir (Fig. 24). Install the hose when referring to the removal or installation proce-
clamp on the fluid supply hose. Be sure hose clamp dures for the power steering hoses listed below.
is installed past bead on fluid reservoir fitting.
(3) Raise vehicle on jack stands or centered on a REMOVE
frame contact type hoist. See Hoisting in the Lubri- (1) Remove cap from power steering fluid reser-
cation and Maintenance section of this service man- voir.
ual, for the required lifting procedure to be used for (2) Using a siphon pump, remove as much power
this vehicle. steering fluid as possible from the power steering
(4) Install power steering fluid supply hose on fluid reservoir.
power steering pump. Install the hose clamp on the (3) Raise vehicle See Hoisting, Group 0. Put oil
fluid supply hose. Be sure hose clamp is installed drain pan under vehicle to catch power steering fluid.
past bead on pump fitting. (4) Raise the heat sleeve on the power steering
(5) Lower vehicle. fluid return hose (Fig. 26) to expose the return hose
(6) Install routing clip on power steering fluid sup- to steel tube connection. Remove the hose clamp from
ply hose. Be sure routing clip is installed in a posi- the power steering fluid return hose (Fig. 26).
tion to correctly align with stud in strut tower. Remove power steering fluid return hose from steel
(7) Install routing clip for power steering fluid sup- tube and allow power steering fluid to drain from
ply hose on stud in strut tower (Fig. 25). pump.
(8) Fill the remote fluid reservoir to the proper
level and let the fluid settle for at least two (2) min-
utes.
(9) Start the engine and let run for a few seconds.
Then turn the engine off.
(10) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(11) Raise the front wheels off the ground.
19 - 20 STEERING NS
REMOVAL AND INSTALLATION (Continued)
Fig. 26 Return Hose Connection To Steel Tube Fig. 28 Power Steering Hose Attachment To
(5) Remove the power steering fluid pressure line Suspension Cradle
from the power steering pump pressure fitting (Fig.
27). Drain excess power steering fluid from hose.
DISASSEMBLY AND ASSEMBLY (3) Force pulley flush with the end of the power
steering pump shaft (Fig. 35).
POWER STEERING PUMP PULLEY
DISASSEMBLY
(1) Remove the pulley from the shaft of the power
steering pump using Puller C-4333 or C-4068 (Fig.
33).
CAUTION: Do not hammer on power steering POWER STEERING PUMP FLOW CONTROL VALVE
pump pulley. This will damage the pulley and the SEAL
power steering pump.
DISASSEMBLE
(2) Replace pulley if it is found to be bent, cracked,
or loose. WARNING: POWER STEERING OIL, ENGINE
PARTS AND THE EXHAUST SYSTEM MAY BE
ASSEMBLY
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
(1) Install the pulley with Installer C-4063 (Fig.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
34). Do not use the tool adapters.
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
SPECIFICATIONS
POWER STEERING SYSTEM SPECIFICATIONS
SPECIAL TOOLS
POWER STEERING PUMP
Installer C-4063B
Puller C-4333
19 - 26 STEERING NS
INDEX
page page
DESCRIPTION AND OPERATION Turning of the steering wheel is converted into linear
travel through the meshing of the helical pinion
STEERING GEAR OPERATION DESCRIPTION teeth with the rack teeth. Power assist steering is
provided by an open center, rotary type control valve
NOTE: The power steering gear (Fig. 1) should NOT which directs oil from the pump to either side of the
be serviced or adjusted. If a malfunction or oil leak integral rack piston.
occurs, the complete steering gear should be Road feel is controlled by the diameter of a torsion
replaced. bar which initially steers the vehicle. As required
steering effort increases, as in a turn, the torsion bar
If a steering gear boot needs to be replaced due to twists, causing relative rotary motion between the
damage, refer to the power steering gear service sec- rotary valve body and the valve spool. This move-
tion in this manual for proper procedure. ment directs oil behind the integral rack piston,
The power steering system consists of these four which, in turn, builds up hydraulic pressure and
major components. Power Steering Gear, Power assists in the turning effort.
Steering Pump, Pressure Hose, and Return Line.
Fig. 16 Removing Tie Rod End Attaching Nut Fig. 18 Tie Rod Boot To Tie Rod Clamp
(3) Remove the tie rod end from the steering
knuckle using Remover, Special Tool MB-991113 (Fig.
17) or MB-990635.
Fig. 24 Tie Rod End Removal From Steering Fig. 25 Torquing Tie Rod End Attaching Nut
Knuckle (6) Adjust the steering gear to inner tie rod boots
ASSEMBLE at inner tie rod if they became twisted during Toe
(1) Install outer tie rod onto inner tie rod. Make adjustment.
sure jam nut (Fig. 22) is on inner tie rod.
(2) Do not tighten jam nut.
(3) Install tie rod end into the steering knuckle. SPECIFICATIONS
Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod STEERING GEAR FASTENER TORQUE
end stationary, tighten tie rod end to steering SPECIFICATIONS
knuckle attaching nut (Fig. 23). Then using a crow-
foot and 11/32 socket (Fig. 25), torque tie rod end DESCRIPTION TORQUE
attaching nut to 54 N·m (40 ft. lbs.). STEERING GEAR:
To Suspension Cradle Bolts. . . .183 N·m (135 ft. lbs.)
CAUTION: During this procedure do not allow the Tie Rod To Steering
steering gear boot to become twisted. (See Wheel Knuckle Nut . . . . . . . . . . . . . . .54 N·m (40 ft. lbs.)
Alignment in the suspension section of this service Outer To Inner Tie Rod
manual). Jam Nut . . . . . . . . . . . . . . . . . .75 N·m (55 ft. lbs.)
Power Steering Hose
(4) Adjust the front Toe setting on the vehicle. Tube Nuts . . . . . . . . . . . . . . .31 N·m (275 in. lbs.)
Refer to the Toe Setting Procedure in Front Suspen- Coupler Pinch Bolt . . . . . . . . . . .28 N·m (250 in. lbs.)
sion Service Procedures in this group of the service
SUSPENSION CRADLE:
manual. Refer to the Specifications Section at the
Cradle Plate To Cradle
end of this group for the desired front Toe specifica-
Attaching Bolts . . . . . . . . . . .165 N·m (123 ft. lbs.)
tion.
(5) Tighten tie rod jam nut (Fig. 22) to 55 N·m (75
ft. lbs.) torque.
NS STEERING 19 - 35
SPECIAL TOOLS
POWER STEERING GEAR
STEERING COLUMN
INDEX
page page
DESCRIPTION AND OPERATION assembly are the key cylinder, ignition switch, multi-
function switch, clockspring, halo lamp, speed control
STEERING COLUMN DESCRIPTION switches, driver airbag, trim shrouds and steering
The steering column (Fig. 1) has been designed to wheel. These replaceable components of the steering
be serviced only as a complete assembly, if a compo- column can be serviced without requiring removal of
nent of the steering column is defective. The only the steering column from the vehicle.
replaceable components of the steering column
DIAGNOSIS AND TESTING CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
STEERING COLUMN occur.
For diagnosis of conditions relating to the steering
column, refer to the steering system diagnosis charts,
in the diagnosis and testing section at the beginning REMOVAL AND INSTALLATION
of this group.
STEERING COLUMN ASSEMBLY
SERVICE PROCEDURES To service the steering wheel and its components
or the air bag, refer to Group 8M, Restraint Systems.
STEERING COLUMN SERVICE PROCEDURE Follow all WARNINGS.
To service the switches, refer to the appropriate
WARNINGS
section of Group 8, Electrical.
WARNING: BEFORE BEGINNING ANY SERVICE To replace the steering column assembly, refer to
PROCEDURES THAT INVOLVES REMOVING THE the steering column removal procedure.
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
REMOVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
(1) Make sure the front wheels of the vehicle are
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
in the straight ahead position before beginning the
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
column removal procedure.
THIS COULD RESULT IN ACCIDENTAL AIR BAG
(2) Disconnect negative (ground) cable from the
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
battery and isolate cable from battery terminal.
(3) Remove the screws attaching the lower steer-
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, ing column cover to the instrument panel (Fig. 2).
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE Remove the lower trim panel from the lower instru-
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL ment panel.
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIR BAG AND POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIR BAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY SUB-
STITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITH AN AIR BAG, REFER TO GROUP
8M, ELECTRICAL FOR PROPER AND SAFE SER- Fig. 2 Lower Steering Column Cover Attachment
VICE PROCEDURES. Locations
(4) Remove the park brake pedal release cable
NOTE: Safety goggles should be worn at all times from the park brake release lever (Fig. 3).
when working on steering columns. (5) Remove the 10 bolts attaching the steering col-
umn cover liner (Fig. 4) to the instrument panel.
Remove the steering column cover liner from the
CAUTION: Disconnect negative (ground) cable lower instrument panel.
from the battery, before servicing any column com- (6) Rotate key cylinder to the lock position and
ponent. remove key. Rotate the steering wheel a half turn to
the left until the steering column lock engages keep-
ing the steering column in the locked position (Fig.
5).
NS STEERING 19 - 39
REMOVAL AND INSTALLATION (Continued)
steering wheel. Remove air bag module from steering
wheel.
(8) Remove wiring harness connectors from air
bag, horn switch wire, and speed control switches
(Fig. 6). Remove the wiring harness routing clip (Fig.
6) from the air bag module studs.
STEERING
CONTENTS
page
INDEX
page page
GENERAL INFORMATION
POWER STEERING PUMP
The power steering pump used with the 2.5L VM
Diesel engine operates the same way as the power
steering pump used with the 2.5/4.0L gasoline
engines. Refer to the Description and Operation sec-
tion for the 2.5/4.0L gasoline engine power steering
pump for more information.
REMOVAL
(1) Remove serpentine drive belt. Refer to Group 7,
Cooling System, for procedure.
(2) Remove power steering pump pulley. Use a hex
wrench to secure the power steering shaft while
removing the pulley bolt with a box wrench. (Fig. 2)
page page
INDEX
page page
Diagnosis Guide
21 - 6 TRANSAXLE AND POWER TRANSFER UNIT NS
DIAGNOSIS AND TESTING (Continued)
Diagnosis Guide
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 7
DIAGNOSIS AND TESTING (Continued)
Diagnosis Guide
21 - 8 TRANSAXLE AND POWER TRANSFER UNIT NS
DIAGNOSIS AND TESTING (Continued)
Diagnosis Guide
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 9
DIAGNOSIS AND TESTING (Continued)
Diagnosis Guide
21 - 10 TRANSAXLE AND POWER TRANSFER UNIT NS
DIAGNOSIS AND TESTING (Continued)
Diagnosis Guide
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 11
DIAGNOSIS AND TESTING (Continued)
Diagnosis Guide
21 - 12 TRANSAXLE AND POWER TRANSFER UNIT NS
DIAGNOSIS AND TESTING (Continued)
Diagnosis Guide
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 13
DIAGNOSIS AND TESTING (Continued)
NOTE: Compressed air supply must be free of all TORQUE CONVERTER LEAKAGE
dirt or moisture. Use a pressure of 30 psi. Possible sources of torque converter leakage are:
• Torque converter weld leaks at the outside diam-
Remove oil pan and valve body. Refer to Valve eter (peripheral) weld.
Body for removal procedure. • Torque converter hub weld.
• Torque converter impeller shell cracked adjacent
FRONT CLUTCH
to hub.
Apply air pressure to front clutch apply passage
• At drive lug welds.
and listen for a dull thud which indicates that front
clutch is operating. Hold air pressure on for a few NOTE: Hub weld is inside and not visible. Do not
seconds and inspect system for excessive oil leaks. attempt to repair. Replace torque converter.
21 - 16 TRANSAXLE AND POWER TRANSFER UNIT NS
SERVICE PROCEDURES (Continued)
CAUTION: Chrysler Corporation does not recom- DIPSTICK TUBE FLUID SUCTION METHOD
mend using any fluid exchanger that introduces (1) When performing the fluid suction method,
additives into the transaxle. make sure the transaxle is at full operating temper-
ature.
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 17
SERVICE PROCEDURES (Continued)
(2) To perform the dipstick tube fluid suction the HOT range. Drive the vehicle a minimum of 10
method, use a suitable fluid suction device (Vaculay miles.
or equivalent). (10) Raise the vehicle on the hoist.
(3) Insert the fluid suction line into the dipstick (11) Check for leaks around the transaxle oil pan
tube. sealing surfaces.
(12) Recheck the fluid level. The level should be in
NOTE: Verify that the suction line is inserted to the the HOT range.
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan. SEVERE USAGE SERVICE
(4) Follow the manufacturers recommended proce- If the vehicle exhibits any of the following symp-
dure and evacuate the fluid from the transaxle. toms, it is recommended that the transaxle oil and
(5) Remove the suction line from the dipstick tube. filter be replaced.
(6) Add 4 Quarts of Mopar ATF Plus 3 Type 7176 • Transaxle oil discolored
transaxle fluid. • Transaxle oil has high mileage
(7) Start the engine and allow it to idle for a min- • Oil feels grimy when rubbed between fingertips
imum of one minute. With the parking brake applied, • Poor shift quality
press your foot on the service brake and cycle the • Delayed gear engagement
transaxle from park to all gear positions ending in • Vehicle shudder between shifts
neutral or park.
(8) Check the transaxle fluid level and add an TRANSAXLE OIL AND FILTER REPLACEMENT
appropriate amount to bring the transaxle fluid level This procedure involves changing the transaxle
to 3mm (1/8 in.) below the ADD mark on the dip- fluid and filter, driving the vehicle for 10 miles and
stick. changing the transaxle fluid a second time.
(9) Recheck the fluid level after the transaxle is at (1) Bring the vehicle up to normal operating tem-
normal operating temperature. The level should be in perature. Drive the vehicle a minimum of 10 miles.
the HOT range. (2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
TRANSAXLE OIL PAN DROP METHOD fluid into a suitable container.
This procedure involves removing the transaxle oil (4) Remove the pan and clean all sealant from the
pan to drain the transaxle fluid. pan and transaxle mating surfaces. Clean the mag-
(1) Bring the vehicle up to normal operating tem- net and the inside of the pan.
perature. Drive the vehicle a minimum of 10 miles. (5) Separate the filter and O-ring from the valve
(2) Raise the vehicle on the hoist. body. Inspect the O-ring for cuts or improper instal-
(3) Loosen the transaxle oil pan and drain the lation. This could lead to delayed garage shifts.
fluid into a suitable container. (6) Install a new filter. Replace the O-ring as nec-
(4) Remove the pan and clean all sealant from the essary.
pan and transaxle mating surfaces. Clean the mag- (7) Apply a 1/8 inch bead of Mopar RTV Sealant to
net and the inside of the pan. the mounting flange of the transaxle oil pan. Apply
(5) Apply a 1/8 inch bead of Mopar RTV Sealant to RTV Sealant to the underside of the attaching bolts.
the mounting flange of the transaxle oil pan. Apply Attach the oil pan to the transaxle. Tighten the bolts
RTV Sealant to the underside of the attaching bolts. to 19 N•m (165 in. lbs.).
Attach the oil pan to the transaxle. Tighten the bolts (8) Lower the vehicle and add 4 Quarts of Mopar
to 19 N•m (165 in. lbs.). ATF Plus 3 Type 7176 transaxle fluid.
(6) Lower the vehicle and add 4 Quarts of Mopar (9) Start the engine and allow it to idle for a min-
ATF Plus 3 Type 7176 transaxle fluid. imum of one minute. With the parking brake applied,
(7) Start the engine and allow it to idle for a min- press your foot on the service brake and cycle the
imum of one minute. With the parking brake applied, transaxle from park to all gear positions ending in
press your foot on the service brake and cycle the neutral or park.
transaxle from park to all gear positions ending in (10) Check the transaxle fluid level and add an
neutral or park. appropriate amount to bring the transaxle fluid level
(8) Check the transaxle fluid level and add an to 3mm (1/8 in.) below the ADD mark on the dip-
appropriate amount to bring the transaxle fluid level stick.
to 3mm (1/8 in.) below the ADD mark on the dip- (11) Recheck the fluid level after the transaxle is
stick. at normal operating temperature. The level should be
(9) Recheck the fluid level after the transaxle is at in the HOT range. Drive the vehicle a minimum of
normal operating temperature. The level should be in 10 miles.
(12) Raise the vehicle on the hoist.
21 - 18 TRANSAXLE AND POWER TRANSFER UNIT NS
SERVICE PROCEDURES (Continued)
(13) Remove the pan and clean all sealant from ALUMINUM THREAD REPAIR
the pan and transaxle mating surfaces. Clean the Damaged or worn threads in the aluminum transaxle
magnet and the inside of the pan. case and valve body can be repaired by the use of Heli-
(14) Separate the filter from the valve body to Coils, or equivalent. This repair consists of drilling out
allow additional fluid to drain from the transaxle. the worn-out damaged threads. Then tapping the hole
Inspect the filter O-ring for any damage and replace with a Heli-Coil tap, or equivalent, and installing a
as necessary. Heli-Coil insert, or equivalent, into the hole. This
(15) After the transaxle has stopped draining, brings the hole back to its original thread size.
reinstall the filter and O-ring. Heli-Coil, or equivalent, tools and inserts are readily
(16) Apply a 1/8 inch bead of Mopar RTV Sealant available from most automotive parts suppliers.
to the mounting flange of the transaxle oil pan.
Apply RTV Sealant to the underside of the attaching FLUSHING COOLERS AND TUBES
bolts. Attach the oil pan to the transaxle. Tighten the When a transaxle failure has contaminated the
bolts to 19 N•m (165 in. lbs.). fluid, the oil cooler(s) must be flushed. The cooler
(17) Lower the vehicle and add 4 Quarts of Mopar bypass valve in the transaxle must be replaced also.
ATF Plus 3 Type 7176 transaxle fluid. The torque converter must also be replaced with an
(18) Start the engine and allow it to idle for a min- exchange unit. This will ensure that metal particles
imum of one minute. With the parking brake applied, or sludged oil are not later transferred back into the
press your foot on the service brake and cycle the reconditioned (or replaced) transaxle.
transaxle from park to all gear positions ending in The recommended procedure for flushing the cool-
neutral or park. ers and tubes is to use Tool 6906A Cooler Flusher.
(19) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level WARNING: WEAR PROTECTIVE EYEWEAR THAT
to 3mm (1/8 in.) below the ADD mark on the dip- MEETS THE REQUIREMENTS OF OSHA AND ANSI
stick. Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB-
(20) Recheck the fluid level after the transaxle is BER GLOVES.
at normal operating temperature. The level should be KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
in the HOT range. AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
FLUID DRAIN AND REFILL BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
(1) Raise vehicle on a hoist (See Group 0, Lubrica- EXTINGUISHER IN THE AREA WHERE THE
tion). Place a drain container with a large opening, FLUSHER WILL BE USED.
under transaxle oil pan. KEEP THE AREA WELL VENTILATED.
(2) Loosen pan bolts and tap the pan at one corner DO NOT LET FLUSHING SOLVENT COME IN CON-
to break it loose allowing fluid to drain, then remove TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
the oil pan. INATION OCCURS, FLUSH EYES WITH WATER FOR
(3) Install a new filter and gasket on bottom of the 15 TO 20 SECONDS. REMOVE CONTAMINATED
valve body and tighten retaining screws to 5 N·m (40 CLOTHING AND WASH AFFECTED SKIN WITH
inch-pounds). SOAP AND WATER. SEEK MEDICAL ATTENTION.
(4) Clean the oil pan and magnet. Reinstall pan
using new sealant. Tighten oil pan bolts to 19 N·m
(165 in. lbs.). COOLER FLUSH USING TOOL 6906A
(5) Pour four quarts of Mopar ATF PLUS 3 (Auto- (1) Remove cover plate filler plug on Tool 6906A.
matic Transmission Fluid) Type 7176 through the Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
dipstick opening. Flushing solvents are petroleum based solutions gen-
(6) Start engine and allow to idle for at least one erally used to clean automatic transmission compo-
minute. Then, with parking and service brakes nents. DO NOT use solvents containing acids, water,
applied, move selector lever momentarily to each gasoline, or any other corrosive liquids.
position, ending in the park or neutral position. (2) Reinstall filler plug on Tool 6906A.
(7) Add sufficient fluid to bring level to 1/8 inch (3) Verify pump power switch is turned OFF. Con-
below the ADD mark. nect red alligator clip to positive (+) battery post.
(8) Recheck fluid level after transaxle is at normal Connect black (-) alligator clip to a good ground.
operating temperature. The level should be in the (4) Disconnect the cooler lines at the transmission.
HOT region.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 19
SERVICE PROCEDURES (Continued)
(5) Connect the BLUE pressure line to the OUT- REMOVAL AND INSTALLATION
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET VEHICLE SPEED SENSOR PINION GEAR
(To) cooler line When the sensor is removed for any reason, a
(7) Turn pump ON for two to three minutes to NEW O-ring must be installed on its outside diame-
flush cooler(s) and lines. Monitor pressure readings ter.
and clear return lines. Pressure readings should sta-
bilize below 20 psi. for vehicles equipped with a sin- REMOVAL
gle cooler and 30 psi. for vehicles equipped with dual (1) Remove harness connector from sensor. Make
coolers. If flow is intermittent or exceeds these pres- sure weatherseal stays on harness connector.
sures, replace cooler. (2) Remove bolt securing the sensor in the exten-
(8) Turn pump OFF. sion housing.
(9) Disconnect CLEAR suction line from reservoir (3) Carefully pull sensor and pinion gear assembly
at cover plate. Disconnect CLEAR return line at out of extension housing.
cover plate, and place it in a drain pan. (4) Remove pinion gear from sensor.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF. INSTALLATION
(11) Place CLEAR suction line into a one quart (1) To install, reverse the above procedure. Make
container of Mopar ATF Plus 3 t type 7176 automatic sure extension housing and sensor flange are clean
transmission fluid. prior to installation. Always use a NEW sensor
(12) Turn pump ON until all transmission fluid is O-ring.
removed from the one quart container and lines. This (2) Tighten bolt to 7 N·m (60 in. lbs.). Tighten
purges any residual cleaning solvent from the trans- speedometer cable to 4 N·m (35 in. lbs.).
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon- PARK/NEUTRAL STARTING AND BACK-UP LAMP
nect flusher lines to cover plate, and remove flushing SWITCH
adapters from cooler lines.
TEST
OIL PUMP VOLUME CHECK The park/neutral starting switch is the center ter-
After the new or repaired transmission has been minal of the 3 terminal switch. It provides ground for
installed, fill to the proper level with Mopart ATF the starter solenoid circuit through the selector lever
PLUS 3 (Type 7176) automatic transmission fluid. in only Park and Neutral positions.
The volume should be checked using the following (1) To test switch, remove wiring connector from
procedure: switch and test for continuity between center pin of
(1) Disconnect the From cooler line at the trans- switch and transaxle case. Continuity should exist
mission and place a collecting container under the only when transaxle is in Park or Neutral.
disconnected line. (2) Check gearshift cable adjustment before replac-
ing a switch which tests bad.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter- REMOVAL
nal damage to the transmission may occur. (1) Unscrew switch from transaxle case allowing
fluid to drain into a container. Move selector lever to
(2) Run the engine at curb idle speed, with the Park, then to Neutral position, and inspect to see the
shift selector in neutral. switch operating lever fingers are centered in switch
(3) If fluid flow is intermittent or it takes more opening.
than 20 seconds to collect one quart of ATF PLUS 3,
disconnect the To Cooler line at the transaxle. INSTALLATION
(4) Refill the transaxle to proper level and recheck (1) Screw the switch with a new seal into tran-
pump volume. saxle case and tighten to 33 N·m (24 ft. lbs.). Retest
(5) If flow is found to be within acceptable limits, switch with the test lamp.
replace the cooler. Then fill transmission to the (2) Add fluid to transaxle to bring up to proper
proper level, using Mopart ATF PLUS 3 (Type 7176) level.
automatic transmission fluid. (3) The back-up lamp switch circuit is through the
(6) If fluid flow is still found to be inadequate, two outside terminals of the 3 terminal switch.
check the line pressure using the Transaxle Hydrau- (4) To test switch, remove wiring connector from
lic Pressure Test procedure. switch and test for continuity between the two out-
side pins.
21 - 20 TRANSAXLE AND POWER TRANSFER UNIT NS
REMOVAL AND INSTALLATION (Continued)
(5) Continuity should exist only with transaxle in (10) Remove bolts securing exhaust flex joint to
Reverse position. exhaust manifold. Disconnect exhaust pipe from
(6) No continuity should exist from either pin to manifold.
the case. (11) Remove torque converter dust cover. Mark
torque converter and drive plate with chalk, for reas-
TRANSAXLE AND TORQUE CONVERTER REMOVAL sembly. Rotate engine clockwise and remove torque
converter mounting bolts.
NOTE: Transaxle removal does NOT require engine (12) Remove engine mount bracket from front
removal. crossmember.
(13) Remove front mount insulator through-bolt
The transaxle and torque converter must be and bellhousing bolts.
removed as an assembly; otherwise, the torque con- (14) Position transaxle jack (Fig. 6) .
verter drive plate, pump bushing, or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the plate during removal.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner and hoses.
(3) Disconnect throttle linkage and shift linkage
from transaxle.
(4) Unplug torque converter clutch connector,
located near the dipstick. Unplug the gear position
switch.
(5) Remove transaxle dipstick tube.
(6) Remove the transaxle cooler lines and plug.
(7) Install engine support fixture (Fig. 5) .
Fig. 6 Transaxle Jack
(15) Remove rear engine mount shield.
(16) Remove rear engine mount bracket bolts and
bracket.
(17) Remove left engine mount thru-bolt.
(18) Remove left engine mount from transaxle.
(19) Remove starter. Remove lower bell housing
bolts.
(20) Carefully work transaxle and torque converter
assembly rearward off engine block dowels and dis-
engage converter hub from end of crankshaft. Attach
a small C clamp to edge of bell housing. This
will hold torque converter in place during tran-
saxle removal. Lower transaxle and remove assem-
bly from under the vehicle.
(21) To remove torque converter assembly, remove
Fig. 5 Engine Support Fixture
C–clamp from edge of bellhousing and slide converter
(8) Remove bell housing upper bolts. out of transaxle.
(9) Raise vehicle. Remove front wheels. Refer to
Group 2, Suspension to remove or install wheel hub INSTALLATION
nut and both drive shafts. (1) When installing transaxle, reverse the above
procedure.
CAUTION: The exhaust flex joint must be discon- (2) If torque converter was removed from transaxle
nected from the exhaust manifold anytime the be sure to align pump inner gear pilot flats with
engine is lowered. If the engine is lowered while the torque converter impeller hub flats.
flex pipe is attached, damage will occur. (3) Adjust gearshift and throttle cables.
(4) Refill transaxle with Mopar ATF PLUS 3
(Automatic Transmission Fluid) Type 7176.
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 21
REMOVAL AND INSTALLATION (Continued)
FRONT PUMP OIL SEAL DISASSEMBLY AND ASSEMBLY
The pump oil seal can be replaced without remov-
ing the pump and reaction shaft support assembly TRANSAXLE
from the transaxle case. Prior to removing any transaxle parts, plug all
openings and clean the unit, preferably with steam.
REMOVAL When disassembling, each part should be washed in
(1) Screw seal remover Tool C-3981-B into seal a suitable solvent, then dried with compressed air.
(Fig. 7), then tighten screw portion of tool to with- Do not wipe parts with shop towels. All mating sur-
draw the seal. faces in the transaxles are accurately machined;
therefore, careful handling of all parts must be exer-
cised to avoid nicks or burrs.
DISASSEMBLY
Fig. 13 Remove Parking Rod E-Clip Fig. 16 Valve Body and Governor Tubes
Remove neutral starting and back-up lamp switch. required. The thrust washer is located between input
Measuring input shaft end play before disassembly and output shafts.
will usually indicate if a thrust washer change is
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 23
DISASSEMBLY AND ASSEMBLY (Continued)
Attach a dial indicator to transaxle bell housing
with its plunger seated against end of input shaft
(Fig. 17).
Fig. 23 Loosen Kickdown Band Adjusting Screw Fig. 26 No. 2 Thrust Washer and Rear Clutch
Fig. 35 Overrunning Clutch Cam Assembly Fig. 38 Low/Reverse Band and Strut
Fig. 36 Overrunning Clutch Rollers and Spring Fig. 39 No. 11 Thrust Washer
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 27
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 40 Install Overrunning Clutch Rollers and Fig. 42 Using Tool L-4553 on Valve Body Screw
Springs
ASSEMBLY
When rebuilding, reverse the above procedure.